Loading and transfer system/assembly for sheet material dispensers

A sheet material dispenser can include a dispenser housing that supports one or more supplies of sheet material, and a feed roller configured to engage and feed the sheet material from the dispenser housing. The dispenser also can include a sheet material loading assembly including a cover that is rotatably connected the dispenser housing and movable between a closed position and an open position. The sheet material loading assembly further can include a roller that is rotatably connected to the cover and configured to be coupled to a portion of sheet material from one of the supplies, with the cover in its open position, and to press the portion of sheet material into engagement with the feed roller body, with the cover in its closed position, to initiate dispensing of the at least one supply from the dispenser.

INCORPORATION BY REFERENCE

The disclosure and figures of U.S. Provisional Patent Application No. 62/861,425, filed Jun. 14, 2019, are incorporated by reference herein as if set forth in their entireties.

TECHNICAL FIELD

The present disclosure is directed to dispensers for flexible sheet materials, and in particular, in one aspect, dispensers with a loading and/or transfer assemblies, mechanisms, or systems. Other aspects also are described.

BACKGROUND

Dispensers for sheet materials, such as for dispensing paper towels, tissue paper, or other paper products, are commonly used in hospitals, restrooms, and other facilities. Loading sheet materials in such dispensers often can prove to be a difficult task. For example, personnel loading the dispensers may have to navigate the sheet material through relatively close or tight clearances between the operative elements, supports and other elements within the dispensers. This can take considerable time and sometimes results in tearing or ripping of the sheet material. Improper loading of the sheet material also is common and can cause jamming of the sheet material in the dispenser, thus resulting in significant down time for the sheet material dispenser.

Additionally, some dispensers can have more than one supply of sheet material, e.g., multiple rolls of sheet material, for dispensing/feeding from the dispensers, and when one of the supply rolls is running low or has been fully dispensed, transfer of the feeding of sheet material to a new supply generally must be manually performed. With some dispensers, when a supply of sheet material is running low, feeding/dispensing is modified such that sheet material from multiple supplies may be dispensed or fed at the same time, i.e., double sheets may be dispensed simultaneously—potentially leading to waste of significant amounts of sheet material.

Accordingly, it can be seen that a need exists for a systems and methods dispenser that addresses the foregoing and other related, and unrelated, problems in the art.

SUMMARY

Briefly described, the present disclosure is generally directed to a dispenser or dispenser assembly for rolled sheet materials, such as paper products including paper towels, tissue paper, etc. and/or other paper products. The dispenser assembly can include a dispenser housing, with one or more support assemblies for supporting one or more supplies of sheet material disposed in or along the dispenser housing. In one embodiment, the one or more supplies of sheet material can include a first supply roll and second supply roll of sheet material. The first or second supply of sheet material can include new, undispensed rolls of sheet material, partially dispensed rolls of sheet material, and/or stub rolls of sheet material. A stub roll of sheet material generally includes a supply roll that has been substantially dispensed, e.g., a supply roll with less than about 50% to about 30% or less of its initial amount of sheet material remaining.

The dispenser assembly further can include a feed roller assembly including one or more feed rollers configured to engage and drive the sheet materials from the one or more supplies of sheet material. The feed roller(s) drive the sheet material along a discharge or feed path from the supply toward and through a discharge of the dispenser housing. The feed roller(s) can be automatically driven, e.g., by one or more powered drive mechanisms, such as a motor or other suitable actuator, or the feed roller(s) can be manually activated, such as by a rotatable knob, handle, or other suitable engagement and/or drive mechanism that can be engaged or rotated by an operator or user.

The dispenser assembly further can include a sheet material loading mechanism/assembly. The sheet material loading mechanism/assembly can include a cover assembly that is movably connected to the dispenser housing. In one example, the cover assembly can include a cover body rotatably or pivotably coupled to a front portion of the dispenser housing, e.g., at a first end of the cover body, and being movable between a closed position and an open position. In the closed position, the cover body at least partially surrounds and/or enclose the feed roller. In its open position, the cover body will be substantially spaced away from the feed roller, e.g., with the cover body extending out and away from the front portion of the dispenser.

The sheet material loading mechanism/assembly further includes a plurality of locking features or locking mechanisms (e.g., biased locking switches or other suitable locking mechanism/features) configured to lock or secure the cover assembly in its closed position. The locking features/mechanisms can be movable or actuatable to release the cover assembly and allow for the cover assembly to be moved to the opening position.

In one embodiment, the cover assembly can be biased towards its open position. For example, the loading mechanism/assembly can include one or more biasing members (e.g., one or more springs, such as torsion springs, or other suitable biasing members) in communication with the cover body and the dispenser housing to bias the cover towards its open position.

The cover assembly further can include a cover roller, which, in some embodiments, can be a pressing or guide roller, connected thereto/integrated therewith. The cover roller can be rotatably connected to the cover body at the second end of the cover body. The cover roller further can be biased or urged (e.g., by one or more biasing members, such as springs or other suitable biasing members) to press or engage the sheet material against the feed roller, with the cover assembly in its closed position. In one example construction, end portions of the cover roller can be received within slots or other suitable openings defined in or otherwise along the second end of the cover body, such that the cover roller is movable therealong. The biasing members further can be coupled to the cover body and can engage the ends or other portions of the cover roller so as to urge the cover roller toward engagement with the feed roller, e.g., the biasing member can bias the ends of the cover roller toward a first end of the slots defined in the cover body.

The cover roller additionally can include one or more sheet material retention features, such as clips, or projections, etc., provided therealong. The sheet material retention features generally are configured to secure the sheet material to the cover roller to help facilitate loading of the sheet material. For example, with the cover assembly in its open position, an operator can connect/engage a portion of the sheet material from the first or second supply roll of sheet material to or about the cover roller by use of the sheet material retention features. Thereafter, the operator can move the cover assembly to its closed position, moving the cover roller into engaging or pressing engagement with the sheet material from the first or second supply roll and against the feed roller. Thereafter, upon actuation of the feed roller, the sheet material can be engaged by the feed roller and urged along the discharge path and toward and through the discharge in the dispenser housing for dispensing a sheet or length of sheet material.

In addition, the dispenser assembly can include a supply roll transfer assembly that can facilitate transfer of feeding of sheet materials between the first and second supply rolls. The transfer assembly can include a transfer arm that is movable between a plurality of positions or configurations to facilitate transfer of feeding between the first and second supply rolls. For example, the transfer arm can be movable between a first position for feeding sheet material from the first supply roll, and a second supply roll position for feeding sheet material from the second supply roll.

When the transfer arm is in the first position, the sheet material from the second supply roll can be engaged with the cover roller of the cover assembly, e.g., via retention features, and the transfer arm can engage a portion of the cover roller such that the cover roller (and the sheet material from the second supply roll engaged therewith) is spaced from the feed roller, sufficient to define a gap or separation spacing between the cover roller and the feed roller. The transfer arm also includes a guide roller rotatably attached to a first end thereof and configured to engage and guide the sheet material from the first supply roll, with the transfer arm in the first position (i.e., when the dispenser assembly is feeding sheet material from the first supply roll). For example, the guide roller can engage and direct the sheet material from the first supply roll so that it is engaged and urged by the feed roller along the discharge path and through the discharge in the dispenser housing with the transfer arm in its first position.

In addition, the supply roll transfer assembly can include a support positioned along or substantially adjacent the transfer arm and generally can be configured to engage the sheet material from the first supply roll during feeding thereof. The sheet material from the first supply roll can be engaged between the guide roller and the support to hold the transfer arm in its first position. Further, when the sheet material from the first supply roller is dispensed and no longer positioned between the support and the guide roller, the transfer arm moves to its second position engaging the cover roller against the feed roller to facilitate feeding sheet material from the second supply roll. More specifically, movement of the transfer arm to the second feeding position allows the ends of the cover roller to move to the first end of the slots to facilitate engagement of the sheet material from the second supply roll received about the cover roller against the feed roller for feeding and dispensing thereof.

In one embodiment, the guide roller can be configured to intermesh or interleave with the support when/after the sheet material from the first supply roll is dispensed, i.e., when there is no longer sheet material from the first supply roll to be engaged between the guide roller and the support. The support can include a plurality of spaced ribs or portions with a plurality of spaces defined therebetween and along a length of the support. The guide roller also can include a plurality of spaced portions defining spaces therebetween along a length of the guide roller. The spaced portions of the guide roller generally are configured to align with the spaces in the support, while the ribs formed in the support are configured to align with the spaces in the guide roller so as to interleave or intermesh when sheet material is absent between the guide roller and the fixed support.

In one example construction, the transfer arm further can be pivotably or rotatably attached to the dispenser housing at a second end thereof. Accordingly, when/after the sheet material from the first supply roll is dispensed, the transfer arm can rotate or pivot to the second feeding position under its own weight (such as due to gravitational forces). In some constructions, however, the transfer arm can be biased towards the second feeding position by one or more biasing members that urge the transfer arm to engage the sheet material from the first supply roll between the guide roller and support, and when the first supply roll is exhausted or otherwise substantially dispensed, will bias or urge the transfer arm to its second feeding position.

Accordingly, with embodiments of the present disclosure, the transfer assembly can allow for substantially seamless transfer of feeding of sheet material between the first and second supply rolls of sheet materials, without requiring refeeding or manual manipulation of the supplies, while also preventing, reducing, or eliminating double sheet dispensing.

In one example construction, a dispenser can include a dispenser housing that at least partially supports a plurality of supplies of sheet material, and has a discharge from which sheet material from the plurality of supplies of sheet material is dispensed. The dispenser includes a feed roller rotatably connected to the dispenser housing. The feed roller has a feed roller body configured to engage and feed sheet material from one of the plurality of supplies of sheet material along a feed path a towards the discharge of the dispenser housing. The dispenser also includes a cover assembly including a cover body connected to the dispenser housing and movable between a closed position and an open position to facilitate loading of the plurality supplies of sheet material into the dispenser housing, and a roller that is rotatably connected to the cover body and configured to engage at least a portion of sheet material from one or more of the plurality of supplies of sheet material.

In addition, the dispenser includes a transfer mechanism configured to transfer feeding between the plurality of supplies of sheet material and operatively connected to the roller of the cover assembly, such that when sheet material from one of the plurality of supplies of sheet material has been substantially dispensed, the transfer mechanism facilitates movement of the roller of the cover assembly toward engagement with the feed roller body to initiate dispensing of sheet material from a different one of the plurality of supplies of sheet material.

The transfer mechanism can have a transfer arm operatively connected to the roller and movable between a plurality of feeding positions for transfer of the feeding of sheet material between the plurality of supplies of sheet material. The plurality of feeding positions can include a first feeding position in which the transfer arm holds the roller away from the feed roller body, and a second feeding position in which the transfer arm is moved to a position to enable engagement between the roller and feed roller body such that at least a portion of the sheet material from a different one of the plurality of supplies of sheet material is pressed against the feed roller body to initiate dispensing of the sheet material from the second supply.

The transfer mechanism further includes at least one guide roller that is configured to engage the sheet material from a first supply of sheet material of the plurality of supplies of sheet material, and at least one fixed support positioned substantially adjacent to the transfer arm and configured to engage the sheet material from first supply such that it is engaged between the at least one guide roller and the at least one fixed support with the transfer arm in its first feeding position.

The at least one guide roller and the at least one fixed support may be configured to intermesh when the sheet material from the first supply of sheet material is substantially dispensed to facilitate movement of the transfer mechanism from its first position towards its second position.

One or more portions of the at least one guide roller can be received within one or more spaces defined along the at least one fixed support and/or one or more portions of the at least one fixed support are positioned into one or more spaces defined along the at least one guide roller when the sheet material from the first supply is substantially dispensed and no longer present between the at least one fixed support and the at least one guide roller.

The transfer mechanism further includes one or more biasing members configured to bias the transfer arm towards its second feeding position.

The roller of the cover assembly can include at least one bearing connected thereto or formed therewith that connects the roller to the cover body, and the transfer arm can include at least one projecting portion that engages at least a portion of the at least one bearing with the transfer arm in its first feeding position.

The dispenser additionally can include a cutting assembly that is integrated with the feed roller and includes one or more cutting portions that are extensible into and out from one or more openings defined in the feed roller body.

Further, the dispenser can include an engagement portion that is operatively connected to the feed roller and configured to be actuated by a user to drive rotation of the feed roller for manual dispensing of the sheet material from the dispenser.

Still further, the dispenser can include a biasing assembly configured to assist rotation of the feed roller. The biasing assembly can include at least one biasing member connected to the feed roller body, and at least one linkage connected to the at least one biasing member and at least one portion that does not rotate with the feed roller body.

In another exemplary construction, a sheet material dispenser can include a dispenser housing within which one or more supplies of sheet material are received, and which includes a discharge from which sheet material from the one or more supplies of sheet material is dispensed. The sheet material dispenser also can include a feed roller rotatably connected to the dispenser housing and having a feed roller body configured to engage and feed the sheet material from the one or more supplies sheet material along a feed path and towards the discharge of the dispenser housing.

Additionally, the sheet material dispenser can have a sheet material loading assembly including a cover rotatably connected to at least a portion of the dispenser housing at a first end and movable between a closed position and an open position to facilitate loading of the one or more supplies of sheet material into the dispenser housing, and at least one roller that is rotatably connected to a second end of the cover. The at least one roller can be configured to receive at least a portion of sheet material from at least one supply of the one or more supplies of sheet material thereabout with the cover in its open position, and to urge the portion of sheet material toward engagement with the feed roller body, with the cover in its closed position, to initiate feeding of the sheet material from the at least one supply for dispensing from the dispenser.

The sheet material loading assembly also can have one or more biasing members coupled to the cover and operatively connected to the at least one roller so as to bias the roller toward engagement with the feed roller body when the cover is in its closed position.

The sheet material loading assembly additionally can include one or more biasing members connected to the cover and biasing the cover toward its open position, and one or more locking features configured to secure the cover in its closed position.

The at least one roller further can include sheet material retention portions that are configured to couple the portion of the sheet material to the at least one roller.

The one or more supplies of sheet material include at least first and second supplies of sheet material, and the sheet material dispenser can have a transfer assembly configured transfer feeding between the first and second supplies of sheet material.

The transfer assembly can include a transfer arm operatively connected to the at least one roller of the sheet material loading assembly and movable between a plurality of feeding positions to facilitate transfer of feeding of sheet material between the first and second supplies of sheet material. The plurality of feeding positions can include a first feeding position in which the transfer arm holds the at least one roller of the sheet material loading assembly away from the feed roller body, and a second feeding position in which the transfer arm enables engagement between the at least one roller of the sheet material loading assembly and the feed roller body such that the portion of sheet material from the first supply is pressed against the feed roller body to initiate dispensing of the sheet material from the first supply.

The transfer assembly further can include at least one guide roller that is configured to engage sheet material from second supply of sheet material, and at least one fixed support positioned substantially adjacent to the transfer arm and configured to engage the sheet material from the second supply of sheet material between the at least one guide roller and the at least one fixed support with the transfer arm in its first feeding position, wherein the at least one guide roller and the at least one fixed support are configured to intermesh when the sheet material from the second supply of sheet material is substantially dispensed to facilitate movement of the transfer arm from its first position towards its second position.

The sheet material dispenser also can have one or more pressing rollers mounted along the discharge so as to engage and direct the sheet material along the feed path as the sheet material is fed from the discharge.

The sheet material dispenser further can have a cutting assembly that is integrated with the feed roller and includes one or more cutting portions that are extensible through one or more openings defined in the feed roller body.

Further, the sheet material dispenser can have an engagement portion that is operatively connected to the feed roller and configured to be actuated by a user to drive rotation of the feed roller and control dispensing of the sheet material from the dispenser assembly.

Even further, the sheet material dispenser can have a biasing assembly configured to assist rotation of the feed roller. The biasing assembly can include at least one biasing member connected to the feed roller body, and at least one linkage connected to the at least one biasing member and at least one portion that does not rotate with the feed roller body.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments by reading the following detailed description of the embodiments with reference to the below listed drawing figures.

DETAILED DESCRIPTION

FIGS. 1-9Cshow a dispenser assembly or dispenser10for a sheet material, such as for paper towels, tissue paper, other paper products, etc. and/or other suitable sheet materials. The dispenser assembly10has a sheet material loading system or assembly100to facilitate loading of supplies sheet material12therein, and a sheet material transfer system or mechanism200to facilitate the transfer feeding of sheet material between a plurality of supplies of sheet material received within or otherwise along the dispenser assembly10.

As shown inFIGS. 1-3B, the dispenser assembly10can include a dispenser housing14having front16, rear18, side20/22, and bottom24sides or portions. The dispenser housing14can be formed from a plastic material, though other suitable polymeric, synthetic, or composite materials can be used without departing from the scope of the present disclosure. The dispenser assembly10further at least partially supports and/or includes a plurality of supplies of sheet material, for example, two or more supply rolls of sheet material, including at least a first supply roll26and a second supply roll28supported within the dispenser housing14. The supplies26/28of sheet material can include new, un-dispensed rolls of sheet material, or at least partially dispensed rolls of sheet material, e.g., including stub rolls. For example, stub rolls may include rolls with less sheet material than a full roll, and in one embodiment, a stub roll can include a full roll that has been substantially dispensed, e.g., a supply roll with less than about 50% to about 30% or less of its initial/starting amount of sheet material remaining. It also will be understood that, while two supply rolls26/28are shown inFIGS. 1A-2B, a greater number of supply rolls, such as 3 or more supply rolls, can be used without departing from the scope of the present disclosure.

The supply rolls28and26are rotatably coupled to the dispenser housing14, by opposing supports30/32(FIGS. 1 and 3A). As shown inFIGS. 1 and 3A, the supports30/32can include one or more arms34/36connected to the dispenser housing14, and which can be rotatably coupled to the ends28A/B and26A/B of the supply rolls28/26, so that the supply rolls28/26of sheet material can substantially freely rotate with respect to the arms34and36as the sheet material is pulled therefrom during dispensing. The supply rolls28/26also may be otherwise rotatably or movably mounted to or along the dispenser housing14without departing from the scope of the present disclosure. In one construction, the arms34can be coupled to the rear portion18of the dispenser housing14(FIG. 3A), and the arms36can be connected to a backing plate38attached to or formed with the rear portion18of the dispenser housing14(FIG. 1).

Additionally, as shown inFIGS. 2A-3B and 7A-9C, the dispenser assembly10also generally includes one or more feed rollers40rotatably mounted therein. The one or more feed rollers40can be rotatably connected to the dispenser housing14. The feed roller (or rollers)40includes a feed roller body42, e.g., formed from a plastic material, though other suitable polymeric, synthetic, or composite materials may be used without departing from the scope of the present disclosure. The feed roller body42further can include a plurality of spaced gripping bands44(e.g., formed from polymeric or other suitable synthetic or composite materials) applied thereabout. The feed roller(s)40is operable to rotate or pull and guide or feed the sheet material12along a feed or discharge path46towards a discharge, such as a discharge chute48, of the dispenser10for dispensing or distribution of an amount or length of the sheet material to a user. The discharge chute48can comprise a discharge opening or slot50arranged along the bottom portion24of the dispenser housing14, as illustrated inFIGS. 3A, 7A and 8A-8B.

A portion of the sheet material27or29from the first26or second28supply rolls will be at least partially disposed about and in engagement or contact with the feed roller40, such that, upon rotation of the feed roller40the sheet material27or29from the first26or second supply rolls28will be pulled, causing the supply rolls26/28to be rotated and an amount or length of sheet material12to thus be fed to and through the discharge chute48. The feed roller40can have a diameter selected for feeding a prescribed or predetermined or known length or amount of sheet material. For example, the feed roll40can have a diameter or size selected to feed a 6″, 8″, 10″, 12″, 14″, 16″, etc. (or other integer or non-integer numbers therebetween and/or other suitable predetermined lengths) of sheet material for each revolution or series of revolutions of the feed roller.

In one construction, the feed roller40can be manually driven. For example, as shown inFIG. 1-3A, the dispenser assembly10can include an engagement portion52, such as a lever, knob, or other suitable engagement portion, that is operatively connector to or otherwise in communication with the feed roller40, and which engagement portion52is configured to be actuated or turned by a user to drive movement/rotation of the feed roller40and thus control dispensing of the sheet material. Users further can engage and pull portions of the sheet material hanging from or in (e.g., hanging tabs) the discharge chute48for dispensing of sheet material.

Additionally, or in alternative constructions, the feed roller40can be automatically driven by a drive mechanism (e.g., including a motor) that activates when one or more sensors detect a predetermined condition. For example, when a sensor, such as an infrared sensor or other similar type of sensor, detects the presence of a user's hand in front of, adjacent, or below the dispenser housing14, or detects the presence or absence of sheet material extending from the discharge chute44. U.S. patent application Ser. Nos. 15/173,970, 15/185,776, and 15/185,937, which are specifically incorporated by reference herein as if set forth in their entireties, show example arrangements of other drive mechanisms for driving the feed roller. However, any suitable driving mechanism, arrangement, or configuration can be employed to drive rotation of the feed roller40for feeding or dispensing sheet material, without departing from the scope of the present disclosure. The drive mechanism further can be activated when a user activates the engagement portion or pulls a hanging tab to provide drive assisted dispensing of sheet material.

FIGS. 1, 2B, and 3A-3Bfurther show that the dispenser assembly10can include one or more guide or pressing rollers54mounted along or substantially adjacent the discharge48. Such as guide or pressing roller (or rollers)54located in a position so as to define a nip and that contact or otherwise engage and direct the sheet material12along a feed path toward the discharge chute as the sheet material is fed from the discharge48for dispensing from the dispenser10. In one embodiment, the guide roller(s)54can be biased, such as by one or more springs or other suitable biasing members to contact and engage the sheet material between the guide roller(s) and a portion of the discharge48. However, the guide roller(s) can be unbiased, without departing from the scope of the present disclosure.

The dispenser assembly10additionally includes a sheet material loading assembly or system100as generally shown inFIGS. 1-8B. The sheet material loading mechanism/assembly100can include a cover assembly102that is movably connected to the dispenser housing14. The cover assembly102includes a cover body104that is rotatably or pivotably coupled to the front portion16of the dispenser housing14, e.g., at a first end104A of the cover body104, such that the cover body104is movable between a closed position106and an open position108. In the closed position106, the cover body104will at least partially surround and/or at least partially enclose the feed roller40, and in the open position108, the cover body104generally will be substantially spaced away or displaced from the feed roller40, e.g., with the cover body extending out and away from the front portion16of the dispenser housing14.

In one embodiment, the cover body104has one or more generally arcuate or curved portions or sections that generally follow or conform to the shape of the feed roller40, though other shapes or constructions can be employed without departing from the scope of the present disclosure. The cover body104further can be formed from a plastic material, though other polymeric, synthetic, or composite materials are possible in accordance with the present disclosure.FIGS. 4A-4Bfurther indicate that the cover body104can have sheet material guide or engagement fingers110formed with or attached thereto. In one example embodiment, the guide fingers110can have an elongated body112with an engagement portion114, such as having a spherical or other suitable shape, at one end thereof and configured to engage the sheet material against the feed roller body42, as generally indicated inFIGS. 4A-4B.

As additionally illustrated inFIGS. 1-8B, the sheet material loading assembly100includes one or more locking features or mechanisms120configured to lock or secure the cover assembly102in its closed position106. In one embodiment, the locking features120can include switch assemblies122having a bracket124coupled to the dispenser housing14and supporting a biased switch member126. The biased switch member126can be biased by a biasing member128, such as a spring or other suitable biasing member, so as to be urged towards an extended position to facilitate locking or securing of the cover assembly102, and a retracted position that allows for release of the cover assembly102in its movement to the open position108. The switch members126can engage and hold a portion of the cover body104to hold the cover assembly102in the closed position106, and further can include a tab or engagement portion130that will be engaged by an operator to move the switch members126along the brackets124to their retracted position for release of the cover assembly102.

FIGS. 7A and 8Afurther show the cover assembly102to be biased towards its open position108, such as by one or more biasing members132. In one embodiment, the biasing members132can include one or more springs, such as torsion springs, or other suitable biasing members that engage the cover body104to bias the cover assembly102towards its open position108. In addition, with the cover assembly102secured in its closed position106, the cover assembly102can be urged towards its open position106by the biasing members132. In this regard, the cover assembly102is moved to its open position upon release or unlocking of the switch members126(i.e., when switch members126are moved to their retracted position).

Additionally, the cover assembly102includes a cover roller140, which can include a guide or pressing roller, connected to the cover body104. For example, as shown inFIGS. 2A-2B, 3A-3B, 4A-4C, 7A-7B, and 8A-8B, the cover roller140can be rotatably connected to the cover body104at the second end104B thereof, and can be biased or urged, e.g., by one or more springs or other biasing members142, so as to press or engage at least a portion of the sheet material against the feed roller body42, when the cover assembly102is in its closed position106. The cover roller140can define a nip along the feed roller body42. The cover assembly102also includes end bearings or bearing portions144that can be connected to or formed with the cover roller140, and that support or connected the cover roller140to the cover body104. The bearings144are received within slots146or other openings defined along/in the second end104B of the cover body104. The cover roller140further is movable along the slots146, e.g., under the control/urging of biasing member(s)142, which can be coupled to the cover body104and can engage the bearings144of the cover roller140to urge the cover roller140towards and into engagement with the feed roller body42, e.g., towards a first end146A of the slots146defined in the cover body104.

In one embodiment, as generally shown inFIGS. 4A-4C, the biasing member(s)142can include a torsion spring150with a body151having a coiled loop portion152, as well as a first and second free ends154/156. The coiled loop portion152is received about a projection158formed along the cover body104to couple the torsion spring150thereto. The first free end154of the torsion spring150can engage a notch or opening160in the cover body104, and the second free end156of the torsion spring150can engage a projecting portion162formed with or otherwise connected to the bearing portions144of the cover roller140. Thus, the spring150will urge the bearing portions towards the first end146A in the slot146and thereby engage the cover roller140against the feed roller body40, with the cover assembly102in its closed position106.

FIGS. 2A-2B, 3A-3B, 4A-4C, and 5also indicate that the cover roller140additionally can include one or more sheet material retention portions or features170, such as clips, sharpened portions, gripping areas, etc., configured to substantially secure or otherwise couple the sheet material to the cover roller140to facilitate loading of the sheet material in the dispenser assembly10. With the cover assembly102in its open position108, an operator can connect/engage a portion of the sheet material from the first or second supply rolls26/28of sheet material with the sheet material retention features170to secure or otherwise couple the portion of the sheet material12about the cover roller140.

In one embodiment, as indicated inFIG. 5, the retention features170can include biased clips172that engage the sheet material12against the cover roller140. The clips172each can include a clip body174connected to the cover roller140at one end174A, such that the clip body174is pressed or engaged against an outer surface176of the cover roller140, and a projecting portion178can be engaged by an operator to move the clip body174away from the cover roller140as needed, such as to allow the sheet material to be inserted and/or positioned between the clip body174and the outer surface176of the cover roller140. With the sheet material positioned between the projecting portions178the clip body174and the outer surface176of the cover roller140, the clip body174presses or engages the sheet material against the outer surface176of the cover roller140to couple the sheet material thereto.

FIGS. 6A-6Dshow schematic diagrams for loading of the dispenser assembly10according to principles of the present disclosure. In particular,FIGS. 6A-6Bshow that after one of the supply rolls, e.g., supply roll28, has been substantially dispensed (FIG. 6A), the supply roll can be removed. In some embodiments, this substantially dispensed supply of sheet material can be moved to a stub roll position, e.g., it can be substituted for and/or it can become the first supply roll26. As indicated inFIG. 6C, a new, un-dispensed supply roll, can be loaded into the dispenser assembly10, into the position of supply roll28, and an end portion180of the sheet material29can be engaged with the retention features170to engage the sheet material29about/along the cover roller140. Thereafter, as shown inFIG. 6D, the cover assembly102can be moved to its closed position106, such that the cover roller140engages or presses the sheet material against the feed roller body42. As a result, upon automatic or manual actuation of the feed roller140, the sheet material can be engaged and urged along the discharge path46and toward and through the discharge48of the dispenser housing14. Accordingly, with embodiments of the present disclosure, operators generally do not have to struggle to load the sheet material through tight clearances in the dispenser assembly, as with traditional dispensers.

FIGS. 7A-8Badditionally show that the dispenser assembly10also can include a supply roll transfer assembly or mechanism200that facilitates transfer of feeding between the first26and second28supply rolls. The supply roll transfer assembly200is operatively connected to or is otherwise in operative communication with the cover roller140. When sheet material from one of the supplies of sheet material, e.g., the first supply roll26or the second supply roll28, has been substantially dispensed, the supply roll transfer assembly200facilitates and/or allows movement of the cover roller140(and sheet material engaged therewith or extending thereabout) toward engagement with the feed roller body42to initiate dispensing of the sheet material from another supply of sheet material, e.g., enabling dispensing from the second supply roll28when the first supply roll has been substantially exhausted, or from the first supply roll26after the second supply roll has been substantially exhausted.

In the illustrated embodiment, as shown inFIGS. 7A-8B, the transfer assembly200includes a transfer arm or other portion202that is movable between a plurality of feeding positions to facilitate transfer of feeding of sheet material between the first26and second28supply rolls—e.g., the transfer arm202is movable between a first feeding position204for feeding sheet material from one supply roll, and a second feeding position206for feeding sheet material from another supply roll.

In particular, the transfer arm202is operatively connected to or otherwise in operative communication with the cover roller140. In the first feeding position204, the transfer arm202is positioned or configured to substantially maintain the cover roller140(and sheet material connected thereto) in a position spaced away from the feed roller body42. In the second feeding position206, the transfer arm202is positioned or otherwise configured to allow engagement between the cover roller140(and sheet material connected thereto) and the feed roller body42, i.e., such that sheet material connected to or engaged by the cover roller140is pressed against the feed roller body42. As a result, sheet material27from the first supply roll26will be fed with the transfer arm202in its first feeding position204, and sheet material29from the second supply roll28will be fed with the transfer arm202in its second feeding position206, though these positions can be reversed without departing from the scope of the present disclosure. To load the sheet material with the transfer arm202in the first feeding position204, sheet material from the first supply roll26can be engaged with the feed roller40, and sheet material from the second supply roll28can be engaged with the cover roller140(e.g., via retention features170).

In the first feeding position204, as indicated inFIGS. 7A-8B, transfer arm202can engage a portion of the cover roller140connected to the cover assembly102, such that the cover roller140(and the sheet material from the second supply roll28received thereabout) is positioned substantially apart or substantially spaced away from the feed roller body42, e.g., to define a sufficient gap or space210between the cover roller140and the feed roller body142. In one construction, the transfer arm202can include a projecting portion or flange208that engages or presses against the bearing portion144of the cover roller140to press the bearing portion144against or to urge the bearing portion144towards the second end146B of the slots146, with the cover roller140spaced away from (i.e., the gap or space210between) the feed roller body42. In one embodiment, the cover roller140can be spaced about 2.5 mm to about 3.5 mm from the feed roller body42, though the cover roller140can be spaced less than about 2.5 mm or more than about 3.5 mm from the feed roller body42without departing from the scope of the present disclosure.

FIGS. 7A-8Bfurther shows the transfer arm202including a guide roller212rotatably attached to a first end202A of the transfer arm202and configured to engage and guide the sheet material27from the first supply roll26, with the transfer arm202in the first position204(i.e., when the dispenser assembly10is feeding sheet material from the first supply roll26). For example, the guide roller212can engage and direct the sheet material27from the first supply roll26so that it is engaged and driven by the feed roller body42along the discharge path46through the discharge48.

The transfer assembly200additionally includes a fixed support or elongated body214positioned along or substantially adjacent to the transfer arm202as generally indicated inFIGS. 7A-8B. The fixed support214generally is configured to engage the sheet material from27the first supply roll26during feeding thereof, such that the sheet material27from the first supply roll26is engaged between the guide roller212and the fixed support214holding the transfer arm202in its first feeding position204(FIGS. 7A-7B). When the sheet material from the first supply roller26is dispensed and no further sheet material therefrom is received between/engaged by the fixed support214and the guide roller212, the transfer arm202will move to its second position206such that cover roller140is engaged against the feed roller body42to facilitate feeding of the sheet material29from the second supply roll28. More specifically, movement of the transfer arm to its second feeding position206allows the bearing portions144of the cover roller140to be moved to the first end146A of the slots146, e.g., under urging or force of the biasing members142connected to the cover roller140, to facilitate engagement of the sheet material29from the first supply roll26received about the cover roller140against the feed roller body42for dispensing thereof.

The guide roller212and the fixed support214are configured to interact, e.g., the guide roller212moves in relation to the fixed support214, to facilitate movement of the transfer arm202from its first position204to its second position206. In one construction, the guide roller212can be configured to intermesh or interleave with the fixed support214when/after the sheet material27from the first supply roll26is dispensed, i.e., there no longer is sheet material27engaged between the guide roller212and the fixed support214. In this regard, the fixed support214can include a plurality of spaced ribs or portions214A with a plurality of spaces214B defined therebetween and arranged along a length of the fixed support214. The guide roller212also can include a plurality of spaced ribs or portions212A defining spaces212B therebetween and arranged along a length of the guide roller212. The spaced portions212A of the guide roller212are configured to align with the spaces214B in the fixed support214, and the spaced portions214A in the fixed support214are configured to align with the spaces212B in the guide roller212. Accordingly, the spaced portions214A of the fixed support214and spaced portions212A of the guide roller212can intermesh or interleave when sheet material is not present therebetween. More specifically, when sheet material is not present between the guide roller212and the fixed support214, the spaced portions214A of the fixed support214and spaced portions212A of the guide roller212are positioned into the corresponding spaces214B and212B of the fixed support214and guide roller212.

FIGS. 7A-8Bfurther show that the transfer arm202is pivotably or rotatably attached (e.g., at pivoting or rotating connection220) to the dispenser housing14at a second end202B thereof. As such, when/after the sheet material27from the first supply roll26is dispensed, the transfer arm202can rotate or pivot to the second feeding position206. In some constructions, as indicated inFIGS. 7A-8B, the transfer arm202can be biased towards its second feeding position206, e.g., by one or more biasing members222, such as tension springs or other biasing member coupled to the transfer arm202. The biasing members222can bias or urge the transfer arm202toward a position to engage the sheet material27from the first supply roll26between the guide roller212and fixed support214in the dispensing positon204, and when the first supply roll26is exhausted/substantially dispensed, can bias or urge the transfer arm202forward its second feeding position206.

Accordingly, with embodiments of the present disclosure, the transfer assembly200can allow for substantially seamless transfer of feeding of sheet material between the first supply roll26and the second supply roll28of sheet materials, without requiring refeeding or manual manipulation of the supplies, while also avoiding double sheet dispensing.

FIGS. 7A, 7B, and 9Ashow a cutting assembly or system320that is integrated with the feed roller40. The cutting assembly320can include a cutting blade322and a base or support324connected to and at least partially supporting the cutting blade322. The base324can be pivotably or otherwise movably mounted within a cavity or chamber42A defined within the feed roller body42, such that teeth or sharpened portions330of the cutting blade322are extensible from the feed roller body, moving between extended and retracted positions out of and back through an opening or slot332defined along the feed roller40by movement of the base324.

The base324will have a body332that can be formed from a plastic material or other polymeric material, though other suitable materials, such as rubber, wood, composites, etc., also can be used without departing from the scope of the present disclosure. The base324generally will be coupled or connected to the cutting blade322along a portion338of the base324, such as by a series of fasteners, e.g. screws, bolts, rivets, etc., though the cutting blade can be otherwise fixed to or integrated with the support/base, without departing from the scope of the present disclosure.

The base324further will be rotatably or pivotally coupled to at least a portion of the feed roller40. For example, as indicated inFIGS. 2A and 7B, the cutting assembly320can be connected to the feed roller40by a pivoting or rotatable connection346, and can move/rotate with rotation of the feed roller40during dispensing of the sheet material. The cutting assembly320also can include one or more biasing members, such as torsion springs, or other suitable biasing members, that provide a biasing force against the support/base324sufficient to urge or bias the support/base324, and thus the cutting blade322, toward a retracted position.

FIGS. 7B and 9Afurther show that the base324also can have a cam follower assembly352arranged along the top portion338thereof. The cam follower assembly352generally will have one or more cam followers354, which can include bearings, rollers, or other rotating members, and which are configured to engage and move along one or more corresponding cam surfaces or tracks366located within the cavity42A of the feed roller body42as the feed roller40is rotated. As the feed roller rotates, the body will be correspondingly pivoted/rotated to move the cutting blade322out from and back into the opening/slot332. For example, in one embodiment, the cutting assembly320can include a cam track370that can be mounted in a substantially fixed or stationary position within the cavity42A of the feed roller body42, such that the feed roller body42and the base324are rotated about such cam track370, such as indicated inFIGS. 16A-E.

The cam track370further can have one or more sections372provided therealong that are engaged by the cam followers350to cause the base/support324to pivot, rotate, or otherwise move and thereby extend the cutting blade322out from the opening/slot332in the feed roller40for at least partial perforation or cutting of the sheet material.

U.S. patent application Ser. Nos. 15/848,643 and 15/185,937, which are specifically incorporated by reference herein as if set forth in their entireties, show example cutting systems that can be used in accordance with the present disclosure.

FIGS. 9B and 9Cfurther show that the feed roller body42, in some embodiments, can include a biasing assembly450disposed within cavity42A and operable to assist rotation of the feed roller body42and movement of the cutting assembly320, for example, upon manual activation of the feed roller body42. An example biasing assembly is shown and described in U.S. Provisional Patent Application No. 62/741,350, which is specifically incorporated by reference herein as if set forth in its entirety.

As shown inFIG. 9B, the biasing assembly450can include one or more biasing members452, e.g. in the embodiment illustrated, a pair of biasing members452are shown extending along the interior surface42B of the feed roller body42. It will be understood that fewer or additional biasing elements also can be used, without departing from the scope of the present disclosure. Each biasing member452can comprise a tension spring or other suitable tensioning or biasing member, having an elongated spring body454with first and second ends454A/B. The biasing members452also generally extend in a direction that is parallel to the longitudinal (or rotational) axis LA (shown inFIG. 9B) of the feed roller body328, and can be fixably attached to the interior surface42B of the feed roller body42.

The first or distal end454A of each biasing member452can engage and couple to a connection mechanism458, such as flange, arm, or other connecting member attached to the feed roller body42by one or more fasteners, (e.g., a screw, rivet, or other fastener). For example, in one embodiment, as illustrated inFIG. 9B, the first end454A of the spring body454of each biasing member452can include a hoop, ring, hook or other suitable feature or mechanism that connects to a protruding portion460formed with, or connected to the connection mechanism458, which portion460has a notch or opening460A for receiving the hoop, ring, or hook of the spring. The second end454B of each biasing member452can be similarly attached to a connecting linkageFIG. 9B.

In one embodiment, the connection mechanism458can include a body462that is connected to, or engages, portions or protrusions464and466fixed to, or integrally formed with, the feed roller body42. The protrusions464and466can be received within openings or apertures defined along body462of the connection mechanism, and/or can include threaded openings defined therein to receive fasteners passed through the openings of the body462of the connection mechanism to secure the body462to the feed roller body42. The body462can have a generally Z-shaped cross-section to facilitate connection of the body462to the portions464/466, though the body can have other suitable shapes and configurations, without departing from the scope of the present disclosure.

In one variation or alternative construction, the feed roller body42can have a plurality of attachment points464/466about interior surface329thereof. For example, the feed roller body328can have multiple portions464/466formed/connected to the feed roller40in spaced series to allow for adjustment (e.g., tightening or loosening) of the biasing members452, e.g., to accommodate different sheet material sizes and/or to correct for time dependent displacement or movements of the spring due to the repeated loading. In one embodiment, up to five attachment points can be provided, though any suitable number of attachment points, e.g., 2, 3, 4, or more than 5, can be employed without departing from the scope of the present disclosure.

FIGS. 9B and 9Cfurther show that each linkage456can include a wire, band, belt, or rod468, or other flexible coupling. The first end456A of each linkage456can be formed as a looped end, and can be connected to a second end454B of a corresponding biasing member454such as by a hook, hoop, or split-ring type of connection forming the second end454B of the biasing member454. The second end456B of each linkage456can be formed with a similar looped end and generally will be rotatably connected to a portion, such as tracks366, that does not rotate, e.g., is fixed in relation to, the feed roller, such as by attachment to a fastener472(e.g., screw, bolt, etc.) or other suitable connection mechanism. The fastener472also can have one or more spacers474received therealong to engage and facilitate alignment of the second looped ends456B of the linkages456(FIGS. 9B and 9C).

Additionally, the biasing assembly450can include one or more pulley assemblies480(as shown inFIGS. 9B and 9C) that engage and facilitate a change in the direction of the linkages456operatively connecting the biasing members452to the feed roller body42. Each of the pulley assemblies480can include a bracket482that is connected to the interior surface329of the feed roller body328and that at least partially supports a pulley484having a track or race486against which at least a portion of the linkage456is engaged and/or moves.

As shown inFIGS. 9B and 9C, the pulley brackets482can be pivotably or rotatably mounted (e.g., by a pinned or hinged connection488) to the interior surface42B of the feed roller body328. The pinned or hinged connection488can help to maintain engagement between, or substantially prevent misalignment of, the linkage456and the pulleys484, e.g., as/when the feed roller body42is rotated and the biasing assembly450is rotated therewith. The interior surface42B of the feed roller body42further can have a notch or recessed portion489formed/defined therein to accommodate movement/pivoting of the brackets482.

In operation, upon activation of the feed roller40(e.g., when a user pulls a hanging tab or portion of sheet material or turns the knob or lever52connected to the feed roller body42), the feed roller body42rotates and carries the biasing assembly450therewith. As a result, the linkages456are caused to be pulled or otherwise engaged about the pulleys484, tensioning and stretching the spring bodies of the biasing members452, thus creating tension in or along the biasing members452. This tension assists in the rotation of the feed roller body40and helps urge the feed roller body42to facilitate return of the feed roller body40to a rest or home position. In one example, the rotation of the feed roller40can be sufficient to generate a tab or portion for pulling or engagement by subsequent users for dispensing a selected portion of sheet material. Also, this tension helps facilitate rotation of the feed roller body42sufficient to cause activation or movement of the cutting blade322of the dispenser assembly10to cut, perforate, or otherwise cause or assist in separation of a sheet of the sheet material. The return movement of the feed roller body42also can cause retraction of the cutting blade322(e.g., into notch, recess in the feed roller body42).

The foregoing description generally illustrates and describes various embodiments of this disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed constructions and systems without departing from the spirit and scope of this disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of this disclosure. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiment, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present invention as set forth in the appended claims.