Restrictor and dispensing system

A restrictor and dispensing system for dispensing sheet material is provided. The restrictor includes a restrictor body positioned on a top sheet of a stack of sheet materials which are positioned in a dispenser. The restrictor assists in one at a time dispensing from a dispensing assembly. The dispensing assembly includes the dispenser, which has a housing including a container and a lid, and the housing is configured to hold and dispense sheet material. The dispenser also includes a sheet mover mounted to the housing. The sheet mover is configured to move over at least a portion of a sheet material away from additional sheet materials for dispensing. The restrictor cooperates with the housing and sheet mover to dispense one sheet material at a time. The restrictor may be provided with the dispenser, or separately. Alternatively, the restrictor may be provided in a cartridge filled with a stack of sheet materials.

BACKGROUND

Sheet materials, such as, but not by way of limitation, wipers stacked in a generally aligned configuration, are used for certain “clean” applications such as surgical rooms, electronic manufacturing, automotive painting and finishing, aerospace applications, and the like. Critical applications, such as procedures in clean rooms where silicone wafers are prepared to produce materials and/or apparatus such as integrated circuit devices, computer hard drives and the like make the use of wound sheet materials or interfolded sheet materials undesirable to use. Wound and/or interfolded sheet materials can result in linting, that is, shedding of small particles which can ultimately contaminate delicate silicone products. Wipers or sheet material for these clean applications must be “lint free” and are generally produced as individual sheets with their edges sealed normally by thermal or laser means. These wipers are usually sold in a stack of wipers which are not interfolded, and which are either dry or premoistened, generally, but not by way of limitation, with an isopropyl alcohol (IPA). Moistening may cause one or more wipers in the stack to cling together, making the separation of one wiper from the stack by an individual wearing gloves very difficult. However, it is desirable to dispense one wipe or sheet at a time, particularly in a clean room setting.

To address this problem, wipers have been wadded or otherwise packaged as a plurality of individual wipers packaged in pouches or pails. Pouches generally have a tabbed opening which is sealed with a resealable adhesive flap. Such adhesives often lose their ability to seal once they are wetted with an IPA or other liquid, and the wipers dry out. Pails employ a lid that can be difficult to remove and/or which often is not adequately sealed after use, allowing the alcohol to evaporate and the wipers to again dry out. Further, use of a pouch or pail requires a user to hold the pouch or pail with one hand and withdraw the wiper with the other hand.

It would be desirable for ergonomic, production efficiency and cost-in-use to provide a dispenser which would dispense one premoistened or dry wiper at a time. Such a dispenser may desirably more easily dispense one wiper to a user.

Further, since the edges of the sheets or wipers are heat or laser sealed to reduce or eliminate lint, the edges may be somewhat irregular. When one wiper is moved or slid across the others in the stack, the irregularities on the edge may cause the wiper to snag or catch another wiper and drag it partially or completely out during dispensing of the stacked wipers, resulting in waste.

To reduce or eliminate such waste, it would be desirable to provide a restrictor, such as a weighted plate, which is provided on the top of such a stack. Such a restrictor is desirably configured to allow for easy dispensing of one wiper at a time, while providing weight to at least a portion of the stack to prevent excessive dispensing from a top sheet being withdrawn snagging or moving one or more sheets below it when the top sheet is being dispensed.

Such a dispensing system may use a restrictor with a dispenser. Alternatively, such a dispensing system may use a restrictor in conjunction with a cartridge holding the stack of sheet materials which is configured to be disposed in the dispenser.

DEFINITIONS

As used herein, the term “exit port” or “dispensing port” is the opening in a housing of a dispenser for the passage of sheet material out of the dispenser.

As used herein, the terms “sheet material”, “sheet materials”, “wiper” “wipes” and “wipers” are interchangeable, and mean a material that is thin in comparison to its length and breadth. Generally speaking, sheet materials should exhibit a relatively flat planar configuration and be flexible to permit folding, rolling, stacking, and the like. Exemplary sheet materials include, but are not limited to, woven natural and/or synthetic material, nonwoven natural and/or synthetic material, cellulosic materials, such as, for example, paper tissue, paper towels, and so forth, or other fibrous material(s), film, polymers, filamentary products, and so forth.

As used herein, the term “fasteners” means devices that fasten, join, connect, secure, hold, or clamp components together. Fasteners include, but are not limited to, screws, nuts and bolts, rivets, snap-fits, tacks, nails, loop fasteners, and interlocking male/female connectors, such as fishhook connectors, a fish hook connector includes a male portion with a protrusion on its circumference. Inserting the male portion into the female portion substantially permanently locks the two portions together.

As used herein, the term “hinge” refers to a jointed or flexible device that connects and permits pivoting or turning of a part to a stationary component. Hinges include, but are not limited to, metal pivotable connectors, such as those used to fasten a door to frame, integrally molded ball and socket type, circular openings in components joined with a hinge pin and living hinges. Living hinges may be constructed from plastic and formed integrally between two members. A living hinge permits pivotable movement of one member in relation to another integrally connected member.

As used herein, the term “couple” includes, but is not limited to, joining, connecting, fastening, linking, or associating two things integrally or interstitially together.

As used herein, the terms “configure”, “configured” and/or “configuration” means to design, arrange, set up, or shape with a view to specific applications or uses. For example: a military vehicle that was configured for rough terrain; configured the computer by setting the system's parameters.

As used herein, the term “sheet mover” refers to a portion of the pivotal leg which is used to move one or a few sheet materials away from a stack or plurality of sheet materials. Specifically, the embodiments shown herein include a toe of the pivotal let having a pick which has at least one tooth thereon. In addition, the embodiments shown herein include a portion of the toe which ruffles or bunches one or a few sheet materials away from a stack or plurality of sheet material. These embodiments are intended to be non-limiting, and other embodiments which create the movement of sheet material, either by snagging or grabbing the sheet material, or, alternatively, by ruffling or bunching the sheet material may be used.

As used herein, the term “pick” refers to a sharp or semi-sharp, generally pointed instrument, in this instance, the pick, and desirably, one or more teeth of the pick, which is used to pierce, make a small hole in, snag without piercing, grab or drag by means of friction a sheet material.

As used herein, the term “pusher” refers to an instrument, in this instance, at least a portion of the pivotal leg, and desirably the toe of the pivotal leg, which acts to ruffle, wrinkle or bunch a portion of one or a few sheet materials away from a stack or plurality of sheet materials.

As used herein, the terms “snag” or “grab” refers to contacting a thing, such as a portion of one or more sheet materials, and seizing and pulling the contacted portion of the sheet material.

As used herein, the terms “push”, “bunch” “ruffle” and/or “wrinkle” refers to contacting and applying pressure to something, such as a portion of one or a few sheet materials, thereby creating a small furrow, ridge, hill or crease on a normally smooth surface for the purpose of moving the portion of the one or a few sheet materials.

As used herein, the term “about” includes plus or minus 10 percent of the numeral of a stated, implied or inherent amount at each end of a range.

As used herein, the term “substantially” refers to something which is done to a great extent or degree; a significant or great amount; for example, as used herein “substantially” as applied to “substantially” covered means that a thing is at least 90% covered.

As used herein, the term “alignment” refers to the spatial property possessed by an arrangement or position of things in a straight line or in parallel lines.

As used herein, the terms “orientation” or “position” used interchangeably herein refer to the spatial property of a place where or way in which something is situated; for example, “the position of the hands on the clock.”

SUMMARY OF THE INVENTION

In response to the difficulties and problems discussed herein, a restrictor is provided. The restrictor is for use in a dispenser adapted to dispense a stack of sheet material, the stack having a top sheet positioned at an upper end of the stack of sheet material and a next sheet positioned under the top sheet. The restrictor comprises a body configured to be positioned on top of and across a back of a top sheet of a stack of sheet material disposed in a dispenser. When the dispenser is activated to remove sheet material, the body permits the top sheet to be dispensed from the dispenser. The body is configured to limit movement of the back of the top sheet and the next sheet. When the top sheet is moved away from the next sheet and dispensed, a front of the next sheet is positioned in a substantially flat position such that the next sheet becomes a new top sheet and it is positioned for dispensing when the dispenser is again activated.

In another aspect of the invention, a restrictor adapted for use in a dispenser which dispenses a stack of sheet material is provided. The restrictor comprises a body positioned to put pressure on a portion of an upper end of a stack of sheet material disposed in a dispenser. The body includes a front portion having narrow perimeter and an opening formed therein which provides a pick/push zone. The body also includes a back portion providing substantial weight relative to the front portion to a top sheet positioned at an upper end of a stack of sheet material thereby restricting its movement and the movement of a next sheet positioned under the top sheet and sheets positioned thereunder. The back portion has an opening which permits movement of the next sheet when a top sheet is dispensed from a dispenser.

In yet another aspect of the invention, a cartridge adapted for use in a dispenser for dispensing a stack of sheet materials is provided. The cartridge comprises a housing having an inner surface which forms an internal compartment for holding a stack of sheet material. The housing has an opening along an upper edge. The cartridge includes a stack of sheet material disposed in the compartment. The stack of sheet material has a top sheet positioned on an upper end of the stack and a next sheet positioned underneath the top sheet. The cartridge also includes a restrictor positioned on at least a portion of the top sheet of the stack of sheet material. The restrictor is positioned to provide pressure on at least a portion of the top sheet to restrict movement of sheet material in the housing. When the cartridge is positioned in a dispenser and when the dispenser is activated to remove sheet material, the restrictor acts to permit the top sheet to be dispensed from the dispenser. The restrictor is configured to limit movement of the top sheet and the next sheet to permit the top sheet only to be dispensed. When the top sheet is dispensed, the restrictor is configured to hold the next sheet in a position such that the next sheet becomes a new top sheet and the dispensing process is ready to be repeated.

In still another aspect of the invention, a system for dispensing sheet material is provided. The system comprises a dispenser including a housing. The housing comprises a container and a lid which cooperate to provide an inner surface formed to include an internal compartment configured to hold sheet material. The housing includes an exit port for withdrawal of sheet material. The housing further includes a sheet mover mounted to the housing. A portion of the sheet mover is configured to move over at least a portion of a sheet material positioned in the housing such that at least the portion of the sheet material is moved away from additional sheet materials positioned adjacent thereto by the sheet mover. When the portion is moved away it is positioned to be easily withdrawn through the exit port by a user. The system also includes a stack of sheet material disposed in the compartment of the housing. The stack of sheet material has a top sheet positioned on an upper end of the stack and a next sheet positioned underneath and next to the top sheet. The system further includes a restrictor positioned on at least a portion of the top sheet of the stack of sheet material. The restrictor is positioned to provide pressure on at least a portion of the top sheet to restrict movement of the sheet material in the housing. When the dispenser is activated to dispense sheet material via movement of the sheet mover, the restrictor acts to permit the top sheet to be dispensed from the dispenser. The restrictor is configured to limit movement of the top sheet and the next sheet to permit only the top sheet to be dispensed. When the top sheet is dispensed, the restrictor acts to hold the next sheet in a position such that the next sheet becomes a new top sheet and the dispensing process is ready to be repeated.

In still yet another aspect of the invention, a system for dispensing sheet material is provided. The system comprises a dispenser including a housing. The housing comprises a container and a lid which cooperate to provide an inner surface formed to include an internal compartment configured to hold sheet material. The housing includes an exit port for withdrawal of sheet material. The housing further includes a sheet mover mounted to the housing. A portion of the sheet mover is configured to move over at least a portion of a sheet material positioned in the housing such that at least the portion of the sheet material is moved away from additional sheet materials positioned adjacent thereto by the sheet mover. The portion moved away is positioned to be easily withdrawn through the exit port by a user. The system also includes a cartridge adapted for use in a dispenser for dispensing a stack of sheet materials. The cartridge comprises a housing having an inner surface which forms an internal compartment for holding a stack of sheet material. The housing also includes an opening formed along an upper edge thereof. The cartridge also includes a stack of sheet material disposed in the compartment. The stack of sheet material has a top sheet positioned on an upper end of the stack and a next sheet positioned underneath the top sheet. The cartridge further includes a restrictor positioned on at least a portion of the top sheet of the stack of sheet material. The restrictor is positioned to provide pressure on at least a portion of the top sheet to restrict movement of the sheet material in the housing. When the cartridge is positioned in a dispenser and when the dispenser is activated to dispense sheet material via the movement of the sheet mover, the restrictor acts to permit the top sheet to be dispensed from the dispenser. The restrictor is configured to limit movement of the top sheet and the next sheet to permit only dispensing of the top sheet. When the top sheet is dispensed, the restrictor is configured to hold the next sheet in a position such that the next sheet becomes a new top sheet and the dispensing process is ready to be repeated.

DETAILED DESCRIPTION

Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention and is not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment or figure can be used on another embodiment or figure to yield yet another embodiment. It is intended that the present invention include such modifications and variations.

The present invention provides an apparatus for dispensing stacks of sheet materials. Such sheet materials may include, but are not limited to, woven materials, nonwoven materials, synthetic materials, natural materials, foils, polymer films, any combination thereof, and so forth. Exemplary sheet materials for which the present invention is suitable include, but are not limited to, absorbent sheet materials such as towels, wipers, tissue, napkins, and so forth. The specific composition of the sheet materials dispensed can vary as desired. Exemplary sheet materials and methods of making the same include, but are not limited to, those described in U.S. Pat. Nos. 3,301,746; 3,322,617; 3,650,882; 4,100,324; 4,436,780; 4,659,609; 4,737,393; 5,048,589; 5,284,703; 5,399,412; 5,494,554; 5,607,551; 5,672,248; 5,674,590; 5,716,691; 5,772,845; 5,776,306; 5,904,971; 6,077,590; 6,248,212; 6,273,996; 6,096,152; and so forth. While woven and/or nonwoven sheet-like products are generally discussed with regard to the sheet material shown and/or described in embodiments herein, it will be understood that various other products could be substituted therefore.

Desirably, but not by way of limitation, the sheet materials for which the present invention is suitable are provided as a stack of sheet materials. Such sheet materials may be connected or un-connected. The sheet materials may be folded, interfolded, tabbed and/or festooned. Desirably, however, the sheet materials are provided as individual sheets in a stack of generally aligned sheet materials.

The present invention, as illustrated inFIGS. 1-22, comprises a system10which includes a dispenser12and sheet materials14. The sheet materials14may be provided in a cartridge16or separately. If the sheet materials14are provided in a cartridge16, it may include a cover17which may also include a removable seal or release sheet18which is positioned as a seal over an opening19therein (shown inFIGS. 10-13). A restrictor20is desirably provided as well (FIGS. 14-21). The restrictor20is desirably positioned on top of the sheet materials14, which are desirably provided in a stack22of sheet materials, whether the sheet materials14are provided separately, or in the cartridge16. Therefore, the restrictor20may be provided separately (FIGS. 14-16) or with the dispenser12, or it may be provided on top of a stack22of sheet materials14contained in the cartridge16(FIGS. 17-21).

The sheet materials14may be premoistened with a liquid. Alternatively, the sheet materials14may be dry. Desirably, the stack22of sheet materials14are provided as single or individual sheet materials which are not connected to each other, and the stack22is desirably provided in a generally aligned and planar orientation.

Referring now toFIGS. 1-9, the system10includes the dispenser12which comprises a dispenser housing23having a tray container24and a lid25. The tray container24includes a front wall26and a back wall28which are spaced-apart and intersect a lower end30, as illustrated inFIGS. 1-5. A pair of spaced-apart side walls32intersect the lower end30and cooperate with the front and back walls26,28to provide an inner surface34which provides an internal compartment36configured to hold sheet materials14, desirably a stack22of sheet materials14or a cartridge16of sheet materials14in the tray container24and dispenser housing23. The front wall26, back wall28and side walls32may include a flange38which is provided along an upper edge39of the tray container24. The flange39, for example, but not by way of limitation, may extend at a generally perpendicular angle relative to the front and back walls26,28and sidewalls32. The tray container24may include a mechanism (not shown) which permits it to releasably coupled to the lid25, which may also have a cooperative mechanism, which permits the lid25to be held in a closed position against the upper edge39and flange38of the tray container24.

The lid25is desirably pivotably coupled to the tray container24, and desirably provides sufficient closure to maintain premoistened sheet material14disposed therein in a premoistened state when such premoistened sheet material14is loaded in the dispenser12or when liquid is provided to the sheet material14disposed in the dispenser12. The lid25may comprise one piece. Desirably, however, as illustrated herein, the lid25may include a first lid section42which is desirably, but not by way of limitation, pivotably coupled to a second lid section44via at least one hinge45to permit the internal compartment36and the sheet materials14therein to be accessed by a user. In addition, this design permits the first lid section42to function as an exit port46. The first lid section42may include a pair of spaced-apart tapered side walls47and a front wall48which cooperate to provide the first lid section42.

The first and second lid sections42,44may also include a lip49which extends outwardly from a lower perimeter edge50of the lid25. The lip49of the lid25desirably cooperates with the upper edge39and flange38to provide a releasable closure to the dispenser housing23and to reduce or prevent moisture contained in the dispenser housing23from evaporating.

A locking assembly51for a sheet mover is provided in the dispenser housing23(FIGS. 2-5and8). The second lid section44includes a rod holder52coupled to an inner surface34of the second lid section44which has a pair of spaced-apart side walls53extending downward from the second lid section44, and opening positioned in each side wall53. A push rod54is pivotably coupled at one end to the rod holder52. The push rod54includes, at the one end, a transversely positioned pivot bar56having a pin58at each end thereof. The pins58extend through openings in the side walls53of the rod holder52to permit the pivot bar56to pivotably couple to the rod holder52. The push rod54includes, at an opposite end thereof, a generally, though not by way of limitation, U-shaped yoke60. The yoke60includes a pair of spaced-apart side arms62, each of which includes a slot (not shown) therein. A shield64for a pivotal leg is positioned on the inner surface34of the first lid section42, and the shield64includes a pair of spaced-apart side walls66which extend downward from the inner surface34at a generally perpendicular angle thereto, each of which has an elongated slot68formed therein. Coupled to the shield64and yoke60is a sheet mover or pivotal leg70, which is one primary operative member of the dispenser12but it is not a part of the locking assembly51.

The pivotal leg70is configured to be moved at least partially out of the shield64yet also received and releasably held in the shield64of the locking assembly, as shown inFIGS. 2-9. The pivotal leg70includes at one end a transversely positioned pivotal bar72(FIG. 2) having, at each end thereof, a pin74. The pivotal leg70also includes at an opposite end thereof a toe76. A body77of the pivotal leg70extends between the leg70and the toe76. The toe76may include, but not by way of limitation, one or more roller(s) or wheel(s)78which are rotatably mounted via a pin80on either side of the toe76which couples the at least one wheel78to the toe76and to permit the wheel78to rotate on an axis81which is generally transverse to the orientation of the toe76. The wheel(s)78desirably moves tangent to a top sheet82of the stack18of sheet materials14to permit smooth movement of the toe76as it contacts and rolls or moves over the top sheet82. Alternatively, the toe76is provided without the at least one roller or wheel (not shown). The toe76is desirably formed to remove frictional resistance and to permit smooth contact and movement of the toe76over the sheet material14until the toe76reaches a point of desirably moving and/or lifting the sheet material14.

A lower surface84of the toe76desirably includes at least one tooth or similar apparatus which acts as a pick86(illustrated best inFIGS. 6-9). As the toe76moves across an upper surface of the top sheet82, the lower surface84of the toe76is slightly rotated due to the changing angle of the toe76as the first lid section42is lifted. This action causes the toe76to move across the top sheet82until it moves or rotates sufficiently such that the pick86comes into contact with the top sheet82of the stack22of sheet materials14. The pick86moves against the top sheet82to desirably snag, grab and pick up a portion of the top sheet82, when the first lid section42of the lid25is lifted, as will be described in greater detail below. Desirably, but not by way of limitation, the pick86is configured to snag or grab the top sheet82and may slightly pierce a very small portion of the upper surface88of the top sheet82without tearing the top sheet82or creating any significant aperture or opening therein. This action moves or lifts a portion89of the top sheet82upward and away from the stack22such that the portion89is puckered, bunched, ruffled, wrinkled, and/or moved upward in a direction90, away from the stack22. Desirably, as the pivotal leg70continues to move, the pick86becomes disengaged (FIG. 9) from the portion89such that the portion89remains in its bunched, ruffled, wrinkled and/or puckered position away from the stack22, for easy removal by a user. Alternatively, the portion89may remain coupled to the pick86for removal by a user. A restrictor20may be used and placed on the top sheet82of the stack22of sheet materials14, as shown inFIGS. 14-16. The restrictor20may greatly enhance the reliable movement or “pick” of each top sheet82when the pivotal leg70moves thereagainst, and will be described in greater detail below.

In another alternative, the top sheet82is pushed by the toe76of the pivotal leg70to cause at least the portion89of the top sheet82to lift up and/or to move away in the direction90from the remaining stack22of sheet material14. The top sheet82, however, is not snagged, grabbed or attached to the pick86or the toe76of the pivotal leg70. Instead, the pick86and/or toe76may be modified to create friction against at least the portion89of the top sheet82without snagging or otherwise attaching itself to the top sheet82. That is, the pick86, toe76and/or any portion of the leg70may be formed to rub, bunch, push and/or move the portion89of the top sheet82upward in the direction90and/or away from the remainder of the stack22. In this manner, the pick86, if any, and/or the toe76may include a material, such as, for example only, rubber, plastic, metal, and so forth and/or be formed with frictional characteristics which would cause sufficient friction against the top sheet82to cause bunching, ruffling, gathering and/or movement of the top sheet82to provide the portion89in the described position. Therefore, the toe76may be provided without a pick (not shown). The toe may include one or more ridges, raised portions, and so forth, to provide friction against the top sheet82(not shown). In this way, the portion89of the top sheet82presents itself to be removed from the dispenser12by a user, who would likely, but not by way of limitation, grasp the portion89between the user's thumb and first finger to do so. In this alternative, the restrictor may also be utilized (not shown).

It will be understood that the top sheet82is the uppermost sheet in the stack22of sheet material14. The top sheet82is situated closest to the exit port46. A next sheet92is provided immediately below and against the top sheet82. When the top sheet82is removed from the stack22, the next sheet92(FIG. 8), underneath the top sheet82, becomes the new top sheet. Therefore, the new sheet under the new top sheet82becomes the new next sheet92. This process desirably continues until all sheet materials14are dispensed from the dispenser12.

Turning back to the locking assembly51, as illustrated inFIGS. 2-5and8, the ends of the pivotal bar72are desirably positioned through the elongated slot68of the shield64and the pins74on the ends73are desirably positioned through the slots (not shown) in the arms62of the yoke60of the push rod54. The shield64may be formed integrally with or formed separately and coupled to the inner surface34of the first lid section42(FIG. 2).

The shield64desirably is generally formed in a shape to surround the pivotal leg70and to generally follow its contours. The shield64includes a retaining bar94(FIG. 2) which couples to and extends between the side walls66of the shield64, which acts to urge and hold the pivotal leg70in a position in the shield64in which a substantial portion of the pivotal leg70rests between the sidewalls66of the shield64and against or closely adjacent the inner surface34of the first lid section42of the lid25. The pivotal leg70is positioned in the shield64such that each end73of the pivotal bar72of the pivotal leg70extends through one of the elongated slots68to permit pivotable movement as well as forward and backward movement of the pivotal leg70within the shield64, as shown inFIGS. 2-5and8. Such movement is further controlled by the pivotal coupling of the pins74on each end73of the pivotal bar72to the slots in the arms62of the yoke60.

As the first lid section42is raised in an opening direction96, the yoke60moves over the pins74of the pivotal bar72which are positioned through the slots in the side arms62of the yoke60which provides a dwell period prior to the pivotal leg70being pulled rearward. This design ensures that the pivotal leg70can pivot or move through the range of movement needed to snag, grab or push the lowest or last sheet material14in the stack22of sheet materials14, i.e. the last top sheet82, before the pivotal leg70starts moving upward into shield64of the locking assembly51.FIGS. 1 and 3illustrates the first lid section42closed and the ends and pins74positioned forward in the elongated slot68in the sidewalls66of the shield64. As first lid section42is opened, the yoke60is moved such that the ends and pins74therein move rearward in the elongated slot68, as shown inFIGS. 4-5, at which time the pivotal leg70is pulled rearward and upward via movement of the ends of the pivotal bar72in the elongated slots68in the sidewalls66of the shield64. When each pin74of the pivotal bar72of the pivotal leg70moves rearward in each elongated slot68of the shield64, the attached yoke60and push rod54pull the pins74and the ends of the leg70rearward within the elongated slot68of the side walls64of the shield64. This action also moves a portion of the body77(or ramp) of the pivotal leg70against the retaining bar94of the shield64. These two actions cooperate to pull the pivotal leg70into the shield64of the locking assembly51when the first lid section42is raised higher in the opening direction96(FIG. 2). With the pivotal leg70completely held by the shield64, the toe76and the pick86are positioned therein and are therefore moved away from a user's hand. The side walls66of the shield64are configured to extend beyond the toe76and the pick86when the pivotal leg70is received and/or held therein. This configuration protects a user's hand from being pricked by the pick86. In addition, the pivotal leg70is moved out of the way so that additional sheet materials14or cartridge16may be added to the tray container24without the sheet material14getting snagged or grabbed by the pick86during insertion. When in a dispensing position, however, the locking assembly51, namely, the rod holder52, the pivot bar56and the shield64are configured to hold the pivotal leg70positioned such that the toe76and pick86of the pivotal leg70will contact and move sufficiently within the internal compartment36and against the top sheet82of the sheet material14contained therein to permit the pick86to snag or grab the lowest or last sheet in the stack18of sheet materials14.

That is, when the first lid section42is moved in a closing direction100(FIGS. 2 and 3), this action permits the toe76of the pivotal leg70to move downward, out of the shield64and into its resting position against the new top sheet82of the stack22of sheet material14. The toe76and pick86thereon are again in a position to move over the new top sheet82to snag or grasp another portion89of the new top sheet82for removal. The first lid section42and lid25desirably closes sufficiently against the tray container24such that evaporation of any moisture contained in the dispenser housing23is reduced or eliminated (FIG. 1).

The sheet material14used as a part of the system10is desirably, but not by way of limitation, contained in a stack22of sheet materials14disposed in a cartridge16, as illustrated inFIGS. 8,10-13and17-21. Such a cartridge16may include a tub102having a front wall104, a back wall106which are spaced-apart and which intersect a lower end108. A pair of spaced-apart side walls110intersect the lower end108as well and cooperate with the front and back walls104,106to provide an inner surface112with defines an internal compartment114configured to hold the stack22of sheet material14. The cartridge16includes an upper edge116and the cartridge desirably includes the cover which is coupled thereto. The cover17desirably includes the release sheet19positioned over the opening20in the cover17. In this manner, when the cartridge16is positioned in the tray container14, the release sheet19is removed and the opening is exposed so that the sheet mover or pivotal leg70may access the sheet material14.

The cartridge16may alternatively be provided as a polymer or plastic package, having a seal or release sheet which is removable over an area which includes an opening or, alternatively, areas of weakness, such as perforations (not shown). In another alternative, the cartridge may include a plastic container having a lid or removable portion on at least a portion of a surface thereof. The cartridge may be formed from any material or combination of materials, and in any configuration, so long as the cartridge operates as shown and/or described herein.

The restrictor20may be used in conjunction with the dispenser12, as illustrated inFIGS. 2,6-9and12-21. The restrictor20acts to assist the dispenser12to permit one sheet material14at a time to be dispensed from the dispenser system10. Further, the restrictor20desirably assists in holding sheet material14positioned in an aligned position in the stack22in the dispenser12or in a cartridge16from being displaced during shipping, delivery and/or dispensing.

The restrictor20operates to reduce or prevent double dispensing, that is, two sheet materials14dispensed together instead of one. Further, the restrictor20operates to reduce or prevent dispensing failure.

The restrictor20is desirably, but not by way of limitation, planar in configuration and desirably follows the configuration of the stack22of sheet material14upon which it rests, as shown inFIGS. 14-16. It desirably includes a body or plate118having an upper surface120, a lower surface122and an outer perimeter124. The restrictor20may also include a front portion126and a back portion128.

The front portion126desirably includes an opening130formed through the restrictor20and sized and configured to permit the pivotal leg70to drop down and travel across the top sheet82which is exposed through the opening130in order to move the portion89of the top sheet82into a bunched, ruffled, wrinkled position to make it easy for a user to grasp the portion89and withdraw the top sheet82from the exit port46of the dispenser housing23. The front portion126desirably provides a narrow outer perimeter124to assist in holding the edges132of the stack22of sheet materials14in a stacked and aligned orientation or position. Moreover, the perimeter124of the front portion126may be formed to include a narrow portion of the perimeter124on only one side134, or, alternatively a narrow portion of the perimeter124may be formed on two sides134. In the present embodiment, the perimeter124includes two narrow sides134and a narrow end portion138extending therebetween and positioned adjacent the front wall of the cartridge104or dispenser26. In another alternative (not shown), the front portion126is not provided, and only the back portion128provides the restrictor20. When the front portion126is included as a portion of the restrictor20, as illustrated in the present embodiment, it desirably assists in positioning and holding the back portion128into a desirable position to permit the restrictor20to operate to reduce or eliminate dispensing problems.

The back portion128is desirably heavier in weight than the front portion126, and is desirably about twice the thickness thereof. The back portion includes a holder140which extends transversely across the length of the restrictor20and is formed along a front of the back portion128. The holder140acts as a holding area in to hold the portion89of the top sheet82when the portion82is snagged or moved against the holder140such that the portion89bunches or ruffles in the direction90upward.

The back portion128includes a wide perimeter edge141which extends about the perimeter in a general U-shape from one side of the holder140to an opposite side. The U-shaped is formed, in part, by an opening142which is formed through the center of the back portion128. The opening142may be, but not by way of limitation, provided as a smaller opening relative to the opening130in the front portion126. The opening142desirably provides a “relief zone” for the next sheet92in that if a portion of the next sheet92is pulled along with the top sheet82when the top sheet82is being dispensed, the portion of the next sheet92which is pulled is generally held in the opening142which assists in preventing double dispensing and/or jamming or wadding of sheet material14in the stack22when one sheet14, i.e., the top sheet82, is being dispensed. While the back portion128desirably includes the wide perimeter edge141, it will be understood that, alternatively, the back portion may be formed as a solid component without an opening (not shown).

Certain types of sheet material14may slide easily, and have a low surface tension. Adding, desirably, isopropyl alcohol and/or other liquids as a moistening solution to premoisten the sheet material14in the dispenser12and/or the cartridge16results in greatly reduced surface tension between the sheets14. Therefore, the sheet material14greatly resists staying in alignment, whether dry or premoistened. Increased slippage of sheet material14results in wadding of sheet material14leading to inadequate dispensing, excessive dispensing and/or dispensing failure. In addition, the liquid may cause some sheets14in the stack22to stick or clump together. These same sheets14may also slip out of alignment in the stack22. The restrictor92acts to reduce or eliminate these problems.

The back portion128, while thicker than the front portion126as described, also may include, but not by way of limitation, a step146on the lower surface of the restrictor20, due to its increased thickness. That is, the step146may position the lower surface122of the front portion126of the restrictor20a small distance from the top sheet82in the area where the front portion126and the back portion128are joined or integrally formed together. Alternatively, the step may be removed and the lower surface of the restrictor tapered (not shown).

The restrictor20provides both weight and structure to prevent movement of the sheet material14. It will be understood that desirably at least about 60 percent of the weight of the restrictor is in the back portion128. Even more desirably, at least about 70 percent of the weight of the restrictor is in the back portion128. Even more desirably, at least about 80 percent of the weight of the restrictor is in the back portion128. Yet even more desirably, at least about 90 percent of the weight of the restrictor is in the back portion128.

In addition, the weight of the restrictor20is desirably in a range from about 30 grams to about 70 grams. Desirably, the weight of the restrictor is in a range of about 40 grams to about 60 grams. Even more desirably, the weight of the restrictor is in a range of about 45 grams to about 55 grams. Yet even more desirably, the weight of the restrictor is in a range of about 48 grams to about 52 grams.

The restrictor20is desirably provided in any shape or configuration so long as the restrictor operates as shown and/or described. The restrictor20may be provided, as previously noted, with only the back portion128(not shown). In this alternative, the dispenser12, the restrictor20and/or the cartridge16may include a rib, other mechanical member, and so forth, to prevent the restrictor from slipping forward. The restrictor20provides improved dispensing when the weight of the restrictor20prevents the perimeter edges132of the sheet materials14, which may have been heat and/or laser sealed, and so forth, from snagging edges132of adjacent sheet materials14when the top sheet82is being withdrawn and dispensed. The relief zone or opening142of the back portion128functions to hold any snagged sheets14in a position which prevents double dispensing or jamming.

While the restrictor20may be provided separately, or it may be provided as a component of the dispenser12(not shown), the restrictor20may also be provided in a cartridge16which may be filled with sheet materials14. In this instance, the restrictor20may desirably include a plurality of ribs150provided on the upper surface120thereof. The ribs150may be provided in any portions of either upper and/or lower surface120,122. In the present embodiment, the ribs150are generally formed adjacent to the outer perimeter124and adjacent at least a portion of an outer perimeter152of the opening130in the front portion126and the perimeter154of the opening142in the back portion128. Additional ribs150may be provided in a spaced-apart configuration and positioned generally transversely on the holder140. It will be understood that other positions of the plurality of ribs are possible.

The plurality of ribs150are provided to assist in supporting the cover17which is desirably coupled in an air-tight configuration and/or sealed to the upper edge116of the cartridge16so that liquid which is used to premoisten the sheet material14does not evaporate, as shown inFIGS. 17-21. Too much air in the cartridge16causes the cover17of the cartridge16to balloon or expand somewhat. It also encourages the sheet material14in the stack to move and become unaligned. Further, when the cartridges16are stacked on top of each other in a box or container for transport, pressure from one cartridge16stacked on top of another may cause the air in each cartridge16to cause the cover17to break open or the seal provided by the release sheet18to break or rupture, resulting in evaporation of the liquid in each cartridge16.

The plurality of ribs150may extend transversely upward from the upper surface120of the restrictor20to assist in supporting the cover17on top of the stack22of sheet materials14. That is, the height of the ribs150, when on top of the full stack22, are about the same height as the upper edge116of the cartridge16. When the restrictor20is in place, the stack22cannot by overly compressed, nor can the air contained within the internal compartment114of the cartridge16. This design of the restrictor20assists in preventing leakage of air and spillage or evaporation of liquid from the cartridge16since it greatly reduces and prevents breakage or openings in the cover17or release sheet18caused by compression or displacement of air, sheet material or liquid. The restrictor20also assists in holding the sheet materials14in an aligned stack20and reduces or prevents displacement and/or misalignment of the sheet materials14in the stack22during shipment.

FIGS. 17-21illustrate the common manner of packing a plurality of cartridges16in a box or container (not shown) for shipping. Often, but not by way of limitation, the cartridges16may be stacked six cartridges one on top of another. The plurality of ribs150on the upper surface120of the restrictor20operate to support each cartridge16one on top of the other without breaking or causing unwanted openings to form in the cover17or the seal of the release sheet18. The sheets14are supported in the stack22in their proper aligned position.

The cover17of the cartridge16may interact with the restrictor20as well. The opening19in the cover17corresponds generally, but not by way of limitation, to the size, shape and location of the opening130in the front portion126of the restrictor20such that a push zone or pick zone156(collectively a pick/push zone) is provided for the pivotal leg70to move downward through the opening19in the cover17and the opening130in the front portion126of the restrictor20so that the leg70may contact and move across the top sheet20to move, pick, bunch, wrinkle, snag, and so forth the portion89within this zone156.

The weight of the back portion128provides both weight, compression and friction to a back158of the stack20of sheet materials14so that movement of the back158of the stack or a portion of a sheet14in the back158is restricted. In this manner, double dispensing, snagging of sheets14together and/or streaming may be reduced or prevented. The front160of the stack22does not compress so that the top sheet82is readily picked or snagged and the portion89is provided in the pick zone156so that the portion89can be easily and readily grasped by a user and removed from the cartridge16and through the exit port46of the dispenser12.

When the release sheet18is removed from the cover17to expose the opening19and the cartridge16of sheet materials14is disposed in the dispenser12, the cover17may operate to interact with the restrictor20to assist in dispensing. That is, when the pivotal leg70snags and bunches the portion89of the top sheet82for withdrawal of the top sheet82from the cartridge16and the exit port46of the dispenser12, the restrictor20, especially the front portion126thereof, may lifts up during the withdrawal of the top sheet82from the dispenser12. The opening19in the cover17is desirably sized smaller than the front portion126of the restrictor20. Therefore, if the front portion126of the restrictor20lifts when the top sheet82is being withdrawn by a user, the surrounding cover17acts to hold the restrictor20in a position within the cartridge16so that the restrictor20continues to be generally positioned for operation over the stack22of sheet materials14. Alternatively, the weight of the restrictor20may be adjusted to hold the restrictor20in a position in the dispenser12or cartridge16. In another alternative, for example, but not by way of limitation, ribs or tabs may be provided in one or more walls or positions in the dispenser or the cartridge to limit movement of the restrictor during dispensing (not shown).

In a method of using a restrictor positioned in a cartridge with a dispenser, the dispenser12described herein, or an equivalent (not shown), is provided, as shown inFIGS. 1-9. Desirably, a cartridge16containing a stack22of sheet materials14is provided. More desirably, a restrictor20is provided positioned on the top of the stack20is provided (FIGS. 10-13). The cartridge may include a cover17having a release sheet18positioned over an opening19therein. Desirably, the release sheet18is removed from the cover17. The first lid section42of the lid25is raised and the cartridge16is positioned in the internal compartment36of the dispenser housing23with the opening19in the cartridge16positioned adjacent the front wall26of the dispenser housing23.

The lid25is closed over the tray container24(FIGS. 1 and 3) and when a user desires to obtain a sheet material from the dispenser12, the user raises the first section42of the lid25. The first lid section42is raised in an opening direction96(FIGS. 2-9) and this action causes the pivotal leg70to move across the top sheet82in the pick zone156. The toe76of the pivotal leg70contacts and maintains this contact while moving across the top sheet82in a direction162until the toe76rotates slightly which positions at least one pick86against the top sheet82such that the pick86snags or grabs the portion89of the top sheet82and pushes the portion89against the holder140of the restrictor20and raises the portion89of the top sheet82in the upward direction90such that it causes an upward bunch, ruffle, wrinkle, and so forth of the portion89. The pivotal leg70is moved by the locking assembly51such the pick86on the toe76of the pivotal leg70detaches from the portion89of the top sheet82. As this occurs, the front portion126of the restrictor20may raise upward. If this occurs, the front end164of the cover17of the cartridge16acts to hold the restrictor20in position so that the restrictor20is not further lifted or moved in the cartridge16. Further, when the top sheet82is removed by a user, the portion of the top sheet82resting under the back portion128of the restrictor20will be moved out from under the back portion128and dispensed through the opening130in the front portion126of the restrictor20, and through the opening19in the cover17of the cartridge16and through the exit port46of the dispenser12. When this occurs the restrictor20acts to positioned at least a front of the next sheet92in a substantially flat position while a back portion of the top sheet82is pulled from underneath the back portion128of the restrictor20. In addition, when the portion89of the top sheet82is grasped and pulled through the opening130in the front portion126, this action may also cause the front portion126of the restrictor20to move upward. Again, the front end164of the cover17may operate to limit movement of the restrictor20. Movement of the restrictor20may be limited by other means or mechanisms shown and/or described herein, or known in the art.

EXAMPLE

Referring now toFIG. 22, which illustrates the results of using the dispenser described herein with and without the restrictor.

Three hundred (300) sheet materials were provided separately in six (6) cartridges, each of which had fifty (50) wipes contained therein, for a total of 300 wipes. The wipes each comprised a woven polyester material, and were aligned in a stack in each cartridge, and the opened cartridge was positioned in the dispenser shown and described herein without a restrictor. The 300 sheet materials were premoistened with isopropyl alcohol. The room temperature was about 75 degrees (plus or minus 5 degrees); the relative humidity was about 50 percent (plus or minus 5 percent). The 300 sheets were then dispensed from the dispenser in the manner described previously herein.

Of that amount, about 48 percent were “picked” or “pushed” as shown and described in detail herein, which resulted in successful dispensing to a user. About seventeen (17) percent were side picked, resulting in a smaller ruffled, wrinkled portion adjacent one side of a front portion of the tray container. About twelve (12) percent of attempted dispenses resulted in two sheets being lifted and dispensed together. About three (3) percent of attempted dispenses did not snag or move the top sheet on the first attempt, and a second attempt was required to obtain a top sheet. About two (2) percent of attempted dispenses resulted in no sheet dispensed in spite of two or more attempts to dispense a sheet material. Drag out, that is, a dispensing of the top sheet and the next sheet being moved out (“dragged out”) with the top sheet even though the next sheet was not directly snagged or moved by the pivotal leg. About eighteen (18) percent of the dispenses resulted in drag out of the next sheet along with the top sheet.

Five hundred (500) sheet materials were provided separately in ten (10) cartridges, each of which had fifty (50) wipes contained therein, for a total of 500 wipes. The wipes each comprised a woven polyester material identical to the woven polyester material used in the test of 300 wipes without a restrictor. The wipes were aligned in a stack in each cartridge, and the opened cartridge was positioned in the dispenser shown and described herein with the restrictor. The 500 sheet materials were premoistened with isopropyl alcohol. The room temperature was about 75 degrees (plus or minus 5 degrees); the relative humidity was about 50 percent (plus or minus 5 percent). The 500 sheets were then dispensed from the dispenser in the manner described previously herein.

Of that amount, about eighty two (82) percent were “picked” or “pushed” as shown and described in detail herein, which resulted in successful dispensing to a user. About ten (10) percent were side picked, resulting in a smaller ruffled, wrinkled portion adjacent one side of the front portion of the restrictor. About five (5) percent of attempted dispenses resulted in two sheets being lifted and dispensed together. About three (3) percent of attempted dispenses did not snag or move the top sheet on the first attempt, and a second attempt was required to obtain a top sheet. About one (1) percent of attempted dispenses resulted in no sheet dispensed in spite of two or more attempts to dispense a sheet material. Drag out, that is, a dispensing of the top sheet and the next sheet being moved out (“dragged out”) with the top sheet even though the next sheet was not directly snagged or moved by the pivotal leg. There were no episodes of drag out when the restrictor was used.

A comparison of these events illustrates that use of the restrictor resulted in about a sixty-five (65) percent improvement of episodes of a “good pick” which resulted in a dispensed sheet on the first attempt. The use of the restrictor reduced incidences of double dispensing by about fifty-eight (58) percent. The use of the restrictor resulted in a one-hundred (100) percent reduction in drag out (which results from the snagging of sheets).

For the system10it will be understood that the pick is not required to push the sheet material away from a stack of sheet materials, or away from adjacent sheet materials. Rather, a pusher, that is, the end of the toe which is configured to cause friction against the top sheet may be used instead to move the top sheet away from the stack of sheet materials or adjacent sheet materials. The term “sheet mover” as used herein is intended to encompass both the “pick” and the “pusher” as well.

The system10may be positioned adjacent and secured to a support surface (not shown) via a mounting bracket. Such a mounting bracket is disclosed in U.S. Pat. No. 6,533,145 to Richard P. Lewis, et al., which is hereby incorporated by reference herein for all purposes. Other mounting apparatus may be used as well. For example, the dispenser may have an adhesive thereon for holding it in place. Alternatively, the adhesive is a cohesive adhesive wherein both a portion of the dispenser and the support surface have some cohesive adhesive thereon. Mechanical fasteners, suction cups, hook and loop materials, and so forth may be used, and are provided herein as non-limiting examples. It will be understood that any apparatus known to those skilled in the art may be used.

It will be appreciated that the system19may, alternatively, be constructed to be a one-use, disposable system. Therefore, when all sheet materials are removed from the dispenser, the dispenser is thrown away or disposed of. In clean room-type situations, this may be desirable, to cut down on contamination by lint, dust, and so forth.

The sheet material (premoistened or dry) may include one or more materials, such as, but not by way of limitation, meltblown fibers, spunbond fibers, polyester, spunlace, cellulose, and so forth. The sheet material may be provided as dry sheet material, and may be dispensed as dry sheet material. A liquid solution may be added to the sheet material, either before or after it is inserted into a dispenser. Such liquid solution may include, alone or in combination, but not by way of limitation, isopropyl alcohol, deionized water, and so forth.

The sheet materials14, stack22of sheet materials14, cartridge16and/or restrictor may be provided in any shape, or combination of shapes and configurations. The sheet material may be provided as symmetrical sheet material, or asymmetrical sheet material. Similarly, the dispenser housing23may be provided in any configuration, so long as such configuration permits sheet material to be inserted therein to be dispensed therefrom.

The cartridge16may comprise one or more of the features or characteristics of the dispenser. For instance, the cartridge may include a housing having a portion which is pivotably movable and a pivotal leg/sheet mover coupled thereto. The cartridge may be positioned in a separate, outer housing for dispensing.

Similarly, the pick, pusher and/or locking assembly shown and/or described herein may be constructed separately and supplied to a dispenser housing23or a cartridge. Such a pick, pusher and/or locking assembly may be constructed from any suitable material that operates as described herein. Such materials may includes plastic, rubber, metal, bristles (natural or synthetic), and so forth.

The dispenser12may be constructed from any suitable material or combination of materials. Such materials include, but are not limited to, plastic, metal, paper, fiber, wood, and so forth; combinations of these materials may be used together as well. If the dispenser12is configured to be a non-refillable, single use, disposable dispenser, it may be constructed from suitable materials for disposal, including, but not limited to, paper, paperboard, plastic, fiber, metal, and so forth. Similarly, combinations of these materials may be utilized. The restrictor is desirably formed from any material or combination of materials, especially, however, those material(s) which are unaffected by long term exposure to a liquid, such as isopropyl alcohol, and so forth. For example, but not by way of limitation, the restrictor may be formed from a plastic, and more desirably, formed from HDPE, polypropylene, styrene, acetyl and so forth. Alternatively, the restrictor is formed from any material and in configuration which permits it to operate as shown and/or described herein.

Moreover, the configuration of any component shown and/or described herein is intended as only non-limiting examples. It will be appreciated that any feature(s) in any embodiment shown and/or described herein may be used, substituted and/or combined with any other feature(s) in any other embodiment.

While certain characteristics are described in specific embodiments, any one or more characteristics, features, and/or elements may be used in any combination in any embodiment, or to create a particular embodiment from the disclosures, teachings, and/or suggestions provided herein. While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.