BACKGROUND AND SUMMARY OF THE INVENTION
The present invention is generally directed to dispensers and, more particularly, to a dispenser that may be transformed from a shipping form to a dispensing form for dispensing folded and stacked paper goods, such as paper towels.
Generally, paper dispensers for use in washroom settings fall into one of three types. Some dispensers are designed to dispense web material from a roll that is either manually rotated by a user or in a mechanized manner using a drive motor. In either case, a user then tears off the dispensed portion of the web material from the roll. A second type of dispenser maintains perforated web material in a roll with the material being fed from the center, when a user physically pulls on a leading edge of the web material extending from the dispenser. A third kind of dispenser is designed to store a stack of folded towels that may then be removed, preferably one at a time, from the dispenser. Typically, the paper towels are loaded into the dispenser such that gravity is used to draw the stack toward an opening or mouth formed in the bottom of the dispenser. The mouth is slightly smaller than the footprint of the stack such that the leading paper towel will be forced and held against the interior side of the bottom of the dispenser. This latter type of dispenser is generally wall mounted and consists of a housing which is openable to permit it to be filled with paper towels and a mouth cut into the bottom end of the housing. As such, there are no moving parts to facilitate the biasing and removal of a paper towel from the dispenser.
Such dispensers have, in the past, been shipped and stored as ready to dispense units. This means that large groups of dispensers to be shipped comprise a significant volume, much of which is air.
The present invention provides a transformable towel dispenser that can be quickly transformed from a low profile shipping form into a full, ready to dispense form in a substantially tool free manner. The transformability of the dispenser allows the dispenser to be shipped and stored in much smaller space than that for ready-to-dispense units. Alternatively, more dispensers can be shipped in the same volume container.
It is contemplated that the dispenser of the present invention may have a cover panel, a pair of side panels, a top panel, a bottom panel, and a back panel. In one embodiment, the side panels are hinged to the back panel in a manner that allows the side panels to fold flat onto the back panel. To assemble the dispenser, the side panels are rotated outward to a position perpendicular to the plane of the back panel. The top and bottom panels and the cover panel are then secured to the side panels and the back panel. Preferably, a snap fit or other substantially tool free means is used to interconnect the panels.
In another embodiment, the side panels are hinged to both the cover panel and the back panel. The top panel and the bottom panel are hinged to either the cover panel or the back panel. This allows the top and bottom panels to be folded inwardly and flat against either the cover panel or the back panel. The side panel hinged connections allow the side panels to also fold flat. To assemble the dispenser, the actions to fold the dispenser are generally reversed. The panels may then be locked or otherwise secured into place.
In yet a further embodiment, the panels that collectively form the dispenser are separated from one another and arranged in a generally flat configuration. To assemble the dispensers, the individual panels are connected to one another, preferably in a substantially tool-free manner.
It is therefore an object of the invention to provide a transformable dispenser that can be stored or shipped in a container smaller than that required to store an assembled dispenser or that can be stored or shipped in greater quantities in the same packaging as that required to store or ship ready-to-dispense dispensers.
It is another object of the invention to provide a dispenser that can be assembled in a relatively quick and tool-free manner.
Other objects, features, and advantages of the invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a dispenser according to one embodiment of the present invention shown in an assembled position relative to a shipping sleeve;
FIG. 2 is an isometric view of the dispenser of FIG. 1 shown in a disassembled, shipping position relative to a shipping sleeve;
FIG. 3 is an isometric view of a dispenser according to another embodiment of the invention shown in a disassembled, shipping position relative to a shipping sleeve;
FIG. 4 is an isometric view of a dispenser according to yet another embodiment of the invention shown in a disassembled, shipping position relative to a shipping sleeve;
FIG. 5 is an isometric view of a dispenser according to another embodiment of the invention shown in an assembled position;
FIG. 6 is an isometric view of the dispenser of FIG. 5 in a shipping form;
FIG. 7 is an exploded view of the dispenser of FIG. 5;
FIG. 8 is a side isometric view of a side panel of the dispenser of FIG. 5;
FIG. 9 is a front elevation view of the base of the dispenser of FIG. 5;
FIG. 10 is a left side elevation view of the base of FIG. 9;
FIG. 11 a rear elevation view of the bottom panel of the dispenser of FIG. 5;
FIG. 12 is a bottom view of the bottom panel shown in FIG. 11;
FIG. 13 is a front elevation view of an alternate bottom panel for use with the dispenser of FIG. 5;
FIG. 14 is a bottom view of the bottom panel of FIG. 13;
FIG. 15 is a side elevation view of the bottom panel of FIGS. 13 and 14;
FIG. 16 is a front elevation view of the front cover of the dispenser of FIG. 5;
FIG. 17 is a side elevation view of the front cover of FIG. 16;
FIG. 18 is a rear elevation view of the front cover of FIG. 16;
FIG. 19 is a side isometric view of a partition plate of the dispenser of FIG. 5; and
FIG. 20 illustrates one exemplary process for transforming the dispenser of FIG. 5 from its shipping form to its dispensing form.
DETAILED DESCRIPTION
FIG. 1 shows a ready to dispense standard towel dispenser 10 and a protective sleeve or package 12 into which the dispenser 10 may be placed for storage and/or shipping purposes. Such a dispenser 10 has a relatively large empty volume creating a relatively large vertical footprint. It will therefore be appreciated that shipping as well as shipping materials costs can be reduced if a smaller shipping container could be used or if more units can be fit into a standard shipping container. Moreover, it would also be preferred to construct the dispenser such that it can be transformed, once its components are removed from the shipping container, in a quick and substantially tool-free manner.
As shown in FIG. 1, the dispenser 10 generally consists of a cover panel 14, a left side panel 16, a right side panel 18, a top panel 20, a bottom panel 22 (“faceplate”), and a back panel 24. A mouth 26 is formed in the bottom panel 22 which allows a paper towel (not shown) to be removed from the interior volume of the dispenser. The dispenser 10 is preferably mounted in an upright position to a wall and thus gravity is used to present a paper towel to the mouth 26. It is contemplated that a mechanical biasing device, such as a spring and plate may also be used to bias the paper towel to the mouth 26. The dispenser 10 has a generally rectangular profile and thus is preferably loaded with a stack of generally rectangular paper towels.
FIG. 2 shows the dispenser 10 in a shipping configuration according to one embodiment of the invention. In the shipping configuration shown in the figure, the dispenser 10 may be loaded, stored and shipped in sleeve 28 which is considerably smaller than the sleeve 12 shown in FIG. 1. While the sleeves 12 and 28 shown in the figures are not to scale, one skilled in the art will appreciate that the differences in the sizes of the sleeves make it possible for many more units of the pre-assembled dispenser 10 of the present invention to be stored or shipped in the same space when compared to the pre-assembled dispensers of the prior art. A sleeve could be any type of container including a plastic bag, cardboard box, carton, or the like. In this embodiment, the panels of the dispenser 10 are loosely retained within the sleeve; although, it is contemplated that wrapping, bubble paper, and the like may be used to prevent marring and shifting of the components during shipping. Still further, multiple dispensers in their shipping configuration can be nested or stacked together. In such an arrangement the dispensers can be packaged as a group rather or individually.
The components of the dispenser 10 are preferably designed to be snap-fit together after the components are removed from the shipping container 28. It is understood that other types of fastening constructs could be used, but it is preferred that the dispenser be capable of being assembled without the need for tools.
Turning now to FIG. 3, a dispenser 10 that may be transformed according to an alternate embodiment of the invention is shown. The dispenser 10, when in a shipping configuration, is designed to fit within sleeve 28 for shipping or storage. In this embodiment, the side panels 16 and 18 are hinged to the back panel 24. This hinged connection allows the side panels 16 and 18 to each be folded inwardly to lay flat on the back panel 24. The cover panel 14, the top panel 20 and the bottom panel 22 are loose from the back panel 24 when stored in the container 28.
To transform the dispenser, the components are removed from the sleeve 28 and the side panels 16 and 18 are rotated from the lay-flat position to an upright position that is substantially perpendicular to the plane of the back panel 24. Preferably, the hinged connection does not permit over-rotation of the side panels 16 and 18. Once the side panels 16 and 18 have been rotated, the top panel 20 and the bottom panel 22 are attached, preferably in a tool-free manner, such as by a snap-fit type connection. The transformed dispenser 10 is then ready to be deployed in a known manner. In FIG. 3, the side panels 16 and 18 are shown in a position that is between the lie flat position and the fully rotated position.
FIG. 4 shows yet another shipping configuration for a dispenser 10 according to another embodiment of the invention. In this configuration, the side panels 16 and 18 are hinged to back panel 24 and the cover panel 14. The top and bottom panels 20 and 22 are also hinged to the cover panel 14. The hinged connection of the top and bottom panels 20 and 22 allows those panels to fold inwardly and generally flat against the cover panel 14. The hinged connection of the side panels 16 and 18 to the cover panel 14 and the back panel 24 allows the side panels to rotate to a generally flat position. When the side panels 16 and 18 are in the flat position, the cover panel 14 is also drawn down toward the back panel 24. Depending upon the degree of flatness the hinged panels 20, 22, 16 and 18 are able to achieve relative to the top panel 14 and bottom panel 24, the embodiment of FIG. 4 is either equivalent to or slightly larger than the “broken down” positions of the embodiments of FIGS. 2 and 3. Regardless, the shipping size of the embodiment of FIG. 4 is still markedly less than the size of the ready to use dispenser 10 of FIG. 1.
Still referring to FIG. 4, to transform the dispenser 10, the side panels 16 and 18 are rotated to their (near) vertical positions. This provides clearance to rotate the top and bottom panels 20 and 22 outwardly. The top and bottom panels 20 and 22 may then be attached to the back panel 24 and/or the side panels 16 and 18 to complete the transformation of the dispenser 10. Preferably, a snap-fit or other tool-free type connection is used to assemble the top and bottom panels 20 and 22 together but it is understood that other types of connections may be used.
FIGS. 5 through 19 illustrate a transformable dispenser according to another embodiment of the invention. FIG. 5 shows the dispenser 10 in its dispensing form and FIG. 6 shows the dispenser 10 in its shipping form. In its shipping form, the profile of the dispenser is approximately one-half of its profile when in the dispensing form. This allows the dispenser 10 to fit in substantially smaller packaging, such as sleeve 28 described above and shown in FIG. 2.
The dispenser 10 has a base 11, collectively defined by top panel 20 and back panel 24, side panels 16, 18, bottom panel 22, and a cover or front panel 14. When assembled into its dispensing form, shown in FIG. 5, the depth or profile of the dispenser, e.g., distance from front cover 14 to back panel 24, is defined by the width of the side panels 16, 18, which in the illustrated embodiment have a forward edge 16a, 18a and a rearward edge 16b, 18b, respectively, as shown in FIGS. 7 and 8. The forward and rearward edges are interconnected by a top edge 16c, 18c, respectively, that mate with the top panel 20 when the side panels 16, 18 are connected to the base 11. As shown particularly in FIGS. 7, 8, and 9, lateral edges 24a, 24b of the back panel 24 include tabs 30 that interfit with notches 32 formed in the rearward edges 16b, 18b of the side panels 16, 18. In a preferred embodiment, the tabs 30 snap into the notches 32 to provide a secure interconnection of the side panels and the base.
As shown in FIG. 10, the back panel 24 has a curvature that is matched by the curvature of the rearward edges 16b, 18b of the side panels 16, 18, respectively. An upper portion 34 of the back panel 24 is flat to fit flat against a mounting structure, e.g., bathroom wall, whereas a lower portion 36 of the back panel 24 is curved. This curvature results in the bottom panel 22 of the dispenser 10 being spaced from the mounting structure and the mouth 38 angled to a more convenient dispensing position.
Referring now to FIGS. 11-12, the bottom panel 22 has an opening or mouth 38 to facilitate the withdrawal of product from the dispenser 10. It should be understood that different, interchangeable bottom panels 22 could be used with the dispenser so that the type of mouth is matched to the type of product to be withdrawn from the dispenser. One exemplary alternate bottom panel 22 is shown in FIGS. 13-15.
The bottom panel 22 has a shaped opening 38 forming a mouth, as described above. The body of the bottom panel 22 has a set of alignment tabs 40 that are received in notches 42 formed in a lower end of the back panel 24. In addition, the bottom panel 22 has flexure tabs 44 that engage notches 46 formed in the side panels 16, 18 to connect the bottom panel 22 to the side panels 16, 18. Extending axially or laterally from the bottom panel 22 is a pair of mounting points 48 that engage the front cover 14 for pivotably mounting the front cover 14 to the bottom panel 22. More particularly, as shown in FIGS. 16 and 17, the front cover 14 has a pair of flanges 50, with each having a keyhole 52 shaped to engage the mounting points 48 of the bottom panel 22. When attaching the front cover 14 to the bottom panel 22, the flanges 50 are flexed slightly outwardly to align the keyholes 52 with the mounting points 48. While keeping this alignment, the flexing force is removed which allows the flanges 50 to move to the default position. In doing so, the mounting points 48 pass through the keyholes 52 thereby interconnecting the front cover 14 and the bottom panel 22. Moreover, the fitting of the mounting points 48 within the keyholes 52 allows the front cover 14 to be rotated about the mounting points 48 to pivot the front cover 14 away from the base 11, such as for loading the dispenser with towels. In one preferred embodiment, the dispenser 10 may also include partitioning plates 54 that snap fit into engagement with the back panel 24.
Referring again to FIGS. 7 and 9 as well as reference to FIG. 18, the back panel 24 includes longitudinal grooves 56 that define multiple positions at which the plates 54 may be connected to the back panel 24. The plates 54 are designed to bookend the stack of towel material (not shown) contained in the dispenser 10 and, in this regard, the plates 54 should be connected to the back panel 24 such that the space between the plates 54 corresponds to the width of the stack of towel material contained in the dispenser. As shown in FIG. 19, the plates 54 have a tab 58 that interfit with a notch 60 formed in the back panel 24 to connect the plates 54 to the back panel 24.
Referring briefly back to FIG. 7, the dispenser 10 also has a finger lock 62 that snap fits into engagement with the back panel 24. When the dispenser 10 is assembled, a key (not shown) may be inserted into keyhole 64 formed in the front cover 10. When the key is inserted into the keyhole, the finger lock 62 is flexed downwardly to disengage teeth 66 from engagement with strike members 68 formed in the underside of the front cover 14, which are shown in FIG. 18, thereby allowing the front cover 14 to be pivoted away from the base 11. It should be understood that the other types of locking assemblies may be used.
Referring now to FIG. 20 the dispenser 10 shown in FIGS. 5-19 can be assembled in four steps without the use of tools. After the components of the dispenser 10 have been removed from their packaging, in step #1, the side panels 16, 18 are slid into engagement with the base 11. More particularly, the top edge 16c, 18c, of the side panels 16, 18, respectively, slide into slots 20a, 20b, FIG. 9, formed on the underside of the top panel 20. When fully slid into place, the tabs 32 of the side panels 16, 18 are received by notches 30 of the base 11 and snap into place to secure the side panels to the base. In a preferred embodiment, this action cannot be undone. Thus, in one embodiment, once the side panels are connected to the base, the side panels cannot be disconnected without damaging the side panels and/or base.
In the next step, step #2, the bottom panel 22 is engaged with the back panel 24 and the side panels 16, 18. The alignment tabs 40 are inserted into notches 42 and then the bottom panel 22 is pivoted upward while maintaining the engagement of the tabs 40 and notches 42. The bottom panel 22 is pivoted upward until flexure tabs 44 snap into engagement with the side panels 16, 18. As noted above, the side panels 16, 18 have notches 46 that receive the flexure tabs 44 when the bottom panel 22 is mounted to the base 11 and the side panels 16, 18. As also noted above, different, interchangeable bottom panels may be used. In this regard, the bottom panel 22 is designed to be removably mounted to the base 11 and the side panels 16, 18.
In step #3 the finger lock 62 is mounted to the base 11. It is understood that the finger lock 62 could be mounted to the base 11 before the bottom panel 22 is mounted into place. Likewise, the lock 62 could be mounted to the base after the front cover is mounted in step #4 described below.
Finally, the front cover 14 is mounted to the bottom panel 22 in step #4. As described above, the flanges 50 are flexed to fit over the mounting points 48 of the bottom panel 22 to enable the mounting points to pass through the keyholes 52. The front cover 14 may be then rotated upward to the closed position, as shown in FIG. 5.
It is contemplated that the dispenser may be formed of known materials, such as PVC, plastic, stainless steel, and the like. Moreover, while a paper towel dispenser has been described, it is understood that the principles of the invention may also be applied to toilet paper dispensers, napkin dispensers, and other types of dispensers. It is also understood that other types of shipping configurations may be used. For example, the side panels, the top panel, and the bottom panel may have an accordion like construction that allows the height of the panels to be reduced for storage and shipping purposes and then extended when the dispenser is being transformed.
While the invention is not limited to any particular size or dimensions, it will be appreciated that in one embodiment, the dispenser 10, when in its shipping form, has a profile that is approximately one-half the height of the dispenser when in its dispensing form. For example, in one embodiment, the dispenser 10 in its dispensing form has a depth (profile) of approximately six inches but has a depth of approximately three inches when in its shipping form. Conventional dispensers are shipped fully assembled and thus it will be appreciated that the present invention allows the dispenser to be shipped in substantially smaller packaging. The reduction in shipping material provides a cost savings that can be reflected in the retail/wholesale price of the dispenser. Additionally, when shipping a bulk of dispensers, the reduction in shipping size allows more dispensers to be loaded into a single shipping container—which also provides a reduction in shipping costs.
Many changes and modifications could be made to the invention without departing from the spirit thereof. The scope of these changes will become apparent from the appended claims.
Patent Application
20120267387
