Method of dispensing sheet material

Information

  • Patent Grant
  • 6826985
  • Patent Number
    6,826,985
  • Date Filed
    Friday, December 15, 2000
    24 years ago
  • Date Issued
    Tuesday, December 7, 2004
    20 years ago
Abstract
A dispenser having a transfer mechanism for transferring between a first source and a second source of sheet material, and a method for transferring between the first source and the second source. Dispensing is transferred from a first source to a second source upon an absence of sheet material from the first source. The transfer mechanism includes a transfer roller with a slot to receive a free end of sheet material from the second source. The transfer roller also includes a plurality of raised portions, the raised portions are free to rotate through a dispensing roller when there is an absence of sheet material from the first source. This rotation introduces the free end of sheet material from the second source to the dispensing roller, and allows dispensing from the second source. Afterwards, the transfer roller is set to receive sheet material from a new source of sheet material.
Description




DESCRIPTION OF THE INVENTION




1. Field of the Invention




The present invention relates to sheet material dispensers in general. More particularly, the present invention relates to sheet material dispensers capable of transferring dispensing from a first mode wherein sheet material is dispensed from a first sheet material supply to a second mode wherein sheet material is dispensed from a second sheet material supply, and a method of transfer.




2. Background of the Invention




Sheet material dispensers are designed to dispense sheet material from various sources including folded sheet material and rolled sheet material. Each type of sheet material source requires a different means of loading and dispensing the sheet material. As a result, each source creates unique refilling problems for maintenance personnel.




Folded sheet material dispensers contain separate sheets of folded sheet material that are dispensed through an opening. Although most of these types of i dispensers are relatively simple, there are drawbacks associated with using folded sheet material because this type of sheet material can be relatively expensive and occupy a rather large volume. In addition, dispensers containing folded sheet material generally need to be filled more often than other dispensers because they permit dispensing of multiple folded sheets simultaneously.




The most common type of sheet dispensers have sheet material wound on rolls. These dispensers have several different means of dispensing paper. The sheets can be removed by either pulling on a free end of a sheet or actuating a lever to advance the sheet. To increase sheet material supply, many roll dispensers are capable of holding two rolls of sheet material. These dispensers often require complicated transfer systems to switch dispensing from one roll to another. One type of transfer system uses a mechanism to detect tension in sheet material from a first roll. Once the tension is removed from the sheet material, indicating the first roll is empty, the mechanism pivots, thereby moving a free end of sheet material from the second roll of sheet material into engagement with a dispensing mechanism. Another type of transfer system involves a transfer mechanism including a complex follower arm, which follows the decreasing diameter of the first roll. Upon depletion of the first roll, the mechanism moves the free end of sheet material from the second roll into engagement with a dispensing mechanism. Both of these types of transfer systems, however, have complex transfer mechanisms and require a relatively long time to load the sheet material rolls.




As a result, maintenance personnel sometimes bypass the transfer system by only maintaining a single roll of sheet material in the dispenser. This has the effect of increasing the number of maintenance checks. This also sometimes leads to a new roll of sheet material being loaded in place of a used roll of sheet material, which is discarded while still having at least some usable sheet material thereon. Such practice can result in significant unnecessary waste of usable sheet material.




It is accordingly a primary object of the invention to provide a simple transfer system that requires minimum time to set up by maintenance personnel.




It is another object of the invention to provide a simple method of transferring between a first roll and a second roll of sheet material.




SUMMARY OF THE INVENTION




Accordingly, the present invention is directed to a sheet material dispenser with a transfer system and a method of transferring dispensing from a first mode where sheet material is dispensed from a first source of sheet material and to a second mode where sheet material is dispensed from a second source of sheet material.




To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention includes a dispenser for dispensing sheet material. The dispenser includes a housing defining an interior for accommodating first and second sources of sheet material, and an outlet through which the sheet material is dispensed. A first rotatable roller is in the housing, and a portion of the sheet material is in contact with the first roller prior to being dispensed through the opening. A transfer mechanism is configured to transfer dispensing of sheet material from a first mode wherein sheet material is dispensed from the first source to a second mode wherein sheet material is dispensed from the second source. The transfer mechanism includes a second rotatable roller which has a slot passing completely through the second roller to retain a free end portion of the sheet material from the second source when the sheet material is dispensed in the first mode.




In another aspect, the first roller has at least one recessed portion, and the second roller has at least one raised portion aligned with the recessed portion. The recessed portion and the raised portion are configured such that when the sheet from the first source covers the recessed portion the transfer mechanism does not transfer dispensing from the first mode to the second mode.




In an additional aspect, the first roller has a first surface, and the second roller has a second surface. The second surface contacts sheet material on the first surface during at least dispensing in the first mode.




In a further aspect, the first surface has a higher coefficient of friction than a coefficient of friction of the second surface.




In yet another aspect, the first surface is formed from rubberized material.




In an additional aspect, the second surface is formed from plastic material.




In another aspect, the transfer mechanism includes at least one biasing element biasing the second roller toward the first roller.




In a further aspect, the dispenser includes a third roller. The third roller forms a nip with the first roller, and the sheet material passes through the nip during dispensing in the first and second modes.




In an additional aspect, the dispenser includes a driving mechanism configured to rotate at least one of the first and third rollers.




In a further aspect, the driving mechanism includes a manually driven element.




In another aspect, the driving mechanism includes an electric motor coupled to one of the first and third rollers.




In a further aspect, the dispenser includes a shield. The shield limits contact between the free end of sheet material from the second source and the first roller before the transfer mechanism transfers dispensing to the second mode.




In yet another aspect, the transfer mechanism is configured to transfer dispensing from the first mode to the second mode when sheet material from the first source is not between the first and second rollers.




In another aspect, the second roller is configured to rotate when sheet material from the first source departs from between the first and second rollers.




In an additional aspect, the third roller includes a cutter for cutting the sheet material.




In another aspect of the present invention, the dispenser includes a housing defining an interior for accommodating first and second sources of sheet material, and an outlet through which the sheet material is dispensed. A first rotatable roller in the housing has at least one recessed portion. A portion of the sheet material is in contact with the first roller prior to being dispensed through the opening. A transfer mechanism is configured to transfer dispensing of sheet material from a first mode wherein sheet material is dispensed from the first source to a second mode wherein sheet material is dispensed from the second source. The transfer mechanism includes a second rotatable roller having a retainer to retain a free end portion of sheet material from the second source when the sheet material is dispensed in the first mode. The second roller has at least one raised portion aligned with the recessed portion. The recessed portion and the raised portion are configured such that when sheet from said first source covers the recessed portion the transfer mechanism does not transfer dispensing from the first mode to the second mode.




In another aspect, the second roller has at least one second raised portion opposite the at least one first raised portion. The second raised portion is configured such that when sheet from the second source covers the recessed portion the second roller is oriented to receive a sheet from a new source.




In yet another aspect, the present invention includes a method of dispensing sheet material. The method includes providing a dispenser containing first and second sources of sheet material. The dispenser further includes a first rotatable roller having at least one recessed portion, and a second rotatable roller having at least one raised portion, the second roller having a retainer. The method includes dispensing sheet material from the first source by passing the sheet material between the first and second rollers, and retaining, in the retainer on the second roller, an end portion of sheet material from the second source. The method includes limiting rotation of the second roller by contacting the raised portion of the second roller against the sheet material between the first and second rollers. The second roller is placed in contact with the first roller when sheet material from the first source is no longer between the first and second rollers. The second roller rotates to feed sheet material from the second source onto the first roller to permit dispensing of sheet material from the second source.




In another aspect, the dispenser includes a third rotatable roller. The third roller forms a nip with the first roller, and the method includes passing sheet material through the nip.




Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.




It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.











BRIEF DESCRIPTION OF THE DRAWINGS




The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one embodiment of the invention and together with the description, serve to explain the principles of the invention. In the drawings:





FIG. 1

is an isometric view of an embodiment of the invention;





FIG. 2

is a view similar to

FIG. 1

with a transfer roller removed to show a dispensing roller and a cutting roller;





FIG. 3

is a schematic cross-section view taken along line III-III of

FIG. 1

having the housing removed;





FIG. 4

is a exploded view of the cutting roller of

FIG. 1

;





FIG. 5

is a detailed view of a portion of

FIG. 3

showing dispensing from a first source;





FIG. 6

is a view similar to

FIG. 5

showing initial rotation of a transfer roller when sheet material from the first source becomes exhausted;





FIG. 7

is a view similar to

FIG. 6

showing sheet material from a second source being fed onto a dispensing roller;





FIG. 8

is a view similar to

FIG. 7

showing dispensing from the second source;





FIG. 9

is an isometric view of a second embodiment of the invention including a lever actuating system; and





FIG. 10

is an isometric view of a third embodiment of the invention including a motor driven system.











DESCRIPTION OF THE PREFERRED EMBODIMENTS




Reference will now be made in detail to the present exemplary embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.





FIGS. 1-3

show an embodiment of a sheet material dispenser


10


. The dispenser


10


includes a housing


12


having an outlet


14


and a cover (not shown). A first sheet material source


16


and a second sheet material source


18


are stored within the housing


12


. A dispensing roller


20


and an optional cutting roller


24


cooperate to dispense sheet material from either the first source


16


or second source


18


through the outlet


14


. A transfer roller


22


cooperates with the dispensing roller


20


to transfer dispensing from a first mode wherein sheet material is dispensed from the first source


16


to a second mode wherein sheet material is dispensed from to the second source


18


, upon depletion of the first source


16


.




In the preferred embodiment, the first source


16


and second source


18


are rolls of sheet material wound on cores


64


and


68


, respectively. The sheet material can be paper towel, toilet paper, tissue paper, wrapping paper, or any other sheet material. In the embodiment shown in

FIGS. 1-3

, the sheet material is preferably formed into individual sheets as it passes over the cutting roller


24


and is cut by a cutter


25


thereon.

FIG. 4

shows one arrangement for the cutter


25


, and will be discussed below. The cutter


25


could also be arranged in a number of other places on the dispenser


10


. Alternatively, the dispenser


10


lacks a cutter


25


and the sheet material includes spaced apart zones of weakness, such as perforation lines, that permit tearing off of separate sheets when they are dispensed.




The first source


16


is supported in a lower portion


26


of the housing


12


by spaced support members


29


and


31


. Alternatively, the support members


29


and


31


can be eliminated, allowing the first source


16


to be supported on the floor in the lower portion


26


. The second source


18


is rotatably supported by spaced support members


28


and


30


. The support members


28


and


30


are mounted in an upper portion


27


of the housing


12


.




The transfer roller


22


is located below the second source


18


. The transfer roller


22


, is rotatably supported by a left support block


42


and a right support block


44


. The transfer roller


22


has a smooth outer surface, and preferably is made of plastic. Transfer roller


22


has a plurality of first raised portions


32


, which are spaced from each other. Opposite each of the first raised portions


32


is one of a plurality of second raised portions


34


. A slot


36


extends completely through the transfer roller


22


between the plurality of first raised portions


32


and the plurality of second raised portions


34


. The slot


36


preferably has a width that is at least as large as the width of the sheet material of the second source


18


so that an end portion of the second source's sheet material can be retained in the slot


36


, as shown in

FIG. 3

, by passing therethrough. Although the slot


36


passing through the transfer roller


22


is preferred to releasably retain the end portion of sheet material, other retaining structure could be used.




Adjacent the transfer roller


22


is the dispensing roller


20


. The dispensing roller


20


includes a plurality of spaced roller sections


38


, wherein each roller section


38


has a surface


40


formed of rubber or some other material having a coefficient of friction greater than that of an outer surface of transfer roller


22


. The roller sections


38


can be made from wood, plastic, or metal. Adjacent pairs of the roller sections


38


are spaced from one another. Each space between the roller sections


38


is aligned with (and at least as wide as) corresponding first and second raised portions


32


and


34


. The dispensing roller


20


is rotatably supported by the left and right support blocks


42


and


44


, and is biased against the cutting roller


24


by springs


46


. Similarly, the transfer roller


22


is biased against the dispensing roller


20


by springs


45


. Alternatively, the weight of the transfer roller


22


can be used to bias the transfer roller


22


against the dispensing roller


20


, thereby eliminating the springs


45


.




The cutting roller


24


is rotatably supported in the housing


12


in any desireable manner, such as shown in FIG.


4


. In the preferred embodiment, the cutting roller is supported by support arms


17


and


19


. A cutter


25


is provided on the cutter roller


24


to cut sheet material into sheet segments as sheet material is dispensed. Support arm


19


includes a cam plate


21


. The cutter


25


is attached to a cam follower


23


which follows the surface of the cam plate


21


. As the cutting roller


24


rotates, the cutter


25


is extended and retracted as the cam follower


23


moves around the cam plate


21


.




In the first embodiment, the cutting roller


24


is rotated as the sheet is pulled from the dispenser, as it is preferred that the driving force for activation of the mechanism is provided by the tension exerted on the sheet as the user draws it from the dispenser. Dispensers so configured are usually referred to as “touchless”. An optional driving mechanism


56


is provided to rotate the cutting roller


24


. In the embodiment of

FIGS. 1-3

, the driving mechanism


56


is a rotatable knob, which in touchless configurations would serve as an emergency feed. Alternatively, the driving mechanism could be a push lever, or an electric motor, which will be described below.




A shield


58


is arranged to prevent sheet material from the second source


18


from coming into contact with the cutting roller


24


before the transfer roller


22


transfers dispensing to a mode wherein sheet material is dispensed from the second source


18


. Mounted to the shield


58


are a plurality of fingers


60


, which also assist in preventing sheet material from the second source


18


from contacting the cutting roller


24


before the transfer process is activated.




To load the dispenser


10


, an individual first opens the cover to expose the lower and upper portions


26


,


27


. The first source


16


is placed in the lower portion


26


of the housing


12


. A free end


62


of the sheet material of the first supply source


16


is placed over the rubberized surfaces


40


of the dispensing roller


20


, and then fed into the nip between the dispensing roller


20


and the cutting roller


24


. The driving mechanism


56


can be activated to advance the free end through the outlet


14


of the housing


12


. Then, the second source


18


is placed in the left and right support brackets


28


,


30


. A free end of sheet material


66


from the second source


18


is unwound and passed through the slot


36


of the transfer roller


22


. A few inches of the free end of sheet material


66


preferably extends beyond the slot


36


. Finally, the cover is closed, and the dispenser


10


is ready for use.




If the dispenser


10


had been loaded previously, then reloading has additional steps. After the cover is initially opened, the second source


18


is removed from the support brackets


28


,


30


. The empty core


64


from the first source


16


can then be removed. Then, the second source


18


can be placed in the lower portion


26


of the housing


12


, essentially replacing the first source


16


. A new second source


18


can be loaded as described above.




The sheet material could be dispensed from the dispenser


10


in any known manner. For example, a user could remove sheet material from the dispenser


10


in a “touchless” manner by merely pulling an end portion of sheet material that extends from the dispenser outlet


14


, or by actuating a proximity sensor that interacts with a dispensing motor for rotating the dispensing and/or cutting rollers


20


and


24


. In addition, the user is also preferably able to dispense sheet material by actuating a manually operated driving mechanism, such as the driving mechanism


56


.




The process of transferring dispensing modes between dispensing from the first source


16


and dispensing from the second source


18


is shown in

FIGS. 5-8

.

FIG. 5

shows the dispenser


10


operating in a first mode where sheet material is being dispensed from the first source


16


. As the cutting roller


24


rotates, the dispensing roller


20


rotates and sheet material is dispensed. The high coefficient of friction of the rubberized surfaces


40


causes the sheet material from the first source


16


to unwind. The transfer roller


22


is prevented from rotation by the plurality of first raised portions


32


coming in contact against the sheet material. The smooth surface


23


of the transfer roller


22


preferably does not hinder the dispensing of the sheet material. As long as sheet material from the first source


16


covers the spaces between the segments of the sections


38


of roller


20


, the transfer roller


22


does not rotate during dispensing.




Once the sheet material from the first source


16


is depleted, a tail end of the sheet material


70


will pass through an area between the dispensing roller


20


and the plurality of first raised portions


32


, as shown in

FIG. 6

, so that the transfer roller


22


contacts the dispensing roller


20


. Without any sheet material between the dispensing roller


20


and the transfer roller


22


, the rollers


20


and


22


become rotationally engaged and the rotation of the dispensing roller


20


causes the transfer roller


22


to rotate. As the transfer roller


24


rotates, the free end of sheet material


66


from the second source


18


contacts the dispensing roller


20


. As seen in

FIG. 7

, the free end of sheet material


66


will be pulled from the slot


36


in the transfer roller


22


. The rubberized surface


40


of the dispensing roller


20


grabs the free end of sheet material


66


and pulls the free end of sheet material


66


into the nip formed between the dispensing roller


20


and the cutting roller


24


. The plurality of second raised surfaces


34


then contact the sheet material on the dispensing roller


20


, thereby preventing further rotation of the transfer roller


22


. The dispenser


10


is now in the second mode of dispensing, as seen in

FIG. 8

, where the dispenser


10


is dispensing sheet from the second source


18


. In this configuration, the transfer roller


22


is set up for the next source to be loaded.




The preferred embodiment of the invention has many advantages, including complete use of sheet material. The transfer roller preferably allows easy loading of sheet material, defeating the need of maintenance personnel to bypass the transfer system. Preferably, less maintenance checks will be required because of the transfer system. In addition, the dispenser will preferably be more economical to use because the entire sheet material from each source will be used.




In a second embodiment of the invention, as seen in

FIG. 9

, the knob roller of the driving mechanism


56


is replaced with a lever actuation device


72


. The lever actuation device


72


includes a toothed wheel


74


and a pivot arm


76


. The toothed wheel


74


is coupled to the cutting roller


24


. The pivot arm


74


can be attached to the housing (not shown) and engages the toothed wheel


74


to rotate the cutting roller


24


. The lever actuation device


72


would serve as an emergency feed when the dispenser is configured as a “touchless” dispenser.




A tear bar


90


is provided to allow a user to tear off a sheet from the roll of sheet material. The tear bar


90


can be arranged in several different orientations at or near the opening of the housing (not shown). In addition the cutting roller


24


can be replaced with any suitable tensioning roller when the tear bar is provided.




In a third embodiment of the invention, as seen in

FIG. 10

, the knob roller of the driving mechanism


56


is replaced with a motor activation device


80


. The motor activation device includes a gear train


82


and motor


84


. The gear train includes a first gear


86


, a second gear


88


, and a drive gear


90


. The drive gear


90


is coupled to the motor


84


and engages the second gear


88


. The second gear


88


engages the first gear


86


, which is coupled to the cutting roller


24


. The motor


84


is activated by the user by any known switch, such as a push button (not shown). In a preferred embodiment, the motor is activated by a proximity sensor, thus providing “touchless” dispensing. The motor rotates the drive gear


90


, which in turn rotates the second gear


88


, which in turn rotates the first gear


86


, which in turn causes the cutting roller


24


to rotate. In addition,

FIG. 10

shows a tear bar


90


which serves the same purpose as described above.




Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. For example, a dispenser according to the invention could be constructed without a cutting roller. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.



Claims
  • 1. A method of dispensing sheet material, comprising:providing a dispenser containing first and second sources of sheet material, the dispenser including a first rotatable roller having at least one recessed portion and a second rotatable roller having at least one raised portion, the second roller having a retainer, the retainer including a slot passing completely through the second rollers; dispensing sheet material from the first source by passing the sheet material between the first and second rollers; retaining, in the retainer on the second roller, an end portion of sheet material from the second source, wherein the retaining includes passing the end portion of the sheet material from the second source through the slot; limiting rotation of the second roller by contacting the raised portion of the second roller against the sheet material between the first and second rollers; placing the second roller in contact with the first roller when sheet material from the first source is no longer between the first and second rollers; and rotating the second roller to thereby feed sheet material from the second source onto the first roller to permit dispensing of sheet material from the second source.
  • 2. A method of dispensing sheet material, comprising:providing a dispenser containing first and second sources of sheet material, the dispenser including a first rotatable roller having at least one recessed portion and a second rotatable roller having at least one raised portion, the second roller having a retainer; dispensing sheet material from the first source by passing the sheet material between the first and second rollers; retaining, in the retainer on the second roller, an end portion of sheet material from the second source; limiting rotation of the second roller by contacting the raised portion of the second roller against the sheet material between the first and second rollers; placing the second roller in contact with the first roller when sheet material from the first source is no longer between the first and second rollers; and rotating the second roller to thereby feed sheet material from the second source onto the first roller to permit dispensing of sheet material from the second source, wherein rotating the second roller includes moving the at least one raised portion into the at least one recessed portion.
  • 3. The method of claim 2, wherein the dispenser includes a third rotatable roller forming a nip with said first roller, and wherein the method further includes passing sheet material through the nip.
  • 4. The method of claim 2, wherein limiting rotation of the second roller includes limiting movement of the at least one raised portion into the at least one recessed portion when there is sheet material between the first and second rollers.
US Referenced Citations (36)
Number Name Date Kind
43692 Hugunin Aug 1864 A
119235 McDonald Sep 1871 A
2930664 Liebisch Mar 1960 A
3288387 Craven Nov 1966 A
3628743 Bastian et al. Dec 1971 A
3917191 Graham, Jr. et al. Nov 1975 A
4010909 Bastian Mar 1977 A
4067509 Graham, Jr. et al. Jan 1978 A
4148442 Baumann et al. Apr 1979 A
4165138 Hedge et al. Aug 1979 A
4203562 DeLuca et al. May 1980 A
4317547 Graham, Jr. et al. Mar 1982 A
4358169 Filipowicz et al. Nov 1982 A
4378912 Perrin et al. Apr 1983 A
4396163 Graham, Jr. et al. Aug 1983 A
4403748 Cornell Sep 1983 A
4487375 Rasmussen et al. Dec 1984 A
4611768 Voss et al. Sep 1986 A
4694714 Focke et al. Sep 1987 A
4756485 Bastian et al. Jul 1988 A
4807824 Gains et al. Feb 1989 A
4846412 Morand Jul 1989 A
4856724 Jespersen Aug 1989 A
4944466 Jespersen Jul 1990 A
5129294 Boldrini et al. Jul 1992 A
5294192 Omdoll et al. Mar 1994 A
5302167 Kley et al. Apr 1994 A
5375785 Boone et al. Dec 1994 A
5400982 Collins Mar 1995 A
5526973 Boone et al. Jun 1996 A
5772291 Byrd et al. Jun 1998 A
5924617 LaCount et al. Jul 1999 A
5979822 Morand et al. Nov 1999 A
6145779 Johnson et al. Nov 2000 A
6354533 Jespersen Mar 2002 B1
6460798 Haen et al. Oct 2002 B1
Foreign Referenced Citations (1)
Number Date Country
0 099 602 Feb 1984 EP