RIBBED PETAL SLOTTED CONICAL NOZZLE

A sheet dispenser lid includes a lid attachable a container and a slotted conical nozzle arranged on the lid. The conical nozzle has an exit port and a plurality of ribs arranged on an interior surface.

The following disclosure(s) are submitted under 35 U.S.C. 102(b)(1)(A): DISCLOSURE: Screen captures from YouTube video clip entitled “Brawny® 2.0 Professional Cleaning Towel System (:30 sec),” 2 pages, uploaded on Nov. 6, 2020 by user Georgia-Pacific Professional, retrieved from the Internet: https://www.youtube.com/watch?v=tunRA11s8-c.

BACKGROUND

The present disclosure relates to a nozzle for a sheet material dispenser, and more particularly, to a ribbed petal slotted conical nozzle for multiple types of sheet substrates.

Single-sheet dispensers, i.e., dispensers that dispense a consistent, fixed quantity of sheet material, are also desired for many reasons. Such dispensers reduce the quantity of sheet material used by an individual patron, thereby saving on material costs, disposal costs, and costs associated with the frequency whereby the dispensers must be refilled. Single-sheet dispensers are also advantageous because they do not require the patron to touch the nozzle of the dispenser, which reduces the chance of transferring disease-causing bacteria, viruses, and other microorganisms. Single-sheet dispensers make the process of obtaining a sheet quick and simple.

Manual single-sheet dispensers dispense single-sheets from rolled products by various methods. For example, rolls of sheet material have offset zones/regions of weakness, i.e., perforations. The dispensers include mechanisms to appropriately tension the sheet material flowing therethrough to allow withdrawal of one sheet at a time from a roll of sheet material to prevent both user waste from excessive dispensing and user frustration from inadequate dispensing. In order to remove a sheet, a patron applies a pulling force to remove the sheet material from the dispenser to cause the zones/regions of weakness between the individual sheets to separate and tear a single sheet from the roll of material within the dispenser.

The single-sheet dispenser mechanisms function either by various mechanisms. In a center-pull mechanism, the patron pulls the sheet directly from the dispenser (i.e., an angle of 90 degrees with respect to the horizontal surface of the dispenser lid), which causes the regions of weakness to separate a single sheet from the roll. In other mechanisms, the patron pulls the sheet from the dispenser at an angle (i.e., an acute angle with respect to the horizontal surface of the dispenser lid) and must perform the work to manually tear the single sheet from the roll.

SUMMARY

According to embodiments, a sheet dispenser lid includes a lid attachable a container and a slotted conical nozzle arranged on the lid. The conical nozzle has an exit port and a plurality of ribs arranged on an interior surface.

According to other embodiments, a sheet dispenser lid includes a lid attachable a container and a conical nozzle arranged on the lid. The conical nozzle has an exit port and a plurality of slots extending from the exit port along sidewalls to form a plurality of flexible petals. The conical nozzle also includes a plurality of ribs arranged on interior surfaces of the plurality of petals.

According to some embodiments, a sheet dispenser includes a container for housing a roll of sheet material, a lid attachable the container, and a slotted conical nozzle arranged on the lid. The conical nozzle has an exit port and a plurality of ribs arranged on an interior surface.

DETAILED DESCRIPTION

Various challenges are associated with manual single-sheet dispensers that dispense single-sheets from rolled sheet material with offset zones/regions of weakness, i.e., perforations. First, the dispenser must include a reliable mechanism(s) to appropriately tension the sheet material flowing therethrough to allow withdrawal of only one sheet at a time from a roll of sheet material. The pulling force that the patron must apply to separate zones/regions of weakness, i.e., perforations, will depend on the type of sheet material. Tearing a single sheet from a roll of thicker and heavier sheet material requires a greater pull force. If the patron does not apply the appropriate force and/or angle if necessary, the perforations do not separate, more than one sheet is pulled from the dispenser, resulting in unnecessary waste.

Another challenge for dispenser manufacturers is that the dispenser mechanism(s) must vary based on the type of sheet material that is to be dispensed, as thicker and heavier materials require more pulling force to tear a single sheet from a roll. Therefore, the different dispensers must be designed for different types of sheet material. Accordingly, there is a need for a single sheet dispenser that reliable dispenses a single sheet of material of multiple types of sheet materials requiring a range of pull forces via a center pull mechanism that does not require additional work from the patron.

In response to the above challenges, described herein is a dispenser with a lid that includes ribbed conical nozzle that dispenses single sheets of multiple types of substrates of varying thicknesses, weights, strengths, and textures. The ribbed conical nozzle with petals and slots reliably dispenses single sheets from rolls of material with regions/zones of weakness (such as perforations), while minimizing failures, such as roping, jamming, sheet tearing, and dispensing multiple sheets. The dispenser dispenses single sheets of various substrates, including hydroentangled (HEF) sheet substrates, spun laced sheet substrates, spunbonded sheet substrates, melt blown sheet substrates, airlaid sheet substrates, paper sheet substrates, resin bonded sheet substrates, natural fiber hydroentangled substrates, and double re-creped sheet substrates.

The lid of the dispenser includes a conical shaped nozzle with an exit port and sidewall slots that form a plurality of flexible petals, with a plurality of ribs arranged on the interior surface of the petals. The ribs flex the petals to variably change the central aperture opening, depending on the substrate sheet thickness and thereby controlling the pull force required to tear a sheet from the roll. The central aperture and slots within the nozzle restrict the sheet so the perforations separate just outside the nozzle. The purpose of the petal ribs is to control the pull force required for each type of sheet material in order to separate the perforations outside the nozzle opening. The ribs accomplish this by changing the angle of the petals and thereby changing the aperture diameter; guiding a larger amount of the thinner materials into the slots to restrict flow; and reducing the amount of heavier material into the slots to reduce excessive force when pulling the sheet material thru the nozzle. When a patron pulls on the sheet material from the exit port, the petals flex to eliminate undesired wearing of the nozzle and to prevent jamming, the conical nozzle opens, and a single sheet is torn from the sheet material roll.

FIG. 1Ais an exploded view of a sheet dispenser system100with a lid102with a conical nozzle108according to embodiments of the present invention. The sheet dispenser system100includes a container104for housing a roll of sheet material (not shown, within container104, but seeFIG. 1B) and a lid102with a conical nozzle108for dispensing single sheets of material from the roll of sheet material with regions/zones of weakness (such as perforations). Although the conical nozzle108is in the center of the lid102in some embodiments, in other embodiments (not shown), the conical nozzle108is not in the center of the lid102.

The container104has a round cylindrical shape in some embodiments; although the container104is not limited to this shape. While not required, in some embodiments, the container104includes a curved handle106affixed to the exterior surface for the user to easily move and transport the sheet dispenser system100.

The roll of sheet material150(seeFIG. 1B) disposed within the container104is a coreless roll of any type of sheet material, wet or dry, as the container104also houses a liquid wetting composition. In some embodiments, the sheet material150dispensed is a wet wipe material, and in other embodiments, the sheet material150dispensed is a dry wipe material.

The sheet dispenser lid102with the conical nozzle108dispenses single sheets of multiple types of substrates of varying thicknesses, weights, strengths, and textures. Non-limiting examples of sheet materials150including hydroentangled (HEF) sheet substrates, spun laced sheet substrates, spunbonded sheet substrates, melt blown sheet substrates, airlaid sheet substrates, paper sheet substrates, resin bonded sheet substrates, natural fiber hydroentangled substrates, and double re-creped sheet substrates. The sheet material150includes natural fibers, including natural cellulosic fibers (wood and non-wood fibers), reconstituted cellulosic fibers, polymeric fibers, or any combination thereof. The sheet substrates are perforated rolls (seeFIG. 1C), that include cores or do not include cores (coreless rolls) and perforated stacks of sheet material (FIG. 1D).

The lid102with the conical nozzle108dispenses single ply sheets and multi-ply sheets, for example, double-ply sheets. The lid102with the conical nozzle108dispenses sheet material150with a range of total thicknesses, for example, sheet material150with thicknesses of about 0.1 to about 1.9 millimeters (mm). In other embodiments, the lid102with the conical nozzle108dispenses sheet material150with total thicknesses of about 0.1 to about 1.5 mm.

The lid102with the conical nozzle108dispenses sheet material150with a variety of basis weights. The lid102with the conical nozzle108dispenses sheet material150with a range of basis weights, for example, sheet material150with basis weights of about 10 to about 30 grams per square meter (gms). In other embodiments, the lid102with the conical nozzle108dispenses sheet material150with basis weights of about 20 to about 150 gsm.

As shown inFIGS. 1B and 1C, the lead end152of a perforated roll of sheet material150dispenses from the center of roll within the container104up through the conical nozzle108. The roll of sheet material150with perforations151is disposed in the container104(seeFIG. 1C). The roll of sheet material150includes a core in some embodiments, and in other embodiments the roll of sheet material150is coreless. The lead end152of the roll of sheet material150is pulled from the roll and through the conical nozzle108in the lid102, and the lid102is attached to the container104, as shown inFIG. 1C. A patron or user pulls the lead end152of the sheet material150through the conical nozzle108, and a single sheet is torn at the perforations.

While the sheet material in a perforated roll in some embodiments, in other embodiments, the sheet material is a stack of sheet material160with perforations161, as shown inFIG. 1D. The stack of sheet material160with perforations161is disposed in the container104(seeFIG. 1D). The lead end162of the stack of sheet material160is pulled from the roll and through the conical nozzle108in the lid102, and the lid102is attached to the container104, as shown inFIG. 1D. A patron or user pulls the lead end162of the sheet material160through the conical nozzle108, and a single sheet is torn at the perforations161.

When a patron pulls on the lead end152of the roll of sheet material150with sufficient tension or force, the flexible petals of the slotted conical nozzle108move to expand and open the exit port204, as the ribs (seeFIGS. 5A and 5B) on the interior surface of the conical nozzle108flex the petals202to change the exit port204opening, depending on the sheet material150thickness. The exit port204and slots206restrict the sheet material150so that the perforations in the sheet material separate just outside of the conical nozzle108. Once the single sheet is torn, another lead end152of the sheet material150remains protruding from the conical nozzle108for the next patron. While the exit port204is shown as being centrally located within the conical nozzle108and arranged at a right angle with respect to the lid102, such orientation is not required, and in other embodiments, the exit port204is not centrally located, and the conical nozzle is angled at any angle with respect to the surface of the lid102.

The sheet material, in the form or a roll or in stacked sheets, have zones/regions of weaknesses, such as perforations. The lids102with the conical nozzles108dispense single sheets of sheet material within a broad range of average pull forces (pounds (lbs) of force). In some embodiments, the lids102with the conical nozzles108dispense single sheets of sheet material150with a pull force of about 2 to about 14 lbs of force. In other embodiments, the lids102with the conical nozzles108dispense single sheets of sheet material108with a pull force of about 4 to about 12 lbs of force. Still yet, in other embodiments, the lids102with the conical nozzles108dispense single sheets of sheet material150with a pull force about or in any range between about 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and 14 lbs of force.

The lid102is attachable to the container104and mounted on or affixed to the container104by means, including but not limited to, threads, snap fitting, inter-engaging ribs, frictional engagement or the like. Although not required, the lid102with the conical nozzle108is integrally formed as a single piece.

The container104and lid102with the conical nozzle108are formed from any suitable polymeric material. Non-limiting examples of materials for the container104and lid102with conical nozzle108include polypropylene, polycarbonate, high density polyethylene, acrylonitrile butadiene styrene, nylon, polyoxymethylene, or any combination thereof.

Referring toFIGS. 2A-2D, the conical nozzle108of the lid102includes an exit port204at the apex of the nozzle and a plurality of slots206extending from the exit port204along sidewalls of the nozzle towards the planar base of the lid102. The slots206define edges of flexible petals202formed in the sloping sidewalls of the conical nozzle108. The conical nozzle108includes a plurality of slots206and a plurality of petals202.

Although five slots206and five petals202are shown throughout the figures, includingFIG. 2A, the conical nozzle108is not limited to this number and includes at least three slots206and at least three petals202. The slots206extend to the base surface of the lid102but extending to the base of the lid102is not required. The plurality of slots206enable the plurality of petals202of the conical nozzle108to be flexible/movable to accommodate multiple types of sheet materials. For example, when the sheet material is thicker and/bulkier, the flexible petals202will flex/move to open the exit port204wider than when the sheet material is thinner. This flexibility allows the conical nozzle108to accommodate a wide range of substrates.

In some embodiments, as shown inFIG. 2B, a lid210with the conical nozzle208includes three slots206and three petals202. In other embodiments, as shown inFIG. 2C, lid220with the conical nozzle222includes four slots206and four petals202. Yet, in some embodiments, as shown inFIG. 2D, the lid230with the conical nozzle232includes six slots206and six petals202.

The sides/edges of the slots206of the conical nozzle108are straight, tapered, or curved.FIG. 3Ais an expanded view of the conical nozzle108with slots206having straight parallel sides302according to embodiments of the present invention. In other embodiments, the sides/edges of the slots206are straight but tapered. The sides/edges of the slots206are parallel or non-parallel.FIG. 3Bis an expanded view of a slot306of a conical nozzle308having non-parallel and curved sides303or edges according to embodiments of the present invention.

The terminal ends of the slots have any shape or end position with respect to its terminal point in contact with the lid.FIG. 4Ais an expanded view of a rounded slot end402shape of the conical nozzle108according to embodiments of the present invention. The rounded slot end402has a larger diameter d than the width w of the slot206. In other embodiments, the diameter of the slot end is the same as or smaller than the width of the slot (not shown).FIG. 4Cis an expanded view of a larger rounded slot end406of a conical nozzle420according to embodiments of the present invention. The diameter d of the larger rounded slot end406is at least two times the width w of the slot206. The terminal end of the rounded slot end402is positioned anywhere along the periphery of the conical nozzle108, as indicated by the arrow419inFIG. 4A. The slot end is not limited to a circular or rounded shape.FIG. 4Bis an expanded view of an oblong slot end404of a conical nozzle410according to embodiments of the present invention.

FIG. 5Ais an expanded interior view, andFIG. 5Bis a partially cut-away expanded interior view of the conical nozzle108according to embodiments of the present invention. The conical nozzle108includes a plurality of ribs501arranged on interior surfaces of the flexible petals202. A combination of the slots206, petal202tension, and exit port204create the hold back force for the sheet perforations to tear appropriately. The plurality of ribs501grasp the sheet150, move the flexible petals202to open the exit port204, and guide the sheet150through the exit port204(seeFIG. 1B). The ribs501flex the petals202to change the exit port204opening, depending on the substrate sheet thickness and thereby controlling the pull force required. The exit port204and slots206restrict the paper so the perforations separate just outside of the nozzle108.

In some embodiments, each flexible petal202includes a rib501on the interior surface, as shown inFIG. 5A. Yet, in other embodiments, each flexible petal202includes more than one rib501. Still yet, in other embodiments, a portion of the flexible petals202includes ribs501, such as for example, every other flexible petal.

The plurality of ribs501have any shape, dimension, or position on the interior surface of the flexible petals202. The ends of the plurality of ribs501are flush with the exit port204in some embodiments, as shown inFIGS. 5A and 5B, as well as inFIG. 8B(see ribs802). Yet, in other embodiments (see ribs801inFIG. 8Aand ribs803inFIG. 8C), the ends of the plurality of ribs501are not flush with (non-flush with) the exit port204and are positioned away from the periphery of the exit port204. As also shown inFIG. 8C, the ribs803protrude into the exit port204in some embodiments. The ends of the ribs501are tapered, as shown inFIGS. 5A and 5Bin some embodiments. Yet, in other embodiments, the ends of the ribs501are not tapered.

FIG. 6is a partially cut-away expanded side view of the conical nozzle108according to embodiments of the present invention. The slopes of the sides606of the conical nozzle108that extend away from the exit port204are variable. At rest, the angles608of the sides606with respect to a horizontal axis of607of the lid is an acute angle or less than 90 degrees. As the sheet moves through the exit port204and the flexible petals202of the conical nozzle108flex and open, which increases the angles608to allow the sheet to move through and tear.

The exit port of the conical nozzle has any shape or dimension. The exit port204has a round or non-round shape.FIG. 7Ais an expanded view of the exit port702of a conical nozzle706having a round shape according to embodiments of the present invention. The diameter d of the exit port702varies and depends on the type of sheet material. For thicker substrate materials, the diameter d is larger.FIGS. 7B and 7Care expanded views of exit ports704,706of conical nozzles708,710, respectively, having non-round shapes according to embodiments of the present invention.

Examples

Various sheet substrates were tested to determine the range of pull forces needed to tear a single sheet from a roll within a conical nozzle dispenser according to embodiments of the present invention.

Using a force gauge, the pull force measurements were recorded in the beginning (0.5 inch from the core), middle (0.5 to 1.5 inch from the core), and end of the roll (1.5 inch from the outer edge of the roll). A piece of string was tied with a loop to the end of the sheet to be removed from the nozzle. A force gauge was hooked on the loop of the string, zeroed, and the string with the sheet was pulled straight up. The peak forces (pounds (lbs)) to pull and tear the sheets from the nozzle were recorded. The average peak force reported is for each beginning, middle, and end.

As shown in Table 1, the D400 substrates had the lowest pull force at just over 2 lbs of force. The H800 substrate had the highest pull force at 14.4 lbs of force. The average pull force of all four substrates tested was about 4 pounds to about 10 pounds.