Patent Grant
8919233
The present invention is directed to a dispenser for dispensing sheets from a roll of a web material, such as, for example a paper towel.
There are a number of dispensers known in the art for dispensing and cutting sheets of paper toweling or other similar materials. These dispensers are generally divided into two types of dispensers. The first type is a dispenser which the user needs to physically contact the dispenser to dispense a sheet of the material from the dispenser. Generally, the first type of dispenser is typically one which has a lever or push bar that the user contacts and manipulates to dispense the sheet of the web material. The second type of dispenser is a “sanitary” or “no-touch” dispenser. “Sanitary” or “no-touch” dispensers allow a user to obtain a sheet of the web material by only touching the web material extending from the dispenser or by activating an electronic sensor to advance the web material. There is no need for a user to touch any part of the dispenser in order to obtain a sheet from the dispenser of the second type.
Currently available sanitary or no-touch dispensers are operated either manually or electronically. In manual sanitary or no-touch dispensers, the process of dispensing and cutting the web material is carried out automatically by a user pulling on the free “tail” end of the web material that extends from a dispensing slot in the dispenser. In a typical configuration, the web material is engaged against a rough friction-enhancing surface of a feed drum and the action of pulling the web tail causes the drum to rotate. The drum often includes a drive mechanism and, after the initial pull on the web tail by a user, the drum is driven a predetermined rotational degree to dispense a metered amount of the web material, which is referred to as a “sheet” or a “sheet of the web material”. A cam driven cutting mechanism may be provided in the rotating drum that pivots out of a slot in the drum to automatically cut the web at the proper length. This type of dispenser typically includes a stored energy mechanism, such as an eccentric cam, that is spring loaded during the initial rotation of the feed drum. This mechanism generally provides energy to aid in cutting the sheet from the web material, which is generally in roll form, and causes the drum to continue to rotate after the web has been cut to form the sheet. The dispensing action of the dispenser cuts the sheet from the roll of the web material. This action causes an additional length of the web material to be fed out of the dispensing slot as the tail for the next dispensing sequence. As a result, the user only touches the tail end of the web material during dispensing of a sheet of the web material.
Although effective, the conventional manual or mechanical sanitary dispensers utilizing automatic mechanical cutting and feeding mechanisms can be relatively difficult for some users, such as young children and elderly adults, to use. For some users, these manual or mechanical dispensers present an inordinate amount of resistance to pulling to obtain a sheet of the web material from the dispenser. This may be particularly true when the initial pulling action by the user also provides the force needed to load the potential energy spring of the automatic tail feeding mechanism. Further, the high resistance to pulling created by loading of the potential energy in the spring mechanism also means it is necessary for the web materials being dispensed from the dispensers to have a relatively high tensile strength. If the tensile strength of the web material is too low, the web will tend to tear during dispensing, which may cause the dispenser to jam. As a result, the next user will not be able to use the dispenser in a hands free mode to retrieve a sheet of the web material from the dispenser. Additionally, the torn pieces, or tabs, of the sheet material are often dropped on the floor presenting an undesired and unsightly mess on the washroom floor. Lower tensile products are desirable as they are generally softer and are more absorbent than higher tensile products.
Advances have been made in the art relating to purely electronic sanitary web material dispensers. With such dispensers, the unit is typically activated upon detection of motion of a user's arm or hand. A motor is subsequently energized through a control circuit and power source to drive a feed roll and thus dispense a measured length of the web material. This type of electronic dispenser requires the user to tear off the sheet of the web material from the dispenser. To do so, the user then grabs the exposed web material and pulls the web material at some angle to the dispenser cover causing a sheet to be separated from the web material on a cutting edge or serrated tear bar. The cycle is repeated for the next user.
Dispensers have become more specialized and are being designed by manufacturers to dispense a particular product. As a result, the dispenser's operation, including speed of operation, is optimized for that particular product or suite of products. If a different product, for example a product of a different product manufacturer, is inserted into the dispenser, the dispenser may not function properly. For example, the product may become jammed in the dispenser or the cutter blade in the dispenser will not properly cut the product being dispensed. This can be a problem for the manufacturer of the dispenser, since the dispenser will be perceived as a low quality dispenser when the product does not dispense properly; or it could be a problem for the manufacturer that manufactured the product being dispensed, the product could be perceived as being inferior.
There is a need in the art for an electronic pre-cut sheet dispenser that will effectively modify the dispensing parameters based on the rolled material placed in the dispenser and/or based on the actions of the user requiring a sheet of material from the dispenser.
Generally stated, the present invention provides a dispenser for dispensing a roll or a web material to a user in need of the web material. The dispenser of the present invention has a housing which forms an interior compartment of the dispenser. Within the interior compartment, there is a holder which serves to support at least one roll of a web material to be dispensed from the dispenser. The dispenser also has an actuator roller located within the compartment. The actuator roller has a cutting blade located within the actuator roller, wherein the cutting blade extends from the actuator roller to cut the web material to form a sheet of the web material to be dispensed from the dispenser during rotation of the actuator roller during the dispensing of a sheet of the web material. The dispenser also has a motor engagably connected to the actuator roller and a control circuit in communication with the motor. There is also a product identification sensor in communication with the control circuit. This product identification sensor detects and identifies information about the roll of the web material placed in the holder and relays this information to the control circuit. The control circuit adjusts dispensing parameters for the actuator roller in dispensing a sheet of the web material from the dispenser.
Also provided by the present invention is a dispenser for dispensing pre-cut sheets from a roll of a web material. The dispenser has a housing which forms an interior compartment of the dispenser; a holder located within the compartment, the holder serves to support at least one roll of a web material to be dispensed from the dispenser. Also present is an actuator roller located within the compartment, the actuator roller having a rotational path. The actuator roller has a cutting blade located within the actuator roller, wherein the cutting blade extends from the actuator roller to cut the web material to form a sheet of the web material to be dispensed from the dispenser during the rotational path of the actuator roller. The dispenser also has a motor engagably connected to the actuator roller; a control circuit in communication with the motor; and a removable battery compartment which facilitates replacement of batteries used to power the dispenser. The dispenser of the present invention further has a power supply electrically connected to the motor. The motor is activated with a motor activation means, which activates the motor, the motor activation means is in communication with the control circuit.
In another embodiment of the present invention the product identification sensor is a RFID reader, an ultraviolet light filter, an infrared filter, a capacitance detector, or a completed electrical circuit sensor.
The dispenser, in a further embodiment of the present invention, has a delay circuit, where the delay circuit delays the dispensing of the next sheet from the dispenser for a period of time. In further aspect of the present invention, the delay circuit delays the dispensing of the next sheet after two sheets are removed within a set period of time. In another embodiment of the present invention, the delay circuit time delay is adjusted with a multi-position switch.
In an additional embodiment of the present invention the dispenser has an activation sensor. The activation sensor is in communication with the control circuit, and the activation sensor detects the presence of a user's hand near the dispenser and sends a signal to the control circuit to dispense a sheet of the web material. In a particular embodiment, the activation sensor comprises an infrared sensor, a capacitive proximity sensor, or an ultrasonic proximity sensor. Generally, the activation sensor is located toward the bottom of the housing, and the activation sensor projects downward from the bottom of the housing.
In another embodiment of the present invention, the dispenser the control circuit adjusts the speed of the motor based on the product recognized.
The dispenser, in another embodiment, the control circuit engages the motor to dispense multiple sheets of the web material when the product identification sensor does not recognize the product loaded in the dispenser.
In an additional embodiment of the present invention the control circuit disengages the motor when the product identification sensor does not recognize the product loaded in the dispenser.
In a further embodiment of the present invention, the dispenser has a series of LED's to convey the maintenance state of the dispenser.
It should be noted that, when employed in the present disclosure, the terms “comprises”, “comprising” and other derivatives from the root term “comprise” are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, and are not intended to preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.
As used herein, the term “sheet” means a defined length of web material dispensed from the dispenser.
As used herein, the term “web material” means the material which is to be dispensed from the dispenser of the present invention prior to forming a sheet. The web material may be rolled onto a roll or may be partially unwound from the roll.
In the following detailed description of the present invention, reference is made to the accompanying drawings which form a part hereof, and which shows by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that mechanical, procedural, and other changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
The present specification is organized to explain the mechanical features of the dispenser and how they operate. After this explanation, the specification describes the electronic aspects of the dispenser and how they operate the mechanical systems.
The dispenser of the present invention is generally used for dispensing a rolled web material. Such rolled web material may include, but are not limited to, woven materials, nonwoven materials, synthetic materials, natural materials, foils, polymer films, any combination thereof, and so forth. The rolled web material is dispensed from the dispenser as a defined length sheet of the web material cut or otherwise removed from the roll of the web material. Specific examples of the web materials which may be dispensed from the dispenser of the present invention include, but are not limited to, absorbent sheet materials such as towels, wipers, tissue, and so forth. The web materials for which the present invention is suitable may be wound around a core (not shown). Alternatively, the web materials are wound into a coreless roll. Optionally, but not required nor preferred, the rolled web material which may be used in the dispenser of the present invention may have regularly spaced zones of weakness extending substantially across the width of the sheet material. The zones of weakness are used to separate or cut the sheet material into individual sheets and may be, for example, defined by a series of perforations, a zone of much lower basis weight, and so forth. Typically, the web material dispensed from the dispenser of the present invention does not contain a zone of weakness, since the cutting blade will cut the web material. In one particular embodiment of the present invention, the dispenser is for dispensing sheets of a paper towel from a roll of a material suitable for use as a paper towel.
Turning to
The rear housing section 112 provides means for attaching the dispenser 10 of the present invention to a vertical surface, such as a wall. Generally, the rear wall 113 of the rear housing 112 will be used to attach the dispenser 10 to a vertical surface, such as a lavatory wall, kitchen wall and the like, in the case that the dispenser 10 is a paper towel dispenser. That is, the rear 113 wall also serves as the mounting means for the dispenser 10. Any known attachment means can be used to attach the dispenser of the present invention to a vertical surface, including screws, adhesives, combinations thereof and the like.
The housing 110 of the dispenser may be formed from a wide variety of materials and is not limited in its construction. Generally, the materials used to prepare the housing should be selected on the basis of durability, providing impact resistance and wear and tear during normal usage. For example, the housing may be prepared from metal, plastic or combinations thereof, so long as the housing is durable. It is also noted that the front housing section 114 and the rear housing section 112 may be prepared from same materials or from different materials. In addition, the dispenser housing 110 of the present invention may have any shape, configuration, color or other aesthetic appearance other than is shown in the Figures of the present specification.
The dispenser 10 also has a dispensing opening 99 located in the front housing section 114. Alternatively the dispensing opening may be formed by a gap between the front housing section 114 and the rear housing section 112. The purpose of the dispensing opening 99 is to provide a means for the web material 13 to exit the dispenser 10. The web material 13 is fed through the dispensing opening 99 to the exterior of the dispenser, making the web material accessible to a user.
The housing 110 of the dispenser 10 forms an internal compartment 111 which contains the operating mechanisms of the dispenser 10. The operating mechanisms of the dispenser may be located in a dispensing module 12, which may be operatively mounted and secured to the housing 110, as is shown in
In an embodiment of the present invention, to hold a roll 11 of the web material 13 that is to be dispensed from the dispenser 10, a roll holder, also referred to as roll supports 14 (shown in
The roll support arms 14, 16 may be pivotally connected to dispensing module 12 by pivot connectors 20. The pivot connectors 20 are located near the lower end 19 of each roll support arm 14, 16. The pivot connectors allow the roll support arms 14, 16 to be moved outwardly so that the engagement members 18 can be inserted into the ends of the roll 11 of web material 13. Generally, the weight of the roll 11 of web material 13 will exert forces on the arms 14, 16 continuously urging the engagement members 18 of the arms 14, 16 toward one another and toward the roll of paper toweling. Alternately, roll support arms, 14, 16, may be formed to be inwardly biased toward the roll 11 and be formed from a flexible material, such as plastic, such that they may be spread to load the roll of material and when released move back in toward the roll 11 to maintain engagement members 18 in contact with the roll 11 of the web material 13. This prevents dislodgment of the roll 11 from the roll engagement members 18 during dispensing of the web material from the dispenser. The roll 11 of web material 13 may optionally have a roll core (not shown) in which the roll engagement members 18 engage rather than the web material 13. This core may also function as a support roller for the roll 11.
In an alternative embodiment of the present invention, the roll support arms may be pivotally connected to the rear housing 112 rather than the dispensing module 12. Generally, when attached to the rear housing 112, the roll support arms function in a similar manner, as is described above.
A dispensing actuator roller 22 is rotatably mounted within the compartment 111. The actuator roller 22 generally has a cylindrically-shaped outer peripheral portion and is rotatable in a predetermined direction of rotation. Generally, the dispensing actuator roller 22 is mounted within the dispensing module 12, as is shown in
The actuator roller 22 will be described below, and will be described as having many different features. It is intended that these features are described as embodiments that can be used to prepare a dispenser 10 within the scope of the present invention and are not intended to limit the actuator roller 22 to one having each and every one of these features. These features are intended to be merely exemplary of features that may be present on the actuator roller 22.
In one embodiment of the present invention, as can be seen in
Generally, the ends of actuator roller 22 may have end plates 40 (see
The actuator roller 22 has a pivotally mounted cutter blade 52 housed within the actuator roller 22. The cutter blade 52 typically will have a plurality of triangular-shaped teeth 53 along an edge 51 thereof. Cutter blade 52, in this configuration is pivotally connected to the actuator roller 22, in particular about a pivot point located near an outer portion of the cylindrically-shaped actuator roller 22. By having the cutter blade 52 pivotally mounted in the actuator roller 22, the cutter blade 52 can be designed to extend outward from the actuator roller 22 to cut the web material 13 into an individual sheet for use by a user at a certain point in the rotation of the actuator roller 22. Alternatively, the cutter blade 52 may only cut the web material 13 to a degree that a individual sheet is not cut completely free from the web material, but to a degree that a user pulling on an exposed portion of the web material will cause the individual sheet to become free from the web material.
In addition, the cutter blade 52 may have a plurality of recesses 54 may extend inwardly from the teeth 53 and between sets of teeth 53. These recesses 54 generally align with the channels 44 in the actuator roller 22. That is, the cutter blade teeth 53 do not extend from the actuator roller 22 in the channels 44 found in the actuator roller. Cutter blade 52 has cam followers 60 attached to each end 55 of the cutter blade 52. Optionally, each cam follower 60 has a cam follower arm 62 and a roller 64 positioned on the follower arm 62, as is shown in both
Channels 44 in the actuator roller 22 may be provided to accommodate a plurality of guide clips 56. The guide clips remain stationary during rotation of the actuator roller 22, and are present to guide the web material 13 from the roll 11 onto the actuator roller 22. The guide clips 56 may be prepared from a variety of materials including metal and plastic type materials. The guide clips 56 are slightly narrower than the channels 44 in the actuator roller 22 and the guide clips are spaced apart from the channels 44 in the actuator roller 22 so that the actuator roller 22 will freely rotate on its axis. The guide clips 56 may be generally configured to have a hook-like configuration, as is shown in
A guide roller or tensioning device 74 may be also mounted in the dispensing module frame 15. Generally, the guide roller or tensioning device will be rotatably mounted in the dispensing module frame 15. The guider roller or tensioning device 74 will serve to guide the web material 13 from the roll 11 to the actuator roller 22, as is shown in
During operation of the actuator roller, it is desirable that the guide roller or tensioning device 74 not contact the cutter blade 52 which may be present in the actuator roller 22. Contact between these elements may result in damage to the cutting blade 52 or the guide roller or tensioning device 74. Damage to one or both of these elements may result in unwanted damage to the web material 13 or make the dispenser 10 unusable for its intended function. To prevent this unwanted interaction between the cutting blade 52 and guide roller or tensioning device 74, the guide roller or tensioning device ends 75 are positioned in slots 88 located in both sides of the dispensing module frame 15. This will allow the guide roller or tensioning device 74 to be displaced by some mechanism as the cutter blade 52 of the actuator roller 22 becomes adjacent to the guide roller or tensioning device 74. One way to cause the guide roller or tensioning device 74 to be displaced is to have protrusions 84 located on the actuator roller 22. One possible location for these protrusions 84 is on the ends 40 of the actuator roller 20, as is shown in
The dispenser 10 of the present invention may also have a guiding plate 80 which is employed to cover the actuator roller 22 and to provide guidance to the web material 13 being dispensed from the dispenser 10. This guide plate 80 may be pivotally mounted to the dispensing module frame 15 using pivot pins 82. Alternatively, the guide plate 80 may be removably mounted without the use of pivots. By having the guide plate pivotally or removably mounted to the dispensing module frame 15, the guide plate 80 may be removed for servicing the actuator roller 22, cutting blade 52 or other parts of the dispensing mechanism. The guide plate may also be provided with fingers 100 which extend over the channels 44 in the actuator roller 22. As is shown in
The dispenser of the present invention also has a power supply 202 which is capable of powering a motor 206, and a control circuit 400 (not shown in
As mentioned, a power supply 202 may be contained within the compartment of the dispenser 111 or the housing 110. The power supply 202 stores and supplies power to the motor 206 and any other control circuitry present in the dispenser. The power supply 202 may include a removable battery compartment 203′, shown in
In the present invention, where the power source 202 contains batteries, the batteries in the battery compartment 203 may be accessible from inside the internal compartment 111 of the dispenser 10 or may be accessible through an access opening 204 located in and through the external surface 118 of the housing 110 of the dispenser 10 and the dispensing frame module 15, as is shown in
Alternatively, the battery compartment 203 may be a removable battery compartment 203′ which is completely removable from the internal compartment 111 of dispenser 10. By having a removable battery compartment 203′, it can be easier for the maintainer of the dispenser to install replacement batteries. The removable battery compartment 203′, will hold the batteries in position so that the batteries can all be installed at once, rather than installing the batteries one at a time. Often in can be difficult to replace batteries in a dispenser on a wall since the batteries may be at a level which makes it difficult for the maintainer to hold batteries in place while additional batteries are installed. Often spring like structures are used to hold batteries in contact with electrical pick-ups. The maintainer will have to carefully manipulate the batteries in place to counter act the compression cased by the spring. An embodiment of the removable battery compartment is shown in
The motor 206 is also mounted within the compartment 111 of the dispenser 10. The motor 206 is electrically connected to the power supply 202 through the control circuit 400. Generally, any motor that is electrically activated may be used. Typically, the motor 206 may be a direct current (DC) motor, generally in the 3 volt to 12 volt range. Larger or smaller motors may also be used and it is within the skill of those skilled in the art to select an appropriately sized motor. A typical motor usable in the present invention will have a shaft 207 with a gear 210 extending from one end of the motor 206. Alternatively, a shaft 207 with a gear 210 may extend from both ends of the motor. Generally, the motor 206 may be mounted in the dispensing module frame 15, as is shown in
The dispenser 10 of the present invention may be provided with an activation sensor 404, which may be mounted to the bottom wall 117 of the housing 110 or may be mounted to the dispensing module 12 at or near the dispensing opening 99. The actual location of the activation sensor is can be varied and could be on the front housing 114. However, since the dispenser 10 is only desired to be operated when a user desires a sheet of the web material, the sensor are generally preferred to be located below the dispenser. The activation sensor may have an adjacent lens 4041, as illustrated in
It will be understood, however, that other activation mechanisms, such as capacitive and ultrasonic, may be used in the present invention. Capacitive proximity sensors produce an electrostatic field that will sense both metal objects and non-metallic materials such as paper, glass, liquids and cloth. Ultrasonic proximity sensors use a transducer to send and receive high frequency sound signals. When a target enters the beam the sound is reflected back to the sensor, causing it to energize or de-energize the output circuit. Another sensor type is inductive. In this case an electromagnetic field is used, however, detection is limited to only metallic objects.
The dispenser of the present invention may also be provided with additional features such as an emergency feed mechanism. One such mechanism is shown in
Another feature, which is shown in
Other features which may optionally be incorporated into the dispenser of the present invention include an additional guide roller 78, as is shown in
To help understand the operation of an embodiment of a dispenser within the scope of the present invention, attention is directed to
During rotation of the actuator roller 22, the cam follower arms 62 or cam roller 64, if present, are caused to move along the cam surfaces within the defining channels 66. This in turn will cause the cutter blade 52 to pivot relative to the actuator roller 22. The cutter blade 52 moves between a first position, shown in
Referring to
The dispenser 10 of the present invention is provided with a control panel 400 which contains a control circuit 401, as is shown in
The toggle switches 403 could be placed on a separate circuit board or could be located in the internal compartment 11 of the dispenser 10. For example, the toggle switches could be located on the dispensing module frame 15, so that they could be easily adjusted by the owner or maintainer of the dispenser 10.
Referring now to
In addition, the control circuit will also have an activation sensor 404, paper type sensor 406, a motor relay 410 and various sensors, timers, adjustors, and LED indicators (described in more detail later). Control circuit 401 is powered by either A.C. power source 412 or D.C. power source 414. The power source may be the same or different power source which is used to power the motor. Typically, the power source will be the same power source. If A.C. power is used, generally the 120 Volt A.C. line input voltage is reduced to, generally, 6-12 volts using a transformer (not shown). The reduced voltage is rectified and fed into linear regulator 413 which maintains the desired D.C. voltage level required by controller 10. One possible alternative embodiment the D.C. power supply is a battery as is described above. The communication connection 416 is provided to facilitate programming/reprogramming of microcontroller 402 and/or communication between dispenser 10 and a remote computer.
In one aspect of the invention, the control circuit is further connected to an activation sensor 404. Depending on the desired operation of the dispenser 10, the activation sensor 404 may be a sensor that detects the presence of a user desiring a sheet of the web material from the dispenser 10. Suitable activation sensors include, for example, a capacitive proximity sensor, an ultrasonic proximity sensor, an infrared radiation (IR) sensor. Each type of sensor can detect a user's hand reaching for a sheet of the web material. Alternatively, the activation sensor 404 may be a motion detector which senses movement on one or more of the roll material, or the actuator roller 26. The activation sensor 404 can be a detector, such as a conventional passive sensor for detecting infrared (IR) radiation comprising a transmitter 404a and receiver 404b. Such passive infrared detectors are known in the art. IR transmitter 404b transmits a periodic (at random intervals or fixed intervals as desired) pulsed IR signal. IR receiver 404a is configured to detect reflected IR signals in the same pattern as the transmitted signal. When such a signal is detected, activation sensor 404 generates an output signal informing microcontroller 402 that a sheet of the web material should be dispensed. Alternatively, the activation sensor may be movement sensor 404c which detects movement of one or more actuator roller or roll of the web material. When this movement sensor 404c detects movement of the actuator roller or the web material to be dispensed, the movement activation sensor 404c generates an output signal informing microcontroller 402 that web material should be dispensed and to activate the motor 206. In another alternative embodiment of the present invention, the activation sensor 404 is activated went the actuator roller 22 nears a particular position in the dispensing cycle. In the or power assist (hybrid) mode, activation sensor 404c or sensor is used to determine the position of the actuator roller in the dispensing cycle which will send a signal to the processor to activate the motor and a second switch or sensor sends a second signal to the processor to deactivate the motor, generally as the cutting blade cuts the web material.
In a further embodiment of the present invention, IR sensitivity adjustments or sensor activation control programs may be performed automatically over communication connection 416 using a remote computer or a computer connected to the communication point. It should be noted, however, that dispenser 10 may allow for manual IR sensitivity adjustments using IR sensitivity adjustments 428. These adjustments may be performed using the toggle or multi-way switches discussed above.
When microcontroller 402 determines that activation sensor 404 has been triggered and that dispenser 10 is ready to dispense a sheet of the web material, microcontroller 402 causes sheet of the web material to be dispensed from dispenser 10 by engaging relay 410, thereby applying power to electric motor 206. As the electric motor 206 turns, the roll 11 of the web material 13 turns and web material is forced out of the front of dispenser 10, generally through the dispensing opening 99. As the web material is being dispensed, the microcontroller 402 may optionally monitor an optional rotation counter 418 which outputs a signal for each motor rotation (or roll 11 rotation, or fraction thereof). When rotation counter 418 generates a predefined number of rotation signals, microcontroller 402 may send a signal to the low paper LED or similar light or signal. Alternatively, the rotational counter 418 could also be used by the microprocessor to disengage the electric motor 206 by disengaging the relay 410, thereby removing power to the motor 206 when the proper amount of the web material has be dispensed through the dispensing opening 99.
Generally, in the operation of the dispenser 10, before engaging relay 410, the microcontroller 402 checks the status of a delay circuit 421. The purpose of delay circuit 421 is to prevent consecutive sheet dispensing events until a predefined amount of time elapses. Upon disengaging relay 410 after a web dispensing event, delay circuit 421 is activated. While delay circuit 421 is active, microcontroller 402 disables relay 410. Delay circuit 421 is designed to “time out” after a predefined amount of time. Such functionality can be achieved using a countdown timer, a count up timer or any other suitable timing technology. For example, delay circuit 421 could be set to “time out” ten seconds after activation. For such a configuration, consecutive sheet dispensing events could not occur faster than once every ten seconds. The processor could be set to dispense multiple sheets consecutively, before the delay circuit 421 is activated. This is called a smart delay, which will allow a user to obtain two or more sheets of the web material before the delay will take effect. This will prevent user frustrations if the user desires more than one sheet of the web material. Generally, the smart delay will allow a user to obtain two sheets of the web material.
Before engaging relay 410, microcontroller 402 checks the status of door open sensor 420, if present. When a user opens front housing 114 or cover to replace the roll 14 or otherwise service dispenser 10, the open door sensor 420 asserts a door open signal that is sensed by microcontroller 402. Upon sensing a door open signal, microcontroller 402 disables relay 410, thereby disabling electric motor 206. This can prevent the maintainer of the dispenser from becoming injured by the cutting blade 52 or otherwise being caught off-guard by a motor 206 activation.
Microcontroller 402 monitors the output of sensor 423. D.C. voltage sensor 423 monitors the output voltage level of D.C. power supply 414. If such voltage level drops below a predefined amount, microcontroller 402 asserts a voltage signal to low D.C. supply voltage LED 422. When such a low signal is asserted, LED 422 will emit light informing a user that the D.C. power source (perhaps a battery) is not providing the proper power to controller 400.
Microcontroller 402 also monitors a low paper sensor 424. One method of sensing a low paper condition may be accomplished using a mechanical arm that rides on roll or positioned on the side of the roll 11 such that sensor will activate with the diameter of the roll is less than a certain value. Generally, the low paper sensor measure the diameter of the roll 11, the low paper sender 424 can be positioned on one of the supports 14 or 16, near the roll engagement member 18. As web material is dispensed from the roll 11 and is dispensed from dispenser 10, roll 11 shrinks in size. Eventually such mechanical arm will activate low paper sensor 424 and a low paper signal will be asserted. When microcontroller 402 detects a low paper signal, microcontroller 402 asserts a signal to low paper LED 426 or similar signal and LED 426 will emit light informing a maintainer or user that the web material source is almost depleted.
Attention is now directed to the product identification sensor 406. When a user opens front housing 114 to replace roll 11 of the web material 13 or otherwise service the dispenser 10, open door sensor 420 asserts a door open signal that is sensed by microcontroller 402. Microcontroller 402, in turn, activates the circuit associated with product identification sensor 406. The product identification sensor determines whether the roll inserted into the dispenser 10 is a recognized product. Suitable product identification sensor 406 may include a simple electrical circuit being completed by the roll 11 of the web material 13 when the roll is inserted into the dispenser, a RFID sensor, an infrared sensor, an ultraviolet light sensor, a capacitance sensor or any other types of sensor which can be used to detect the type of paper that is inserted into the dispenser 10. Each type of product recognition sensor will be described in more detail below.
The simplest paper type detector is completing an electrical circuit. For example, a simple circuit which is completed when the roll 11 is placed in the dispenser 10 on the roll holder 18. On particular example is the core of the roll or web material may have electrical connections therein or thereon that will complete a circuit with contacts on one or both the roll holders. This electrical circuit can run along the length of the core or could simple be located at one of the ends. In this regard, attention is directed to
Referring to
A particular type of desired roll product 11 may have a core 2016 with a metal coating 2040 located on the inside of the core 2016. Any type of conductive metal or substance may be applied to the inside of the core 2016. For example, the metal coating 2040 may be a layer of copper or aluminum foil that is applied to some or all of the inside of the core 2016. Additionally, other types of electrically conductive materials such as an electrically conductive metal-oxide, iron filings, or electrically conductive silicon may be used. Insertion of the roll product 11 into the dispenser 11 causes the contacts 2023 and 2024 to touch the metal coating 2040 so that the electrical circuit 2022 may be completed from one arm 14 to the other 16. In this manner, the sensor 406 will know that the electrical circuit 2022 is complete and consequently that a particular known type of roll product 11 is present in the dispenser 10. Details of the electrical circuit 2022, such as a power supply thereto, may be provided in any manner commonly known to one having ordinary skill in the art.
Various exemplary embodiments are included for the completion of the electrical circuit 2022. For example, an electrically conductive adhesive 2042 may be applied to the core 2016 for holding the core 2016 together and/or holding sheets onto the core 2016. The electrically conductive adhesive 2042 may be, for example, glue that has iron filings mixed therein, or the electrically conductive adhesive 2042 may be electrically conductive silicon. As such, the core 2016 may be made from materials that are electrically conductive in order to complete the electrical circuit 2022 so as to identify the roll product 11. When formed as a coreless roll, the roll product 11 may be treated with an electrically conductive material during converting when a taffy stick part of the roll is formed so as to be electrically conductive and hence capable of being identified by the dispenser 10.
A particular type of roll product 11 with a core 2016 is shown in
The first type of product 2036 has a pair of conductive elements 2030 and 2032 located on the inside of the core 2016. The second type of product 2038 has an additional conductive element 2034 also located on the inside of the core 2016. The conductive elements 2030, 2032 and 2034 may be, for example, rings made from an electrically conductive material that is either applied to the outside of the inner surface of the core 2016 or located in a recess of the inner surface of the core 2016. Placement of the first type of product 2036 into the dispenser 10 causes the core 2016 to be received by the roll support 18 so that the conductive element 2030 aligns with the first contacts 2024 and so that the conductive element 2032 aligns with the second contacts 2026. The conductive element 2030 is made wide enough to extend between the first contacts 2024 and hence cause completion of the electrical circuit 2022 representative of the first contacts 2024. The conductive element 2032 is configured in a likewise manner so as to complete the electrical circuit 2022 associated with the second contacts 2026 upon placement of the core 2016 onto the roll support 18. In this instance, the electrical circuit 2022 will be closed with respect to the first and second contacts 2024 and 2026, and the electrical circuit 2022 will be open with respect to the third contacts 2028, so that the sensor 406 will know that the first type of product 2036 is located in the dispenser 10. The term “closed” simply means that a part of the electrical circuit 2022 becomes closed.
Placement of the second type of product 2038 into the dispenser 10 will cause the conductive elements 2030, 2032 and 2034 to align with the first, second and third contacts 2024, 2026 and 2028 on the roll support 18. In this instance, the electrical circuit 2022 will become closed with respect to the first, second and third contacts 2024, 2026 and 2028 so that the sensor 406 will know that the second type of product 2038 is present in the dispenser 10. In this manner, the dispenser 10 may be arranged in a variety of manners so that identification information from various types of product 2014 may be obtained and used in the previously disclosed exemplary embodiments for desired dispensing cycles, monitoring, purchasing, or the like.
The electrical circuit 2022 may be arranged so that a variety of combinations are possible to identify various types of products 2014. For example, if only a single pair of the contacts 2024, 2026, or 2028 are closed, the system will be capable of distinguishing between three different types of products 2014. Further, the closing of different combinations of the contacts 2024, 2026 and 2028 may be used to indicate additional types of product 2014 that may be identified in the dispenser 10. Still further, additional contacts may be employed, for example on the other roll support 18′, and incorporated into the electrical circuit 2022 so that any number of various products 2014 can be identified in the system.
One possible embodiment of a product identification sensor transmitter/receiver is an RFID based sensor. Ideally, paper roll 14 is associated with an RFID smart tag. For such a configuration, paper type sensor transmitter/receiver 406 transmits an RFID smart tag trigger signal and listens for transmissions from RFID smart tags associated with paper roll 14. At least part of the received smart tag data is stored in a memory associated with microcontroller 402. Such smart tag data ideally comprises paper type identification information. Such information may be used by microcontroller 402 to automatically configured dispenser 10 operation based on the type of paper inserted into dispenser 10. In this regard, attention is directed to
The smart tag 2062 contains information relating to the type of sheet material on the roll 11, for example information relating to the absorbency, the basis weight, manufacturer, etc. of the web material 13 In use, the scanner 406 interrogates the smart tag 2062 with an electronic signal, and the smart tag 2062, which includes an internal antenna (not visible), in turn generates and transmits an electromagnetic pulse that is readable by the scanner to identify the type of web material 131 on the roll 11. The scanner 406 typically is configured to retrieve information from the smart tag 2062 and to decode the information.
RFID smart tag technology is known and understood by those skilled in the art, and a detailed explanation thereof is not necessary for purposes of describing the dispenser and method of the present invention. Generally, conductive or passive smart tags consist of silicon or other semiconductors, a coiled, etched, or stamped antenna, a capacitor, and a substrate on which the components are mounted or embedded. A protective covering typically is used to encapsulate and seal the substrate. Inductive or passive smart tags have been introduced by Motorola under the name BISTATIX®. A detailed description of the BISTATIX® device may be found in U.S. Pat. No. 6,259,367 to Klein, the entire contents of which is incorporated herein by reference. Further information on smart tags and related technology is disclosed in U.S. Pat. No. 6,451,154 to Grabau et al; U.S. Pat. No. 6,354,493 to Mon; U.S. Pat. No. 6,362,738 to Vega; and PCT publication WO 02/48955. Various different RFID tags and scanners are available. RFID tags and scanners suitable for use with the dispenser 10 are available from, for example, Philips Semiconductors of Eindhoven, The Netherlands; Sokymat of Lausanne, Switzerland; Checkpoint Systems Inc. of Miami, Fla.; and Omron Company of Tokyo, Japan.
Alternatively, the smart tags 2062 may be an active device. In this configuration, the smart tag 2062 includes active transceiving circuitry that has the capability to selectively respond to coded request signals transmitted by a scanner. An active smart tag 2062 may include the capability to receive and store additional information beyond the information contained in its fixed code. An active smart tag 2062 requires an internal power supply, such as a micro-battery, thin film battery, and so forth (not shown).
In the case of the ultraviolet light product identification sensor, an ultraviolet light emitter/detector sensor 406 is directed at a portion of the roll 11 loaded into the dispenser 10. The portion of the roll 11, including a roll cap or the side of the paper will have an invisible ink that is fluorescent when exposed to ultraviolet light from the transmitter. This configuration is shown in
The fluorescent area 2044 may be present from the material making up the core 2016 or the web material in the roll product 11 that could be naturally fluorescent. Further, the fluorescent area 2044 may be applied to the rolled product 11 by fluorescent pigments, paints or inks so as to render the rolled product 11 UV-responsive. In this instance, the substance may be sprayed onto the side of the rolled product during manufacturing. The fluorescent area 2044 may be clear and invisible under normal light yet detectable by the sensor 406. Any type of sensor 406 capable of detecting the fluorescent area 2044 may be employed. For example, a fluorescent sensor manufactured by EMX Industries, Inc. having offices at 4564 Johnston Parkway, Cleveland, Ohio may be used in accordance with one exemplary embodiment.
The use of a fluorescent area 2044 may be desirable in that the substance, if used, to provide the UV marker may be incorporated into adhesives or other necessary parts of the rolled product 11. Also, the fluorescent area 2044 may be a substance that does not react with or otherwise impede the functionality of the rolled product 11. Additionally, as the fluorescent area 2044 may be invisible under normal lighting conditions, the rolled product 11 may be marked in an inconspicuous manner to the end consumer. Although described as being applied to the side of the rolled product 11, the fluorescent area 2044 may be located at other portions on the rolled product 11 in accordance with other exemplary embodiments.
Infrared or visible light product identification sensor may also be used. The infrared or visible light emitter will direct the light in a direction, for example, through the core of the rolled product.
Other types of product type identification sensors may be use, including, for example, ultrasonic and capacitance sensors.
Generally, the control circuit 401 may be powered by a separate power supply (not shown) or may be powered by the power source 202 is used to power the motor 206 of the dispenser. In any event, the control circuit 401 is in electrical communication with the power source 202 and the motor 206 and controls the power supplied to the motor 206.
Depending on the desired functionality of the dispenser 10, the dispenser 10 can also have other features and functions. One particular dispenser 10 may have a series of multi-positioned switches 403, that may be located on the control circuit 400 or located in the internal compartment 111 such that a maintainer of the dispenser 10 will be able to easily select the mode in which the dispenser 10 will operate. For example, the switches 403 may be located on the dispensing module 12. The dispenser 10 of the present invention can be set to dispense product in different modes, including fully electronically, partially electronically or manually. A three-way switch 403 could be used to allow the maintainer to select the mode in which the dispenser dispenses the web material. In the full electronic mode, the dispenser will have an activation sensor 404, which is described above. The activation sensor 404 which will detect the users hand proximate to the dispenser 10 or may detect that the user has removed the sheet of the web material 13′ form the dispenser 10. In the full electronic mode, the dispenser 10 could be set up such that the sheet of the web material 13′ is not dispensed until a user's hand is detected under the dispensing opening 99 the dispenser 10. This mode is often referred to as the hygienic mode. In this mode, the activation sensor 404 will sense the user's hand around the dispensing opening 99 and will send a signal to the control circuit 401. The control circuit 401 will activate the motor 206 through the relay 410 and the dispenser will dispense a sheet of the web material to the user. As is stated above, the dispenser 10 of the present invention pre-cuts the sheet of towel for the user so the user needs little force to remove the sheet form the dispenser 10. Once removed, the dispenser 10 will not dispense another sheet of the web material 13′ until a user's hand is placed proximate dispensing opening 99 and/or activation sensor 404.
Alternatively, in the full electronic mode, the dispenser 10 could be set to leave a sheet of the web material 13 extending from the dispensing opening 99 of the dispenser 10, as is shown in
Another mode the dispenser 10 of the present invention can operate is called an assist mode. In the assist mode, a portion of the web material 13 is exposed below in the dispensing opening 99 of the dispenser 10. The exposed portion is often referred to as a tail. A user pulls on the tail to remove the sheet similar to a manual dispenser. However, an activation switch 404c detects movement of the web material 13 or the actuator roller 22 in the dispenser 10 and communicates this information to the control circuit 401. The control circuit 401 activates the motor 206 through the motor relay 410 and assists the user in removing a sheet 13′ of the web material from the dispenser 10. The motor will shut off at a predetermined point where the momentum generated by the user and the motor 206 will be sufficient to leave another tail of the web material 13 for the next user to repeat the process. This predetermined point may be detected by a sensor or a switch. An example of an assist mode dispenser is disclosed in U.S. Patent Application Publication 2009/0140001 by Lewis et al. Generally, in the assist mode, a one way drive system is coupled with the motor to engage the motor such that if a user continues to pull on the towel when the motor engages, the motor will be caused to disengage from the actuator roller, thereby saving battery life and wear on the motor. A one way drive system is shown in, for example U.S. Patent Application Publication 2007/0079684 by Friesen et al. Generally, the one-way drive may utilize a bearing clutch, a floating gear or another mechanism which is effective in disengaging the motor form the actuator roller. In the power assist (hybrid) mode a tail of sheet material is exposed below the dispensing opening. As the user grasps and pulls on exposed sheet, the actuator roller begins to rotate. The rotation of the actuator roller will activate a switch located beneath on a cam or in communication with the actuator roller. The switch activates the drive motor dispensing the sheet. If user continues to pull the sheet as the motor is running, the one-way drive effectively removes the load from the motor and therefore the drain on batteries. An emergency feed knob incorporates three cam surfaces and three switches, which may be located on the circuit board located beneath the emergency knob, which are used to signal motor start and stop, determine position of a sheet, advance a short tail to the proper position, adjust for incorrect dispensing such as sheet over pull.
In another mode of operation, the dispenser 10 may be fully manual, meaning that the user will need to apply force to the towel material to advance and remove a sheet of the web material from the dispenser. In the fully manual mode, a portion of the sheet 13′ is exposed below in the dispensing opening 99 of the dispenser. The exposed portion is called a tail. A user pulls on the tail to remove the sheet of the paper towel. The cutter blade severs a sheet of the towel from the roll and leaves a new tail portion for the next user.
Each of these three modes may be selected by the maintainer of the dispenser by providing a three-way switch, one way for each dispensing mode. Alternatively, the control circuit 401 could select the mode in which the dispenser is going to operate, depending on the towel material installed in the dispenser. For example, if the product identification sensor senses a product which is unknown the dispenser could automatically be switched to a manual mode or a power assist (hybrid) mode. Alternatively, if the power source is deemed by the control circuit to be low on power, the dispenser may switch to a power assist (hybrid) mode or a manual mode to preserve power.
The delay circuit 421 can be set to various times. The circuit may be set such that there is no delay, a short delay such as a 1-5 second, or a delay that takes effect after two or more sheets of the towel are dispensed by the dispenser. A reason to set the delay is to prevent the dispenser from dispensing more sheets than necessary for a given task. By placing a delay of a few seconds, a user will more than likely not stand and wait for additional sheets to be dispensed from the dispenser and will use the sheet or sheets provided. This will prevent waste of the sheet material dispensed from the dispenser. In one embodiment of the present invention, the delay will not take effect until two sheet have been dispensed in rapid succession, which is referred to herein as a smart delay. That way a user will be provided with a sufficient amount of paper towels to dry their hands, if the dispenser is used in restrooms. However, if the dispenser is used in a location where rapid towel dispensing is needed, such as food service, to clean-up a spill, the dispenser could be set to dispense without any delay. A multi-way switch may be used to set the time delay. Alternatively, the time delay may be set in the processor through the communication port.
As previously discussed this dispenser may operate in three modes of operation. In the hygienic or hidden mode, the sheet material is held within the dispenser until an end user places their hand beneath the hand sensor (activation sensor to trigger a dispenser cycle. Once the sheet has been dispensed, the hand sensor remains off until the system determines the dispensed sheet has been removed. Since there are multiple sensors incorporated in the unit, sensors other than the hand sensor may be used to determine if the sheet has been removed. The combination of sensors can be used in the various modes to detect the presence or position of the sheet. In the exposed mode a sheet would be dispensed and left hanging until removed by a user. Once the dispenser, via the sensors, determines that the sheet has been removed, a delay, if applicable or desired, is applied followed by the dispensing of a new sheet of material for the same or next user upon detection or redetection of the user's hand.
To summarize, some of the features of the dispenser of the present invention can be adjusted by the maintainer of dispenser. include a) mode setting—hidden, exposed and power assist; b) smart delay—no delay, delay after every sheet and delay after two sheets or more sheets have been dispensed in succession; c) delay time—initially set at 1, 3 and 5 seconds; d) hand sensor sensitivity—short, medium and long. Also included in the system is a lock out switch that removes power from the motor and sensors when the dispenser cover is open. Additionally, although not needed if the unit has an emergency knob, a sheet feed button may be incorporated to assist in loading a new roll of sheet material.
In another embodiment of the present invention, the dispenser incorporates a translucent emergency feed knob 102 shown in
The microprocessor 402 and the control circuit 401 can effectively operate the dispenser. If the product sensor 406 is unable to identify the roll product 11 placed in the dispenser, the microprocessor will be able to change the dispensing parameters, including speed the web material 13 is dispensed, the length of the delay 421, the ability to change from one dispensing mode to another, dispense multiple sheets and the like. Generally, if the roll product 11 is not recognized, the dispenser will switch to a fully manual mode, where the user will have to input power to dispense the sheet material. Alternatively, the dispenser could switch the mode to a fully sanitary mode, dispensing multiple sheets at a time. It may be desirable to dispense multiply sheets, in the absorbency of the roll product in the dispenser would not be known.
In a further embodiment, if the product is recognized, the dispenser could set the dispensing mode which is best suited for dispensing the recognized product. For example, one product would be best suited to be dispensed in a fully electronic mode, while others will be better suited for a power assist mode.
Although the present invention has been described with reference to various embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of the invention.
| Number | Name | Date | Kind |
|---|---|---|---|
| 3361021 | Toth | Jan 1968 | A |
| 4826262 | Hartman et al. | May 1989 | A |
| 5141142 | Ramsey | Aug 1992 | A |
| 5217035 | Van Marcke | Jun 1993 | A |
| 5704566 | Schutz et al. | Jan 1998 | A |
| 5772291 | Byrd et al. | Jun 1998 | A |
| 5984049 | Lammers | Nov 1999 | A |
| 6069354 | Alfano et al. | May 2000 | A |
| 6079305 | Bloch et al. | Jun 2000 | A |
| 6168679 | Biagiotti | Jan 2001 | B1 |
| 6279777 | Goodin et al. | Aug 2001 | B1 |
| 6293486 | Byrd et al. | Sep 2001 | B1 |
| 6321963 | Gracyalny et al. | Nov 2001 | B1 |
| 6409401 | Petteruti et al. | Jun 2002 | B1 |
| 6412678 | Gracyalny et al. | Jul 2002 | B2 |
| 6412679 | Formon et al. | Jul 2002 | B2 |
| 6419136 | Formon et al. | Jul 2002 | B2 |
| 6607160 | Lewis et al. | Aug 2003 | B2 |
| 6669071 | Menna | Dec 2003 | B1 |
| 6685074 | Gracyalny et al. | Feb 2004 | B2 |
| 6861025 | Erickson et al. | Mar 2005 | B2 |
| 6892620 | Kapiloff | May 2005 | B2 |
| 6953292 | Menendez et al. | Oct 2005 | B2 |
| 7040566 | Rodrian et al. | May 2006 | B1 |
| 7044421 | Omdoll et al. | May 2006 | B1 |
| 7149658 | Kadaba | Dec 2006 | B2 |
| 7546973 | Budz et al. | Jun 2009 | B2 |
| 7624664 | Morris et al. | Dec 2009 | B2 |
| 7726599 | Lewis et al. | Jun 2010 | B2 |
| 7987756 | Lewis et al. | Aug 2011 | B2 |
| 8581722 | Romaine et al. | Nov 2013 | B2 |
| 8698606 | Choi et al. | Apr 2014 | B2 |
| 20020030061 | Formon | Mar 2002 | A1 |
| 20020109036 | Denen et al. | Aug 2002 | A1 |
| 20030025027 | Ebisawa et al. | Feb 2003 | A1 |
| 20030167893 | Morris et al. | Sep 2003 | A1 |
| 20050011987 | Lemaire et al. | Jan 2005 | A1 |
| 20050145745 | Lewis et al. | Jul 2005 | A1 |
| 20060173576 | Georg et al. | Aug 2006 | A1 |
| 20070152010 | Denen et al. | Jul 2007 | A1 |
| 20070158359 | Rodrian | Jul 2007 | A1 |
| 20090024584 | Dharap et al. | Jan 2009 | A1 |
| 20090025524 | Kasugai et al. | Jan 2009 | A1 |
| 20090140001 | Lewis et al. | Jun 2009 | A1 |
| 20090177315 | Goeking et al. | Jul 2009 | A1 |
| 20090256022 | Maurer | Oct 2009 | A1 |
| 20100120593 | Bohm et al. | May 2010 | A1 |
| 20100132529 | Miyazaki | Jun 2010 | A1 |
| 20100301157 | Keily et al. | Dec 2010 | A1 |
| 20110162499 | Cooper | Jul 2011 | A1 |
| 20120125968 | Friesen et al. | May 2012 | A1 |
| Number | Date | Country |
|---|---|---|
| WO 2009055473 | Apr 2009 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20120167739 A1 | Jul 2012 | US |
