US20110253828A1 - Automated sheet product dispenser - Google Patents
Automated sheet product dispenser Download PDFInfo
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- US20110253828A1 US20110253828A1 US13/169,683 US201113169683A US2011253828A1 US 20110253828 A1 US20110253828 A1 US 20110253828A1 US 201113169683 A US201113169683 A US 201113169683A US 2011253828 A1 US2011253828 A1 US 2011253828A1
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- United States
- Prior art keywords
- sheet product
- dispenser
- roll
- paper
- baffle
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
- A47K10/36—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means with mechanical dispensing, roll switching or cutting devices
- A47K10/3656—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means with mechanical dispensing, roll switching or cutting devices with paper jam preventing devices
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
- A47K10/36—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means with mechanical dispensing, roll switching or cutting devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H16/00—Unwinding, paying-out webs
- B65H16/005—Dispensers, i.e. machines for unwinding only parts of web roll
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
- B65H20/00—Advancing webs
- B65H20/02—Advancing webs by friction roller
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
- A47K10/36—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means with mechanical dispensing, roll switching or cutting devices
- A47K10/3606—The cutting devices being motor driven
- A47K10/3612—The cutting devices being motor driven with drive and pinch rollers
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
- A47K10/36—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means with mechanical dispensing, roll switching or cutting devices
- A47K10/3606—The cutting devices being motor driven
- A47K10/3625—The cutting devices being motor driven with electronic control means
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
- A47K10/36—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means with mechanical dispensing, roll switching or cutting devices
- A47K2010/3668—Detection of the presence of a user
-
- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
- A47K10/00—Body-drying implements; Toilet paper; Holders therefor
- A47K10/24—Towel dispensers, e.g. for piled-up or folded textile towels; Toilet-paper dispensers; Dispensers for piled-up or folded textile towels provided or not with devices for taking-up soiled towels as far as not mechanically driven
- A47K10/32—Dispensers for paper towels or toilet-paper
- A47K10/34—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means
- A47K10/38—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means the web being rolled up with or without tearing edge
- A47K2010/3881—Dispensers for paper towels or toilet-paper dispensing from a web, e.g. with mechanical dispensing means the web being rolled up with or without tearing edge with tearing edges having movable parts
Definitions
- the present disclosure generally relates to sheet product dispensers and, more particularly, to sheet product dispensers having controlled dispensing mechanisms.
- Electronic paper product dispensers are well known in the art, including dispensers that automatically dispense a metered length of paper material upon sensing the presence of a user.
- This type of dispenser has become known in the art as a “hands-free” dispenser in that it is not necessary for the user to manually actuate or otherwise handle the dispenser to initiate a dispense cycle.
- the control systems and mechanical aspects of conventional hands-free dispensers are wide and varied. Electric drive motors are often used to power dispensing mechanisms. Known control systems provide abrupt activation and deactivation of these drive motors during a dispense cycle. Such abrupt changes in motor speed results in impulses which are transferred to system components and the paper product during the dispense cycle. Paper jamming and excessive parts wear may result.
- paper product remains engaged with the tear bar after the dispensed sheet has been removed by a user. If left in place, this engagement by the sheet and the tear bar often results in jamming during a subsequent dispense cycle.
- a sheet product dispenser comprises a sheet product feed mechanism coupled to a DC stepper motor, the mechanism moving a sheet product out of the dispenser during a dispense cycle; and a control unit controlling the DC stepper motor to move the sheet product with a gradually increasing acceleration during a portion of the dispense cycle.
- a roller assembly for a sheet product dispenser comprises a roller frame; and a plurality of flexible rubber portions spaced along a length of the roller frame, the rubber portions being overmolded onto the roller frame.
- a sheet product dispenser comprises a back cover; and a pair of flexible support arms having hub ends adapted to couple to a sheet product roll support shaft, with one of the support arms engaging a base extending away from a rear wall of the back cover and the other support arm being connected to the rear wall, wherein the base limits the deflection capability of one of the support arms, wherein insertion of the sheet product roll support shaft into hub ends causes the support arm connected to the rear wall to deflect to a substantially greater degree than the other support arm.
- a sheet product dispenser comprises a roller carried within a chassis of a dispensing mechanism, the roller being supported at its ends by a pair of shaft plugs, the shaft plug including an aperture for receiving a portion of a roller shaft and an aperture sized to receive a spring, the chassis defining a pair of plug retainers for holding the plugs and roller, the springs tending to bias the roller away from the spring retainers.
- a sheet product dispenser comprises a cover; a pair of arms supporting a roll of sheet product within the cover, the roll of sheet product rotating upon activation of the dispenser during a dispense cycle; and a baffle adapted to deflect upon contact with the roll of sheet product and remain engaged against the roll of sheet product during at least a significant portion of a roll life.
- FIG. 1 is a schematic illustration of a dispenser
- FIG. 2 is an illustration of a portion of a dispenser
- FIG. 3 is an illustration of a portion of the dispenser
- FIG. 4 is an illustration of speed and acceleration curves for motor speed or paper product dispense speed for a dispenser
- FIG. 5 is an illustration of a paper product speed curve
- FIG. 6 is an illustration of a paper product speed curve
- FIG. 7 is an illustration of a paper product speed curve
- FIG. 8 is a flow diagram of a control system operation
- FIG. 9 is an exploded view of a dispenser
- FIG. 10 is an exploded view of a dispenser
- FIG. 11 is a perspective view of a support arm for a dispenser
- FIG. 12 is a side view of a support arm for a dispenser
- FIG. 13 is a top perspective view of a back cover for a dispenser with a baffle
- FIG. 14 is an enlarged view of a portion of a back cover for a dispenser with a baffle
- FIG. 15 is a perspective view of a shaft plug for a dispenser
- FIG. 16 is an enlarged portion of a dispenser highlighting shaft plugs, compression spring, and spring retainer.
- FIG. 17 is a side view of a drive roller for a dispenser
- FIG. 18 is an exploded view of a drive roller for a dispenser
- FIG. 19 is a side view of a pinch roller for a dispenser.
- FIG. 20 is an exploded view of a pinch roller for a dispenser.
- sheet products is inclusive of natural and/or synthetic cloth or paper sheets. Further, sheet products can include both woven and non-woven articles. Examples of sheet products include, but are not limited to, wipers, napkins, tissues, and towels. For ease in discussion, however, reference is hereinafter made to embodiments particularly suited for paper products.
- FIG. 1 a schematic illustration of a sheet product dispenser, generally designated 10 , is provided to illustrate various mechanical components employed in exemplary automatic sheet product dispensers with the understanding that the mechanical components disclosed herein are not limiting to the invention.
- Exemplary mechanical aspects of dispensers include, but are not limited to, those mechanical aspects disclosed in U.S. Pat. Nos. 6,592,067; 6,793,170; 6,838,887; 6,871,815; 7,017,856; 7,102,366; 7,161,359; 7,182,288; 7,182,289; and U.S. Patent Publication No. 2007/0194166, each patent and patent application being incorporated herein by reference in its entirety.
- the sheet product dispenser 10 includes a sheet product supply, such as a roll 11 of sheet product (e.g., tissue or paper towel) and a feed mechanism for moving sheet product within and out of dispenser 10 .
- Feed mechanism may include a feed roller 20 , pinch roller 21 and sheet product chute 22 .
- Dispenser 10 may be adapted for hands-free operation for dispensing one or more rolls 11 of sheet product.
- Dispenser 10 may further include a tear bar assembly 13 allowing a sheet of the sheet product to be separated from sheet product roll 11 .
- tear bar assembly 13 includes a tear bar 30 and switch 31 in communication with a microprocessor (also referred to interchangeably as controller) as described in more detail hereinafter.
- a microprocessor also referred to interchangeably as controller
- a user pulls portion 32 downward against stationary tear bar 30 .
- contact is made between the sheet and movable arm 34 causing arm 34 to rotate into contact with switch 31 .
- switch 31 signals controller 16 that a tear operation has taken place.
- the tear bar 30 may be omitted.
- Dispenser 10 includes a DC (direct current) stepper motor 14 and transmission 15 .
- Transmission 15 may include gears, pulleys, belts, and the like to transfer rotational forces from stepper motor 14 to feed mechanism 12 .
- transmission 15 includes a motor shaft, which directly couples stepper motor 14 to feed roller 20 .
- Stepper motor 14 is powered by power supply (not shown), such as a battery pack or external AC (e.g., with an appropriate transformer and adapter) or DC power supply.
- power supply not shown
- the dispenser 10 may be configured to be switched between battery power and AC power.
- DC stepper motors are typically brushless. Failure-prone components of brushes and commutator are eliminated in stepper motors. Stepper motors move in quantified increments or steps and as long as the motor runs within its specification, the position of the shaft is known at all times without the need for a feedback mechanism.
- a controller such as proportional integral differential (PID) microcontroller, can be used for implementation of stepper motor control techniques. Other microcontrollers could also be used.
- PID proportional integral differential
- controller 16 includes a microcontroller 46 .
- CMOS FLASH-based 8-bit microcontroller model PIC16F72, which features 5 channels of 8-bit analog-to-digital (A/D) converter with 2 additional timers, capture/compare/PWM (pulse-width-modulation) function and a synchronous serial port.
- A/D analog-to-digital
- PIC16F72 model PIC16F72
- Inputs to controller 16 can include a battery voltage signal, a tear bar activation signal, a cover switch signal, a paper length switch signal, a towel delay switch, a manual advance switch signal and an on switch signal.
- Outputs of control unit 16 can include a motor control signals and LED signals. Motor control signals are used to control stepper motor 14 and hence the speed of paper moved by feed mechanism 12 as described herein.
- Stepper motor 14 can be a bipolar stepper motor. Stepper motor 14 can run more efficiently than a regular DC motor with gear reduction. Stepper motor 14 allows for a smaller battery package using three D-Cell batteries, rather than four or more D-cell batteries of prior art dispensers, with comparable battery life per roll.
- FIG. 4 illustrates relationships between sheet product dispense speed, acceleration and time over a dispense cycle of the dispenser 10 .
- FIG. 4 also illustrates velocity and acceleration curves exhibited by stepper motor 14 during the dispense cycle.
- a dispense cycle is initiated by ON switch activation (i.e., a user dispense request).
- the ON switch signal may be provided, for example, by a push button switch, an I/R (infrared) proximity sensor, a capacitance-based proximity sensor or another electronic proximity sensor.
- a length of sheet product is dispensed during a dispense cycle.
- FIG. 4 shows possible curves for both the speed and acceleration of stepper motor 14 speed during initial, intermediate and terminal portions of the dispense cycle.
- stepper motor 14 speed increases to a maximum motor speed.
- stepper motor 14 speed is generally constant. The length of the intermediate portion may be fixed or variable as determined by controller 16 .
- stepper motor 14 speed gradually decreases to zero.
- the dispense cycle has a length of between 5 to 10 seconds for a non-continuous mode of operation.
- Controlled acceleration of the sheet product may also decrease the impulse loads applied through the transmission and dispensing mechanism.
- FIG. 4 illustrates particular curves of velocity and acceleration during a dispense cycle
- curves of velocity and acceleration during a dispense cycle may vary.
- motor velocity may increase linearly during the initial portion of the dispense cycle or the length of the intermediate portion may be shortened or lengthened depending on a particular application or product and depending on the voltage measured during the cycle or preceding cycles. It is envisioned that a variety of different curves could be utilized to practice the concept of controlled velocity and/or acceleration of the product during a dispense cycle.
- FIG. 5 illustrates another paper speed curve during a dispense cycle.
- the paper direction is initially reversed prior to forward advancement. In some situations, this reverse paper movement disengages the paper product from contact with the tear bar in order to avoid paper jamming.
- a tear bar switch signal may be used to initiate a reverse paper movement. For example, if the tear bar switch 31 is activated upon a user request (via IR sensor, for example), controller 16 could initially reverse paper movement to pull the paper product away from tear bar 30 . The length of reverse paper movement can be accurately controlled via controller 16 .
- FIG. 6 illustrates another paper speed curve wherein multiple reversals are made to the paper product upon activation of a dispense cycle.
- FIG. 7 illustrates yet another example of a paper speed curve wherein a paper reversal occurs after forward movement of the paper through dispenser 10 ( FIG. 1 ). Such a paper reversal may be triggered by detection of a tear bar switch activation after some period of time. Alternatively, such a paper reversal may occur during each dispense cycle regardless of whether the tear bar switch remains activated or not.
- the paper cycle may include an initial paper reversal followed by forward motion and finally yet another paper reversal.
- FIG. 8 illustrates an embodiment of a process flow chart for dispenser 10 .
- Dispenser 10 remains in a Standby state until IR sensor detects a user request at step 1002 .
- An inquiry of tear bar switch status is made at step 1004 . If tear bar switch is activated, controller 16 drives stepper motor 14 in reverse at step 1006 , for example, following a reverse curve of FIGS. 5-7 . If tear bar switch is not activated or upon completion of a paper reversal at step 1006 , controller 16 drives stepper motor 14 in a forward direction at step 1008 , for example following forward motion curves of FIGS. 5-7 . A time delay based on towel delay switch occurs at step 1010 prior to a return to the Standby state.
- dispenser 10 includes back cover 1101 , battery lid 1102 , battery contact 1103 , chassis 1104 , chassis cover 1105 , circuit board 1106 , compression spring 1107 , drive roller 1108 , front cap 1109 , front cover 1110 , stepper motor 14 , lens 1112 , lock 1113 , lock latch 1114 , pinch roller 1115 , shaft plug 1116 , support arm 1117 and tear bar 1118 .
- the drive roller assembly is packaged in a modular unit with tear bar 1118 , stepper motor 14 , battery pack, IR sensor assembly, and circuit board 1106 .
- the modular unit can be assembled away from the remaining portions of dispenser 10 . Dispenser components can then be brought together at final assembly.
- the modular unit can also be used as a service kit to replace only the modular unit of a defective dispenser 10 without removing dispenser 10 from the customer site.
- a pair of support arms 1117 are provided to support hub ends of a paper product shaft.
- One of the arms 1117 is secured against base 1702 while the other arm 1117 is secured against base 1703 (shown in FIG. 13 ).
- An opening 1804 at support arm 1117 end provides for a snap-fit connection between arm 1117 and the paper shaft hubs.
- Each arm 1117 includes a rib 1806 . Rib 1806 engages extension 1704 of base 1702 . Base 1703 does not have extension 1704 and arm rib 1806 does not directly engage base 1703 .
- the deflection capability (in a direction toward outer walls of the dispenser) of arm 1117 secured against base 1702 is significantly less than the deflection capability of the other arm 1117 secured against base 1703 (rib 1806 contacting extension 1704 limits deflection of one arm). Consequently, when the paper roll is inserted into dispenser 10 , arm 1117 secured against base 1703 deflects to a substantially greater degree than the other arm 1117 .
- the deflection of support arms 1117 promotes ease of assembly and improved stability of the mounted roll holder and assists in inserting the roll of paper product 11 during replacement.
- FIGS. 12 and 13 illustrate an overspin baffle 200 attached to back cover 1101 .
- overspin baffle 200 is connected to cover 1101 through hinge element 202 .
- Hinge element 202 can be a living hinge or other known structure. Hinge element may be optional.
- one end of baffle 200 may be rigidly connected to cover 1101 .
- Baffle 200 is preferably a resilient element adapted to deflect upon contact with the roll of paper product 11 and remain engaged with the roll throughout at least a significant portion of the roll life. Baffle 200 provides sufficient friction to limit overspin of the roll.
- baffle 200 is generally triangular in form and made of a flexible plastic or metal sheet. Other shapes and cross sections would be practicable.
- baffle 200 may be coupled to other portions of back cover 1101 or front cover 1110 .
- FIGS. 15-16 illustrate shaft plug 1116 , spring 1107 , and pinch roller 1115 in detail.
- Shaft plug 1116 includes an aperture 2402 sized to receive shaft 3302 ( FIG. 19 ) of pinch roller 1115 or shaft 2812 of feed roller 1108 ( FIG. 18 ).
- a bearing surface for pinch roller 1115 and feed roller 1108 is provided by aperture 2202 .
- Plug 1116 includes an aperture 2404 sized to receive one end of spring 1107 .
- the other end of spring 1107 engages spring retainer 2602 ( FIG. 16 ).
- a pair of plugs 1116 are used to connect pinch roller 1115 to chassis 1104 .
- Each pinch roller plug 1116 is able to slide along plug flange structure 2502 .
- drive roller 1108 is coupled to stepper motor 14 at end hub 2602 .
- a motor shaft portion is inserted into end hub 2602 of drive roller 1108 .
- a d-shaped motor shaft may be inserted into a correspondingly-shaped slot at end hub 2602 .
- Drive roller 1108 is provided with a flexible coupling 2604 at end hub 2602 .
- Flexible coupling 2604 for interconnecting drive roller 1108 to stepper motor 14 accommodates shaft misalignments and permits limited deflection in non-axial directions.
- Flexible coupling 2604 in this illustrated embodiment, is helical beam coupler.
- the beam coupler 2604 includes one or more sets of flexible elements, in effect curved beams.
- Helical beam coupling 2604 reduces motor vibration for increased paper feed stability and reduces sound generation.
- Beam coupling 2604 in the illustrated embodiment, is integrated with the balance of drive roller 1108 . In other embodiments, a beam coupling may be a separate component.
- both pinch roller 1115 and drive roller 1108 may be assembled using an overmolding technique whereby a relatively rigid roller frame is molded onto a shaft and flexible roller rubber portions are then overmolded onto the roller frame to define roller surfaces.
- An example method of manufacturing includes inserting shaft 2812 of feed roller 1108 into a die form and molding roller frame 2810 around shaft 2812 . The shaft 2812 and frame 2810 are then inserted into another die form where roller rubber portions 2808 are molded into contact with roller frame 2810 .
- frame 2810 is injection molded acetal and rubber portions 2808 are injection molded EPDM.
- a similar method may be used to manufacture pinch roller 1115 of FIGS. 33-34 .
- rollers 1115 and 1108 are more easily assembled as compared to prior art roller assemblies having multiple separate roller rubber portions and frame portions needing to be aligned along a roller shaft during assembly.
- Benefits of such overmolded rollers include improve paper feed quality and a reduction in component assembly cost.
Abstract
A sheet product dispenser includes a cover, a pair of arms supporting a roll of sheet product within the cover, and a baffle. The roll of sheet product rotates upon activation of the dispenser during a dispense cycle. The baffle is adapted to deflect upon contact with the roll of sheet product and remain engaged against the roll of sheet product during at least a significant portion of a roll life.
Description
- This application is a divisional application of U.S. Ser. No. 11/866,510, filed Oct. 3, 2007, which claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/849,209, filed Oct. 3, 2006, and U.S. Provisional Patent Application No. 60/849,194, filed Oct. 3, 2006, all of which are herein incorporated by reference in their entirety.
- The present disclosure generally relates to sheet product dispensers and, more particularly, to sheet product dispensers having controlled dispensing mechanisms.
- Electronic paper product dispensers are well known in the art, including dispensers that automatically dispense a metered length of paper material upon sensing the presence of a user. This type of dispenser has become known in the art as a “hands-free” dispenser in that it is not necessary for the user to manually actuate or otherwise handle the dispenser to initiate a dispense cycle. The control systems and mechanical aspects of conventional hands-free dispensers are wide and varied. Electric drive motors are often used to power dispensing mechanisms. Known control systems provide abrupt activation and deactivation of these drive motors during a dispense cycle. Such abrupt changes in motor speed results in impulses which are transferred to system components and the paper product during the dispense cycle. Paper jamming and excessive parts wear may result.
- In some situations, paper product remains engaged with the tear bar after the dispensed sheet has been removed by a user. If left in place, this engagement by the sheet and the tear bar often results in jamming during a subsequent dispense cycle.
- Accordingly, a continual need exists for improved automated sheet product dispensers.
- Disclosed herein are automated sheet product dispensers.
- In one embodiment, a sheet product dispenser comprises a sheet product feed mechanism coupled to a DC stepper motor, the mechanism moving a sheet product out of the dispenser during a dispense cycle; and a control unit controlling the DC stepper motor to move the sheet product with a gradually increasing acceleration during a portion of the dispense cycle.
- In one embodiment, a roller assembly for a sheet product dispenser comprises a roller frame; and a plurality of flexible rubber portions spaced along a length of the roller frame, the rubber portions being overmolded onto the roller frame.
- In one embodiment, a sheet product dispenser comprises a back cover; and a pair of flexible support arms having hub ends adapted to couple to a sheet product roll support shaft, with one of the support arms engaging a base extending away from a rear wall of the back cover and the other support arm being connected to the rear wall, wherein the base limits the deflection capability of one of the support arms, wherein insertion of the sheet product roll support shaft into hub ends causes the support arm connected to the rear wall to deflect to a substantially greater degree than the other support arm.
- In one embodiment, a sheet product dispenser comprises a roller carried within a chassis of a dispensing mechanism, the roller being supported at its ends by a pair of shaft plugs, the shaft plug including an aperture for receiving a portion of a roller shaft and an aperture sized to receive a spring, the chassis defining a pair of plug retainers for holding the plugs and roller, the springs tending to bias the roller away from the spring retainers.
- In one embodiment, a sheet product dispenser comprises a cover; a pair of arms supporting a roll of sheet product within the cover, the roll of sheet product rotating upon activation of the dispenser during a dispense cycle; and a baffle adapted to deflect upon contact with the roll of sheet product and remain engaged against the roll of sheet product during at least a significant portion of a roll life.
- The above described and other features are exemplified by the following Figures and detailed description.
- Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:
-
FIG. 1 is a schematic illustration of a dispenser; -
FIG. 2 is an illustration of a portion of a dispenser; -
FIG. 3 is an illustration of a portion of the dispenser; -
FIG. 4 is an illustration of speed and acceleration curves for motor speed or paper product dispense speed for a dispenser; -
FIG. 5 is an illustration of a paper product speed curve; -
FIG. 6 is an illustration of a paper product speed curve; -
FIG. 7 is an illustration of a paper product speed curve; -
FIG. 8 is a flow diagram of a control system operation; -
FIG. 9 is an exploded view of a dispenser; -
FIG. 10 is an exploded view of a dispenser; -
FIG. 11 is a perspective view of a support arm for a dispenser; -
FIG. 12 is a side view of a support arm for a dispenser; -
FIG. 13 is a top perspective view of a back cover for a dispenser with a baffle; -
FIG. 14 is an enlarged view of a portion of a back cover for a dispenser with a baffle; -
FIG. 15 is a perspective view of a shaft plug for a dispenser; -
FIG. 16 is an enlarged portion of a dispenser highlighting shaft plugs, compression spring, and spring retainer. -
FIG. 17 is a side view of a drive roller for a dispenser; -
FIG. 18 is an exploded view of a drive roller for a dispenser; -
FIG. 19 is a side view of a pinch roller for a dispenser; and -
FIG. 20 is an exploded view of a pinch roller for a dispenser. - Disclosed herein are automated sheet product dispensers. The term “sheet products” is inclusive of natural and/or synthetic cloth or paper sheets. Further, sheet products can include both woven and non-woven articles. Examples of sheet products include, but are not limited to, wipers, napkins, tissues, and towels. For ease in discussion, however, reference is hereinafter made to embodiments particularly suited for paper products.
- Referring now to
FIG. 1 , a schematic illustration of a sheet product dispenser, generally designated 10, is provided to illustrate various mechanical components employed in exemplary automatic sheet product dispensers with the understanding that the mechanical components disclosed herein are not limiting to the invention. Exemplary mechanical aspects of dispensers include, but are not limited to, those mechanical aspects disclosed in U.S. Pat. Nos. 6,592,067; 6,793,170; 6,838,887; 6,871,815; 7,017,856; 7,102,366; 7,161,359; 7,182,288; 7,182,289; and U.S. Patent Publication No. 2007/0194166, each patent and patent application being incorporated herein by reference in its entirety. - In one embodiment, referring to
FIGS. 1-3 , thesheet product dispenser 10 includes a sheet product supply, such as aroll 11 of sheet product (e.g., tissue or paper towel) and a feed mechanism for moving sheet product within and out ofdispenser 10. Feed mechanism may include afeed roller 20,pinch roller 21 andsheet product chute 22.Dispenser 10 may be adapted for hands-free operation for dispensing one ormore rolls 11 of sheet product.Dispenser 10 may further include atear bar assembly 13 allowing a sheet of the sheet product to be separated fromsheet product roll 11. - As shown in
FIG. 3 ,tear bar assembly 13 includes atear bar 30 and switch 31 in communication with a microprocessor (also referred to interchangeably as controller) as described in more detail hereinafter. In operation, to remove aportion 32 ofsheet product roll 11, a user pullsportion 32 downward againststationary tear bar 30. Assheet portion 32 is pulled againsttear bar 30, contact is made between the sheet andmovable arm 34 causingarm 34 to rotate into contact withswitch 31. Upon engagement witharm 34, switch 31signals controller 16 that a tear operation has taken place. In cases where perforated paper is dispensed, thetear bar 30 may be omitted. -
Dispenser 10 includes a DC (direct current)stepper motor 14 andtransmission 15.Transmission 15 may include gears, pulleys, belts, and the like to transfer rotational forces fromstepper motor 14 tofeed mechanism 12. In one embodiment,transmission 15 includes a motor shaft, which directly couplesstepper motor 14 to feedroller 20.Stepper motor 14 is powered by power supply (not shown), such as a battery pack or external AC (e.g., with an appropriate transformer and adapter) or DC power supply. Moreover, it is to be understood that thedispenser 10 may be configured to be switched between battery power and AC power. - DC stepper motors are typically brushless. Failure-prone components of brushes and commutator are eliminated in stepper motors. Stepper motors move in quantified increments or steps and as long as the motor runs within its specification, the position of the shaft is known at all times without the need for a feedback mechanism. A controller, such as proportional integral differential (PID) microcontroller, can be used for implementation of stepper motor control techniques. Other microcontrollers could also be used.
- In one embodiment,
controller 16 includes a microcontroller 46. One suitable microcontroller is Microchip, Inc.'s CMOS FLASH-based 8-bit microcontroller, model PIC16F72, which features 5 channels of 8-bit analog-to-digital (A/D) converter with 2 additional timers, capture/compare/PWM (pulse-width-modulation) function and a synchronous serial port. - Inputs to
controller 16 can include a battery voltage signal, a tear bar activation signal, a cover switch signal, a paper length switch signal, a towel delay switch, a manual advance switch signal and an on switch signal. Outputs ofcontrol unit 16 can include a motor control signals and LED signals. Motor control signals are used to controlstepper motor 14 and hence the speed of paper moved byfeed mechanism 12 as described herein. -
Stepper motor 14 can be a bipolar stepper motor.Stepper motor 14 can run more efficiently than a regular DC motor with gear reduction.Stepper motor 14 allows for a smaller battery package using three D-Cell batteries, rather than four or more D-cell batteries of prior art dispensers, with comparable battery life per roll. -
FIG. 4 , with periodic reference toFIG. 1 , illustrates relationships between sheet product dispense speed, acceleration and time over a dispense cycle of thedispenser 10. As the speed ofstepper motor 14 is proportional to the sheet product dispense speed,FIG. 4 also illustrates velocity and acceleration curves exhibited bystepper motor 14 during the dispense cycle. A dispense cycle is initiated by ON switch activation (i.e., a user dispense request). The ON switch signal may be provided, for example, by a push button switch, an I/R (infrared) proximity sensor, a capacitance-based proximity sensor or another electronic proximity sensor. In response to ON switch activation, a length of sheet product is dispensed during a dispense cycle. -
FIG. 4 shows possible curves for both the speed and acceleration ofstepper motor 14 speed during initial, intermediate and terminal portions of the dispense cycle. During the initial portion of the dispense cycle,stepper motor 14 speed increases to a maximum motor speed. During an intermediate portion of the dispense cycle,stepper motor 14 speed is generally constant. The length of the intermediate portion may be fixed or variable as determined bycontroller 16. During a terminal portion of the dispense cycle,stepper motor 14 speed gradually decreases to zero. In one embodiment, the dispense cycle has a length of between 5 to 10 seconds for a non-continuous mode of operation. - By controlling the acceleration and deceleration of the sheet product as it is dispensed, product damage and jamming can be minimized. This is especially significant with light weight tissue paper products. Controlled acceleration of the sheet product may also decrease the impulse loads applied through the transmission and dispensing mechanism.
- While
FIG. 4 illustrates particular curves of velocity and acceleration during a dispense cycle, curves of velocity and acceleration during a dispense cycle may vary. For example, motor velocity may increase linearly during the initial portion of the dispense cycle or the length of the intermediate portion may be shortened or lengthened depending on a particular application or product and depending on the voltage measured during the cycle or preceding cycles. It is envisioned that a variety of different curves could be utilized to practice the concept of controlled velocity and/or acceleration of the product during a dispense cycle. -
FIG. 5 , with periodic reference to features found inFIGS. 1-3 , illustrates another paper speed curve during a dispense cycle. In this example, the paper direction is initially reversed prior to forward advancement. In some situations, this reverse paper movement disengages the paper product from contact with the tear bar in order to avoid paper jamming. A tear bar switch signal may be used to initiate a reverse paper movement. For example, if thetear bar switch 31 is activated upon a user request (via IR sensor, for example),controller 16 could initially reverse paper movement to pull the paper product away fromtear bar 30. The length of reverse paper movement can be accurately controlled viacontroller 16. -
FIG. 6 illustrates another paper speed curve wherein multiple reversals are made to the paper product upon activation of a dispense cycle.FIG. 7 illustrates yet another example of a paper speed curve wherein a paper reversal occurs after forward movement of the paper through dispenser 10 (FIG. 1 ). Such a paper reversal may be triggered by detection of a tear bar switch activation after some period of time. Alternatively, such a paper reversal may occur during each dispense cycle regardless of whether the tear bar switch remains activated or not. In yet another example, the paper cycle may include an initial paper reversal followed by forward motion and finally yet another paper reversal. -
FIG. 8 , with periodic reference to features found inFIGS. 1-3 , illustrates an embodiment of a process flow chart fordispenser 10.Dispenser 10 remains in a Standby state until IR sensor detects a user request atstep 1002. An inquiry of tear bar switch status is made atstep 1004. If tear bar switch is activated,controller 16drives stepper motor 14 in reverse atstep 1006, for example, following a reverse curve ofFIGS. 5-7 . If tear bar switch is not activated or upon completion of a paper reversal atstep 1006,controller 16drives stepper motor 14 in a forward direction atstep 1008, for example following forward motion curves ofFIGS. 5-7 . A time delay based on towel delay switch occurs atstep 1010 prior to a return to the Standby state. - Referring to
FIG. 9 , in one embodiment,dispenser 10 includesback cover 1101,battery lid 1102,battery contact 1103,chassis 1104,chassis cover 1105,circuit board 1106,compression spring 1107,drive roller 1108,front cap 1109,front cover 1110,stepper motor 14,lens 1112,lock 1113,lock latch 1114,pinch roller 1115,shaft plug 1116,support arm 1117 andtear bar 1118. The drive roller assembly is packaged in a modular unit withtear bar 1118,stepper motor 14, battery pack, IR sensor assembly, andcircuit board 1106. The modular unit can be assembled away from the remaining portions ofdispenser 10. Dispenser components can then be brought together at final assembly. The modular unit can also be used as a service kit to replace only the modular unit of adefective dispenser 10 without removingdispenser 10 from the customer site. - In one embodiment, referring particularly to FIGS. 10 and 11-14, a pair of
support arms 1117 are provided to support hub ends of a paper product shaft. One of thearms 1117 is secured againstbase 1702 while theother arm 1117 is secured against base 1703 (shown inFIG. 13 ). Anopening 1804 atsupport arm 1117 end provides for a snap-fit connection betweenarm 1117 and the paper shaft hubs. Eacharm 1117 includes arib 1806.Rib 1806 engagesextension 1704 ofbase 1702.Base 1703 does not haveextension 1704 andarm rib 1806 does not directly engagebase 1703. The deflection capability (in a direction toward outer walls of the dispenser) ofarm 1117 secured againstbase 1702 is significantly less than the deflection capability of theother arm 1117 secured against base 1703 (rib 1806 contactingextension 1704 limits deflection of one arm). Consequently, when the paper roll is inserted intodispenser 10,arm 1117 secured againstbase 1703 deflects to a substantially greater degree than theother arm 1117. The deflection ofsupport arms 1117 promotes ease of assembly and improved stability of the mounted roll holder and assists in inserting the roll ofpaper product 11 during replacement. -
FIGS. 12 and 13 illustrate anoverspin baffle 200 attached to backcover 1101. As illustrated,overspin baffle 200 is connected to cover 1101 throughhinge element 202.Hinge element 202 can be a living hinge or other known structure. Hinge element may be optional. For example, one end ofbaffle 200 may be rigidly connected to cover 1101.Baffle 200 is preferably a resilient element adapted to deflect upon contact with the roll ofpaper product 11 and remain engaged with the roll throughout at least a significant portion of the roll life.Baffle 200 provides sufficient friction to limit overspin of the roll. In the illustrated example, baffle 200 is generally triangular in form and made of a flexible plastic or metal sheet. Other shapes and cross sections would be practicable. In other embodiments, baffle 200 may be coupled to other portions ofback cover 1101 orfront cover 1110. -
FIGS. 15-16 illustrateshaft plug 1116,spring 1107, andpinch roller 1115 in detail.Shaft plug 1116 includes anaperture 2402 sized to receive shaft 3302 (FIG. 19 ) ofpinch roller 1115 orshaft 2812 of feed roller 1108 (FIG. 18 ). A bearing surface forpinch roller 1115 andfeed roller 1108 is provided by aperture 2202.Plug 1116 includes anaperture 2404 sized to receive one end ofspring 1107. Upon assembly, the other end ofspring 1107 engages spring retainer 2602 (FIG. 16 ). A pair ofplugs 1116 are used to connectpinch roller 1115 tochassis 1104. Eachpinch roller plug 1116 is able to slide along plug flange structure 2502.Springs 1107 tend to biasplugs 1116 away fromspring retainer 2602. Limited non-axial deflection ofpinch roller 1115 is thus provided byplugs 1116 and flange structure 2502. Such non-axial deflection is useful, particularly during roll replacement.Plugs 1116, springs 1107 andspring retainers 2602 provide an additional benefit during assembly as compared to prior art pinch roller designs. - Referring to
FIGS. 16-17 ,drive roller 1108 is coupled tostepper motor 14 atend hub 2602. In one embodiment, a motor shaft portion is inserted intoend hub 2602 ofdrive roller 1108. For example, a d-shaped motor shaft may be inserted into a correspondingly-shaped slot atend hub 2602. Driveroller 1108 is provided with aflexible coupling 2604 atend hub 2602.Flexible coupling 2604 for interconnectingdrive roller 1108 tostepper motor 14 accommodates shaft misalignments and permits limited deflection in non-axial directions.Flexible coupling 2604, in this illustrated embodiment, is helical beam coupler. Thebeam coupler 2604 includes one or more sets of flexible elements, in effect curved beams. Stresses induced in the couple are spread evenly between the beams. Other benefits include single piece construction with no moving parts or elastomeric elements to wear, and backlash free operation with low wind-up.Helical beam coupling 2604 reduces motor vibration for increased paper feed stability and reduces sound generation.Beam coupling 2604, in the illustrated embodiment, is integrated with the balance ofdrive roller 1108. In other embodiments, a beam coupling may be a separate component. - Referring to
FIG. 16 , both pinchroller 1115 and driveroller 1108 may be assembled using an overmolding technique whereby a relatively rigid roller frame is molded onto a shaft and flexible roller rubber portions are then overmolded onto the roller frame to define roller surfaces. An example method of manufacturing includes insertingshaft 2812 offeed roller 1108 into a die form andmolding roller frame 2810 aroundshaft 2812. Theshaft 2812 andframe 2810 are then inserted into another die form whereroller rubber portions 2808 are molded into contact withroller frame 2810. In one embodiment,frame 2810 is injection molded acetal andrubber portions 2808 are injection molded EPDM. A similar method may be used to manufacturepinch roller 1115 ofFIGS. 33-34 . In this manner,rollers - While the disclosure has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.
Claims (5)
1. A sheet product dispenser comprising:
a cover;
a pair of arms disposed and configured to support a roll of sheet product within the cover, the roll of sheet product configured to rotate upon activation of the dispenser during a dispense cycle; and
a baffle adapted to deflect upon contact with the roll of sheet product and remain engaged against the roll of sheet product during at least a significant portion of a roll life.
2. The sheet product dispenser of claim 1 , wherein the baffle is connected to a back portion of the cover.
3. The sheet product dispenser of claim 1 , wherein the baffle is disposed and configured to provide a force that tends to slow a roll rotation to limit roll overspin.
4. The sheet product dispenser of claim 1 , wherein the baffle is a sheet element.
5. The sheet product dispenser of claim 1 , wherein the baffle is connected to the cover via a hinge.
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2007
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- 2007-10-03 RU RU2009116633/12A patent/RU2425617C2/en not_active IP Right Cessation
- 2007-10-03 WO PCT/US2007/080316 patent/WO2008042964A2/en active Application Filing
- 2007-10-03 CA CA2664853A patent/CA2664853C/en active Active
- 2007-10-03 EP EP07853751A patent/EP2066211A2/en not_active Withdrawn
- 2007-10-03 MX MX2009003432A patent/MX2009003432A/en active IP Right Grant
- 2007-10-03 US US11/866,510 patent/US7984872B2/en active Active
- 2007-10-03 EP EP07853747A patent/EP2066210A2/en not_active Withdrawn
- 2007-10-03 CN CN2007800370295A patent/CN101522085B/en not_active Expired - Fee Related
- 2007-10-03 US US11/866,515 patent/US9144352B2/en active Active
-
2011
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2013
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- 2013-07-26 US US13/951,718 patent/US8919688B2/en active Active
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8496198B2 (en) | 2006-10-03 | 2013-07-30 | Georgia-Pacific Consumer Products Lp | Automated tissue dispenser |
US8882021B2 (en) | 2006-10-03 | 2014-11-11 | Georgia-Pacific Consumer Products Lp | Automated tissue dispenser |
US9999326B2 (en) | 2016-04-11 | 2018-06-19 | Gpcp Ip Holdings Llc | Sheet product dispenser |
US10588469B2 (en) | 2016-04-11 | 2020-03-17 | Gpcp Ip Holdings Llc | Sheet product dispenser |
US11395566B2 (en) | 2016-04-11 | 2022-07-26 | Gpcp Ip Holdings Llc | Sheet product dispenser |
US11412900B2 (en) | 2016-04-11 | 2022-08-16 | Gpcp Ip Holdings Llc | Sheet product dispenser with motor operation sensing |
Also Published As
Publication number | Publication date |
---|---|
WO2008042964A3 (en) | 2008-07-24 |
EP2066210A2 (en) | 2009-06-10 |
US20080128446A1 (en) | 2008-06-05 |
RU2009116633A (en) | 2010-11-10 |
CN101522085B (en) | 2013-03-27 |
WO2008042964A2 (en) | 2008-04-10 |
MX2009003432A (en) | 2009-04-14 |
EP2066211A2 (en) | 2009-06-10 |
CA2664846C (en) | 2014-12-23 |
US20130306785A1 (en) | 2013-11-21 |
US9144352B2 (en) | 2015-09-29 |
CN101522085A (en) | 2009-09-02 |
WO2008042962A2 (en) | 2008-04-10 |
US9027871B2 (en) | 2015-05-12 |
CA2664853A1 (en) | 2008-04-10 |
RU2425617C2 (en) | 2011-08-10 |
US8919688B2 (en) | 2014-12-30 |
WO2008042962A3 (en) | 2008-07-17 |
CA2664853C (en) | 2016-10-18 |
US20080078777A1 (en) | 2008-04-03 |
US20130306786A1 (en) | 2013-11-21 |
US7984872B2 (en) | 2011-07-26 |
CA2664846A1 (en) | 2008-04-10 |
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Legal Events
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |