Abstract:
The invention comprises a method and apparatus for more efficiently and easily dispensing paper products, such as toilet tissue, from commercial wall mounted dispensers. The invention may comprise spring loaded projections on the interior of the housing that are adapted to receive and suspend within the housing rolls of paper tissue. Doors within the housing are configured to allow insertion of a new roll of paper into the dispenser when located in the open position; further, such doors suspend the tail of the paper roll for easy access to the tissue user when the doors are in the closed position. An accessory feature facilitates the dispensing of a stub roll or partially consumed roll, as well as a new roll, upon reloading of the dispenser. One or more windows are provided to enable maintenance personnel to determine when reloading the dispenser is required.

Description:
FIELD OF THE INVENTION 
     This invention relates to dispensing apparatus and methods, and in particular rolled paper dispensing apparatus for delivering absorbent paper products such as toilet tissue, hand towels and the like. 
     BACKGROUND OF THE INVENTION 
     Commercial and consumer absorbent paper products typically are distributed and dispensed from rolls. Rolled paper products may be dispensed, stored and maintained using a hollow cylindrical core which forms the support structure about which the paper is wrapped. Most paper toweling and consumer toilet tissue products contain a cardboard core, and the rolled product is often dispensed by mounting the core on a spindle passing through the core of the roll. In some cases, a mounting structure or wire frame operatively engages each end of the core, thereby suspending the rolled product to facilitate dispensing of the paper. 
     Large or jumbo sized toilet tissue rolls are dispensed in restrooms of commercial buildings and in other locations where high volumes of rolled paper products are needed. Typically, these large size rolls include a core in the center of the roll. Usually, the rolls are mounted in dispensers so that the core of the roll is supported on a hub, or axis of rotation, within the dispenser housing. These large size rolls may be largely invisible to the consumer, as they often are dispenser. Other dispensers employ a hinged housing cover, which must be opened or moved laterally to facilitate reloading the dispenser. Reloading dispensers is a time consuming task for maintenance personnel. In general, it is desirable to provide a process for reloading dispensers in a manner that is efficient and simple. One challenge in commercial dispenser design is to provide a dispenser that may be reloaded easily and quickly, but still offers security to the rolled paper product, thereby protecting the dispenser contents from vandalism and theft. 
     Coreless rolls of paper product are employed in applications where it is desirable to avoid using a core in the center of the rolled product. Coreless rolled products may be manufactured as provided in U.S. Pat. No. 5,620,148 to form a depression in the side of the roll that facilitates supporting and dispensing the roll. Devices capable of dispensing coreless rolled paper products have been disclosed as provided for example in U.S. Pat. No. 5,697,576. Another patent, U.S. Pat. No. 5,875,985, is directed to a method of treating a coreless roll to create a mounting hole in at least one end of the roll to provide a self-supporting roll for mounting in a rotary dispenser. 
     In reloading dispensers, it is common practice to remove a partially consumed roll when placing a new roll into the dispenser. It is desirable to employ some method of using the partially consumed roll, sometimes called a “stub roll.” If there is no convenient way to dispense the partially consumed rolls, then such rolls may not be used, undesirably increasing the overall cost of providing paper products to users. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide an assembly for dispensing an absorbent roll, wherein the assembly is simple and economical to manufacture, install, and use. These and other objects of the invention are provided by the disclosed structure and method, or may be learned from practice of the invention. 
     In accordance with one aspect of the present invention, an assembly for dispensing an absorbent paper roll is provided having an interior space and an exterior cover. The assembly includes a pair of opposed support members, wherein the support members are adapted to engage sides of a paper roll. The support members are mounted on the interior of the housing in spaced relation to each other. In some embodiments of the invention, there is a first pair of projections within the interior space of the housing to articulate with sides of the roll, thereby forming a fixed mounting axis from which the roll may be dispensed. A stub roll unit side feature, sometimes called an “escort” or stub roll, facilitates the storage and dispensing of a partially dispensed roll in addition to the main or primary roll. Further, the assembly is adapted for automatically receiving and mounting a paper roll within the interior space of the housing upon the insertion of the paper roll into the housing. 
     The invention comprises a method and apparatus for more efficiently and easily dispensing paper products, such as toilet tissue, from commercial wall mounted dispensers. The dispenser may be re-loaded in most instances by way of a single operation that usually requires only one hand. Further, the housing protects the paper from vandals and improper tampering, while being configured for a simple reloading procedure without the necessity for using keys, locks, and the like to gain access to the housing. 
     The invention may comprise spring loaded projections on the interior of the housing that are adapted to receive and suspend within the housing rolls of paper tissue. Doors within the housing are configured to facilitate insertion of a new roll of paper into the dispenser when located in the open position. Further, such doors suspend the tail (end) of the paper roll for easy access to the tissue user when the doors are in the closed position. 
     In one embodiment, the projections are spring loaded. The opposed support members are biased against the sides of the paper roll in one configuration of the invention. The paper roll may contain a core, or alternatively, may be coreless. If the paper roll is coreless, the roll is supported within the housing by projections capable of articulating with indentations or spaces in the sides of the paper roll. 
     In accordance with another aspect of the invention, an assembly for dispensing a coreless absorbent paper roll is presented including a housing having an interior space and an exterior cover. Further, opposed support members are adapted to engage the sides a paper roll, the support members being mounted on the interior of the housing in spaced relation to each other within the housing. The assembly is adapted for automatically receiving and mounting a paper roll within the interior space of the housing upon insertion of the roll into the housing. A first pair of spring-loaded projections are provided within the interior space of the housing, adapted to engage indentations in the sides of the coreless paper roll forming a fixed mounting axis from which the coreless paper roll may be dispensed. A stub roll unit is adapted to dispense a partially consumed roll. 
     The assembly may further include a release mechanism to facilitate the release and removal of a paper roll from the assembly prior to depletion of the paper roll. In one embodiment, the assembly includes at least one door capable of holding the tail of a paper roll in spaced relation to the housing. The opposed support members typically are flexible, thereby facilitating engagement with opposite sides of the roll as the roll is inserted into the housing. 
     At least one of the first pair of projections may be actuable between: (a) a fully erect position for engaging a mounted paper roll, and (b) a disabled position to facilitate removal of a mounted paper roll from the assembly. Removal of a paper roll may be desirable, for example, when only one-half, or less, of the roll is remaining in the dispenser, and a period of heavy use is anticipated in the near future. The ability to remove a partially dispensed roll assists in preventing the undesirable depletion of the roll during a time when no maintenance personnel are available to refill the dispenser (i.e. sometimes called a “run out” condition). 
     In some embodiments, a release bar is used to actuate a projection, thereby enabling removal of a partially dispensed roll. The release bar may slidably engage the projection to disable the projection, thereby facilitating the removal of a paper roll from the assembly. The assembly further may include a second pair of projections capable of articulating with indentations in the sides of a coreless stub roll. 
     In some embodiments, the stub roll is oriented within the housing such that the ends of the stub roll are situated in parallel to the full paper roll. The assembly may further include a housing comprising one or more windows to facilitate visual observation of the amount of depletion of rolls in the housing. 
     In accordance with another aspect of the invention a method of mounting a new absorbent paper roll in a dispenser is provided. As a first step, existing stub rolls are removed from the primary dispensing means of the housing. Then, a new paper roll is placed adjacent to the dispenser and in alignment with the dispenser housing. The dispenser has elongated support members on its interior. Next, a new paper roll is inserted into the housing of the dispenser. The new paper roll engages elongated support members along the sides of the paper roll. As a next step, projections are activated on each side of the paper roll, to articulate with the paper roll and support the roll within the housing for dispensing paper to the exterior of the housing. Optionally, the stub roll may be mounted in a stub roll unit of the housing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A full and enabling disclosure of this invention, including the best mode shown to one of ordinary skill in the art, is set forth in this specification. The following Figures illustrate the invention: 
     FIG. 1 is a perspective view of the dispenser with the accessory unit containing a stub roll; 
     FIG. 2 shows a partial sectional side view of the dispenser taken along line  2 — 2  in FIG. 1; 
     FIG. 3 shows an end partial sectional view (with cutaway) of the dispenser taken along line  3 — 3  in FIG. 1; 
     FIG. 4 illustrates loading a paper roll into the dispenser; 
     FIG. 5 shows a side view of the dispenser including the step of FIG. 4 illustrating the loading of a paper roll into the dispenser; 
     FIG. 6 is an end view showing the paper roll inserted fully into the dispenser; 
     FIG. 7 is a cross-sectional view showing the spring-loaded projection inserted into the side of a paper roll; 
     FIG. 8 shows the release bar pulled downward to disable the spring-loaded action of a projection, thereby facilitating removal of a full paper roll from the dispenser; and 
     FIG. 9 shows another embodiment of the invention with the stub roll facing in a direction that is offset ninety degrees from the embodiment shown in FIG. 1, such that paper feeds from the stub roll in a plane that is perpendicular to the plane of paper feed from the primary roll. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference now will be made to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not as a limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made to this invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features and aspects of the present invention are disclosed in or are obvious from the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions. 
     Turning to FIG. 1, a dispenser is shown with a housing  21  having an exterior surface  22 , a lower margin  23 , and a side  31 . Exterior cover  22   a  and interior surface  22   b  are also shown in the Figure. Tissue tail  28  is available to users below the housing. The housing typically is mounted on a restroom wall or stall. A paper roll  29  with center core space  30  having a relatively large size (8 inches in diameter is typical in the industry) is provided in the dispenser as shown on the left side of the Figure by dashed lines. A stub roll  24  having core space  27  is shown on the right portion of the housing within stub roll unit  48 . A window  26  serves to indicate to maintenance personnel when the stub roll is nearly exhausted. A similar window  25  is provided detecting depletion of the roll  29 . 
     FIG. 2 shows a cross-sectional view of the dispenser with bombay doors  46  and  47 . Hinges  41  and  42  provide articulation for movement of the bombay doors from an open position to accommodate the insertion of a new paper roll to a closed position in which they act to suspend the paper tail  28  within reach by the user. Release bar  33  is an optional feature that facilitates the removal of a paper roll from the dispenser, as further discussed below in connection with FIGS. 7 and 8. Interior housing  34  and centering ribs  35  and  36  form a cavity for the paper roll  29 . Plate  37  is mounted on end portions  37   a  and  37   b  at the upper portion of the housing so as to be vertically slidable between ribs  35  and  36 . Plate  37  forms a curved surface against which the paper roll may be pushed to engage and lift t-bars  38  to thereby lift support members  43  and  44  to allow projections  50  and  55  to articulate with the core spaces  30  on either side of the paper roll, as will be further discussed below. 
     Spring cavities  39  are hollow spaces in which spring  45  and  88  may be placed for providing tensioning downward force on support members  43  and  44  (see FIG.  3 ). T-bars  38  extend from the tops of support members  43  and  44  to receive springs  86  and  87 . Plate  37  typically rests on shoulders  37   a  adjacent t-bars  38 , as shown in FIG. 2, when no paper roll  29  is presently in use. Tissue  49  is unwound from roll  29  and is held in spaced relation to the housing lower margin for convenient access by the user. Serrated gripping plate  40  on each interior wall of the housing serves to provide a frictional stop on the rotation of the roll when the roll is misaligned on its axis, such as if a cored roll is inserted into a coreless unit, preventing damage to the dispenser. 
     A stub roll unit  48  is shown on the right side of the housing, and it provides a stub roll  24  for feeding paper. Typically, when a new, full roll is inserted into the dispenser, the partially used stub roll  24  is first removed from the housing and placed in the stub roll unit  48 . A dividing wall  61  separates the stub roll unit from the main housing. 
     As seen in FIG. 3, a first pair of support members  43  and  44  engage the sides of the roll, and flex during insertion of the roll. The support members are free to bend about their long axis when loaded with force. The support members are free to travel vertically, and are urged downward by springs  45  and  88  (seen in FIG.  5 ). Space  48  above the roll provides needed space to rotate the roll  29  on its axis, and to facilitate insertion into the dispenser. The support members are held by struts  60  and  65  respectively. 
     Interior housing  34  shown in FIG. 2 thus surrounds the paper roll, and provides centering ribs  35  and  36  which connect to the curved plate  37  while in the dispensing position. 
     Hub  49  in FIG. 3 helps seat and hold the primary paper roll. Lug  53  forms the end of the hub  49 . Projection  55 , which is bullet-shaped, is held in spring tension by spring  54  and is naturally tensioned to push into the paper roll. Spring-loaded retainer  51  is connected to base  62  on the opposite side of the housing as hub  49  and supports projection  50 . Roll  29  is thus supported by projections  50  and  55 . 
     Mandrel  52  is connected to the projection  55  such that under some circumstances the mandrel may be activated to compress the spring  54  to withdraw the bullet-shaped projection  55  into hub  49 , facilitating removal of a roll. This removal operation is made possible by slidable movement of release bar  33 , as further discussed below in connection with FIGS. 7 and 8. 
     FIG. 3 shows stub roll  24  in the lower portion of the Figure. C-adapters  80  and  81  include spring-loaded projections  83  and  82  on each end of the roll. These projections are injected into the holes or cavities at each end of a coreless roll to suspend the stub roll  24  in position for dispensing followed by spring-loaded projections  82  and  83  may be constructed and mounted similar to projection  50 , so no further description of projections  82  and  83  is required hereon to describe and allow practice of the invention. 
     In FIG. 4, door supports  63  and  64  support the respective bombay doors. Retainer  59  provides a base for the flexible support members. Direction arrows  56  and  57  show the insertion pathway for paper roll  29 . Engagement hole  58  provides a pathway for a projection  50  to proceed through the flexible support  44  and into the cavity of the paper roll. 
     In FIG. 5, a side view shows the paper roll  29  being inserted into the housing. The flexible supports  43  and  44  are in an A-shaped configuration to receive the roll sides against their inner surfaces. During the insertion, projections  50  and  55  are pressed against the flexible supports  43  and  44  by spring action. As shown in FIG. 5, projections  50  and  55  do not yet protrude through the hole  58  in each flexible support  43  and  44 . Spring  45  and spring  88  each provide a tensioning force for support members  43  and  44 . Springs  86  and  87 , which are connected to supports  84  and  85 , also provide a tensioning force holding flexible support members  43  and  44  towards the midline of the dispenser. Struts  60  and  65  are intimately attached to support members  43  and  44 . 
     FIG. 6 shows many of the features, which have been reviewed above, in a different orientation. For example, FIG. 6 shows the paper roll after insertion into the dispenser, in which the roll had been inserted upwards to the top of the interior housing against plate  37 , and then dropped down in direction of arrows  56   a  and  57   a  into position such that projections  50  and  55  articulate with each side of the paper roll  29 . 
     To insert a paper roll, the roll is pushed completely into the housing, with the plate  37  and t-bars  38  slid upward to the top of the housing. The upward force of the roll pushes the flexible supports upward and outward, compressing springs  45  and  88  and stretching springs  86  and  87 . In FIG. 5, one can see notches  75  and  76  on the surface of the flexible supports. When the roll is inserted fully into the housing, the notches are pulled above the bullet-shaped projections  50  and  55  and urged outward. In FIG. 6, the projections  50  and  55  now have aligned with holes  58  in the flexible supports  43  and  44 , and the projections protrude through the flexible supports to engage the indentations or cavities in each side of the paper roll, suspending the paper roll in the dispenser. The paper roll is now held firmly in place in the dispenser, and typically cannot be removed by simply pulling on the roll from below. The projections firmly engage the indentations in the coreless roll. In the case of a cored roll, the projections engage the free space inside the core. 
     Release bar  33  is in the “up” position in FIG. 6 and 7, as the paper roll  29  is fully inserted into the housing. In FIG. 8, release bar  33  has been pulled into the “down” position in which it urges mandrel  52  to the right along with projection  55 , thereby compressing spring  54 . Projection  55  is thus no longer disposed within, into the paper roll  29 . The projection  55  has two slots  78  and  79 , which are directly in, line vertically with one another. When release bar  33  is pulled into the down position, track section  77  (see FIGS. 7 and 8) of the release bar is placed through the slots. In this configuration, the projection is relaxed and no longer is applying a horizontal force into the paper roll  29 . Thus, the paper roll  29  may be removed from the dispenser when release bar is pulled down into the release position, as shown in FIG.  8 . 
     Removal of a partially used paper roll from the dispenser is especially useful in those situations in which a period of very heavy use of the dispenser is anticipated, or where there is likely to be no opportunity to refill the dispenser during the period of heavy use. Other times in which removal of a roll is advantageous is in the situation in which paper roll  29  becomes contaminated or damaged. One example of such damage is a soaking with water, such as may occur in a restroom washdown. In that instance, the ability to release a paper roll  29  and remove it from the dispenser is valuable. Once a partially used roll (stub roll) is removed, it may be placed into the dispenser stub roll unit so that both the stub roll and the primary roll  29  are then available for use for a period of time. 
     FIG. 9 shows another embodiment of the invention  121  with the stub roll  124  facing in a direction that is offset ninety degrees from the embodiment shown in FIG. 1, such that paper feeds from the stub roll in a plane that is perpendicular to the plane of paper feed from the primary paper roll  129 . Otherwise, the structure and operation of embodiment  121  is substantially similar to that of embodiment  21 . Like reference numerals are used to identify like parts in the disclosed embodiments. 
     The invention is particularly set forth in the appended claims. Further, it should be understood that aspects of the various embodiments disclosed in this specification may be interchanged both in whole or in part without departing from the invention. Furthermore, those of ordinary skill in the art will appreciate that this description is by way of example only, and is not intended to limit the invention as described in the claims.