Sheet product dispenser

Some example product dispensers that accommodate two full paper towel rolls are provided herein. The product dispenser may employ separate dispensing mechanisms for each product roll and may include roll holders that articulate out from the housing to facilitate easy loading and access to replacement and loading of the other product roll. A roll partition may be utilized to separate the web paths of the two product rolls and enable rotation of front roll holders. Example funnel covers and nip covers can aid with intuitive installation. Example roll holders with retention mechanisms help prevent unintentional dropping of the installed product roll. Other beneficial features include utilizing motor operation sensing to dispense a desired sheet length, automatic/assisted loading into the dispensing mechanism, automatic switching between dispensing of product rolls, and always dispensing from the smaller product roll first. Many other features/structures of example product dispensers are also described herein.

FIELD OF THE INVENTION

Example embodiments of the present invention generally relate to dispensers and, more particularly to, sheet product dispensers.

BACKGROUND

Hand towel dispensers (e.g., sheet product dispensers or product dispensers) are useful in many environments for providing on demand paper towels for users. Due to their compact nature, it is difficult to provide a large, long standing supply of paper towels. Thus, janitors or other maintenance personnel (e.g., maintainers) are often required to replace empty paper towels. The variable nature of use, however, makes it difficult for a maintainer to predict when a replacement will be needed. Moreover, schedule demands of a maintainer and the desire to avoid wasting paper left on a roll leads to the situation where the maintainer may be unsure whether or not to replace a towel roll. In this regard, the situation of having no paper towels in the dispenser (a completely empty scenario) may arise.

BRIEF SUMMARY

Some example embodiments of the present invention include a dispenser that can accommodate two full paper towel rolls. This gives the greatest opportunity to avoid a completely empty scenario and also allows a maintainer to wait to replace a roll until it is completely used (since a full second roll is available), which helps reduce waste by avoiding a maintainer discarding a partially used sheet product roll.

Further, some example embodiments of the present invention provide two separate dispensing mechanisms, one for each roll. This avoids the need for a transfer mechanism, enables easy switching between dispensing from each roll, and can simplify management of the webbing from each paper towel roll within the dispenser.

Additionally, however, another goal of some example dispensers described herein is to provide for quick and easy/intuitive loading. In this regard, some example embodiments of the present invention provide a configuration that makes each dispensing mechanism and roll holder easily accessible for loading (as either product roll may need to be replaced and loaded into the corresponding dispensing mechanism). For example, various described embodiments herein enable the bottom roll holders to move away from their storage position within the dispenser. This movement enables a maintainer to manipulate the web path leading from the top product roll to the corresponding dispensing mechanism and/or the web path leading from the bottom product roll to the corresponding dispensing mechanism—offering flexibility in loading. Further, some example embodiments separate the movable bottom roll holders from the cover, enabling more flexibility in positioning of the bottom roll holders with the cover open. Many concepts utilizing this general configuration are described herein.

A further goal of some embodiments of the present invention includes providing a dispenser that avoids jamming or other complications through effective web management. In this regard, some embodiments of the present invention seek to separate the two web paths from the two product rolls to avoid undesired interaction that may lead to a jamming scenario. To accomplish this, some example embodiments of the present invention provide web guide structures that separate the web paths and product rolls. In some embodiments, the web guide structures move out of the dispenser housing when the cover opens to facilitate easy loading of new product rolls. Many concepts utilizing web guide structures are described herein.

In some embodiments, a roll partition is provided to achieve many of the above noted desired benefits. In this regard, the roll partition may separate the web paths for each product roll and aid in intuitive loading of each product roll. In some embodiments, the roll partition may articulate out of the dispenser housing separately from the cover to enable a user full access to a second product roll for replacement and loading into a back/rear dispensing mechanism. Various features such as funnel covers and nip covers can be utilized to further aid with intuitive installation. Roll holders with retention mechanisms can be utilized to prevent unintentional dropping of the installed product roll, such as when the roll partition is rotated forward.

Some embodiments of the present invention provide software related features that enable efficient operation of the product dispenser. For example, some embodiments of the present invention employ motor operation sensing to aid in dispensing a product according to a desired sheet length. Some embodiments of the present invention provide for automatic or assisted loading of the leading edge of the product roll into the dispensing mechanism. Other beneficial features include automatic switching between product rolls for dispensing when one of the product rolls is depleted, always dispensing from the smaller (e.g., more depleted) product roll first, and many others described herein.

An example embodiment of the present invention provides a sheet product dispenser comprising a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The housing is sized such that a full size first product roll and a full size second product roll fit within the housing when the cover is in the closed position. The sheet product dispenser further includes a first dispensing mechanism configured to receive sheet product of the first product roll and dispense a portion of the sheet product of the first product roll. The sheet product dispenser further includes a second dispensing mechanism configured to receive sheet product of the second product roll and dispense a portion of the sheet product of the second product roll. The second roll holder is movable between a first position and a second position spaced from the first position. The second roll holder is configured to move separately from the cover.

In some embodiments, movement of the second roll holder to the second position may enable a user to at least one of load the first product roll into the first roll holder, load the sheet product of the first product roll into the first dispensing mechanism, load the second product roll into the second roll holder, or load the sheet product of the second product roll into the second dispensing mechanism.

In some embodiments, movement of the second roll holder to the second position may enable a user to at least one of load the first product roll into the first roll holder or load the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, movement of the second roll holder to the second position may prevent a user from being able to load the sheet product of the second product roll into the second dispensing mechanism.

In some embodiments, the sheet product dispenser may further include a roll partition pivotally attached to the base portion and movable between a first roll partition position within the base portion and a second roll partition position spaced from the first roll partition position. The second roll holder is connected to the roll partition and movable with the roll partition. The roll partition is movable independent of the cover. When the roll partition is in the second roll partition position, a user is able to at least one of load the first product roll into the first roll holder or load the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, the sheet product dispenser may further include a nip cover movable between a first nip cover position and a second nip cover position. The nip cover may be configured to move between the first nip cover position and the second nip cover position with movement of the roll partition from the first roll partition position to the second roll partition position. The nip cover may be configured to prevent access to the first dispensing mechanism by the user when in the first nip cover position. The nip cover may be configured to prevent access to the second dispensing mechanism by the user when in the second nip cover position.

In some embodiments, the second roll holder may comprise a retention mechanism configured to prevent removal of an installed second product roll when the roll partition rotates to the second roll partition position.

In some embodiments, the roll partition may separate a first web path from a second web path. The first web path leads from the first product roll to the first dispensing mechanism, and the second web path leads from the second product roll to the second dispensing mechanism.

In some embodiments, the roll partition may comprise side wall portions that are configured to fit between the base portion and the cover when the cover is in the closed position. The side wall portions may each form a portion of an exterior of the sheet product dispenser.

In some embodiments, the sheet product dispenser may further comprise at least one dampener configured to dampen rotation of the roll partition between the first roll partition position and the second roll partition position.

In some embodiments, the roll partition may be configured to removably attach to the base portion of the housing when in the first roll partition position. In some embodiments, the roll partition and the base portion of the housing may be configured such that attachment of the roll partition to the base portion of the housing or detachment of the roll partition from the base portion of the housing creates an audible noise to indicate occurrence of attachment or detachment. In some embodiments, the second roll holder may comprise an attachment linkage. The base portion of the housing may comprise an attachment feature that receives the attachment linkage of the second roll holder when the roll partition is in the first roll partition position.

In some embodiments, the second roll holder is configured to move to the second position with movement of the cover to the open position.

In some embodiments, movement of the second roll holder to the second position may be independently actuable from movement of the cover to the open position.

In some embodiments, the housing may define a first web path leading from the first product roll to the first dispensing mechanism and a second web path leading from the second product roll to the second dispensing mechanism. The dispenser may further comprise at least one web guide structure configured to separate at least one of the first web path or the first product roll from at least one of the second product roll or the second web path. The at least one web guide structure may be attached to the cover such that the web guide structure is removed from the base portion when the cover is in the open position to enable a user to load the sheet product of the first product roll into the first dispensing mechanism without having to route the sheet product of the first product roll around any structure.

In some embodiments, the sheet product dispenser may further comprise at least one motor configured to actuate at least one of the first dispensing mechanism or the second dispensing mechanism.

In some embodiments, the sheet product dispenser may further comprise a first sensor positioned proximate the first dispensing mechanism and configured to sense the presence of a portion of the first product roll. The sheet product dispenser may further comprises a second sensor positioned proximate the second dispensing mechanism and configured to sense the presence of a portion of the second product roll. The sheet product dispenser may further comprise a controller. The controller may be configured to cause actuation of the first dispensing mechanism in an instance in which the first sensor senses the presence of the portion of the first product roll to load the first dispensing mechanism with the portion of the first product roll. The controller may be further configured to cause actuation of the second dispensing mechanism in an instance in which the second sensor senses the presence of the portion of the second product roll to load the second dispensing mechanism with the portion of the second product roll.

In some embodiments, the sheet product dispenser may further comprise a first chute sensor positioned within a first chute associated with the first dispensing mechanism. The first chute sensor may be configured to sense the presence of the portion of the first product roll. The sheet product dispenser may further comprise a second chute sensor positioned within a second chute associated with the second dispensing mechanism. The second chute sensor may be configured to sense the presence of the portion of the second product roll. The controller may be configured to cause the first dispensing mechanism to cease operation in an instance in which the first chute sensor senses the presence of the portion of the first product roll within the first chute. The controller may be further configured to cause the second dispensing mechanism to cease operation in an instance in which the second chute sensor senses the presence of the portion of the second product roll within the second chute.

In some embodiments, the cover may be pivotally mounted to the base portion around a first axis. The second roll holder may be pivotally mounted to the base portion around a second axis. The first axis may be different than the second axis.

In some embodiments, the first roll holder and the first dispensing mechanism may be color coded a first color and the second roll holder and the second dispensing mechanism may be color coded a second color to enable intuitive loading by a user.

In some embodiments, the sheet product dispenser may further comprise a controller that is configured to operate the first dispensing mechanism to dispense the portion of the first product roll. The controller may be further configured to automatically switch from operating the first dispensing mechanism to dispense from the first product roll to operating the second dispensing mechanism to dispense from the second product roll in an instance in which the first product roll becomes unavailable or empty.

In some embodiments, the controller may be further configured to determine which of the first product roll or second product roll has less product remaining and operate the first dispensing mechanism in an instance in which the first product roll has less product remaining than the second product roll or operate the second dispensing mechanism in an instance in which the second product roll has less product remaining than the first product roll.

In some embodiments, the sheet product dispenser may further comprise a first product level sensor configured to sense an amount of product remaining on the first product roll and a second product level sensor configured to sense an amount of product remaining on the second product roll.

In some embodiments, at least one of the first product level sensor or the second product level sensor may be an infrared product level sensor.

In some embodiments, the sheet product dispenser may further comprise a chassis that includes the first dispensing mechanism and the second dispensing mechanism. The chassis may be configured to removably attach to the base portion of the housing. The cover may be configured such that the chassis may be removed from attachment with the base portion while the cover is in the closed position.

In some embodiments, the first dispensing mechanism may include a first drivetrain comprising a first gear and a second gear. The first gear and the second gear may form a first gear ratio. The second dispensing mechanism may include a second drivetrain comprising a third gear and a fourth gear. The third gear and the fourth gear may form a second gear ratio. Each of the first gear ratio and the second gear ratio may be optimized based on one or more factors including feed roller diameter, resistance to motion, and motor performance.

In some embodiments, the second roll holder may be pivotally attached to the base portion.

In another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The housing is sized such that a full size first product roll and a full size second product roll fit within the housing when the cover is in the closed position. The sheet product dispenser further includes a first dispensing mechanism configured to receive sheet product of the first product roll and dispense a portion of the sheet product of the first product roll. The sheet product dispenser further includes a second dispensing mechanism configured to receive sheet product of the second product roll and dispense a portion of the sheet product of the second product roll. The second roll holder is movable between a first position and a second position spaced from the first position. The second roll holder is configured to enable a user to load the sheet product of the second product roll into the second dispensing mechanism when in the first position. The second roll holder is configured to enable the user to load the sheet product of the first product roll into the first dispensing mechanism when in the second position.

In some embodiments, the second roll holder may be configured to prevent the user from loading the sheet product of the first product roll into the first dispensing mechanism when in the first position. The second roll holder may be configured to prevent the user from loading the sheet product of the second product roll into the second dispensing mechanism when in the second position.

In some embodiments, the second roll holder may be configured to prevent the user from loading the sheet product of the first product roll into the second dispensing mechanism or the sheet product of the second product roll into the first dispensing mechanism when in either the first position or the second position.

In some embodiments, the sheet product dispenser may further comprise a roll partition pivotally attached to the base portion and movable between a first roll partition position within the base portion and a second roll partition position spaced from the first roll partition position. The second roll holder is connected to the roll partition and movable with the roll partition. The roll partition is movable independent of the cover.

In some embodiments, the sheet product dispenser may further comprise a nip cover movable between a first nip cover position and a second nip cover position. The nip cover may be configured to move between the first nip cover position and the second nip cover position with movement of the roll partition from the first roll partition position to the second roll partition position. The nip cover may be configured to prevent access to the first dispensing mechanism by the user when in the first nip cover position. The nip cover may be configured to prevent access to the second dispensing mechanism by the user when in the second nip cover position.

In yet another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The base portion defines a top and a bottom. The housing is sized such that a full size first product roll and a full size second product roll fit within the housing when the cover is in the closed position. The sheet product further includes a partition movable relative to the base portion between a stowed position and an unstowed position. The second roll holder is attached to the partition. The partition is positioned proximate the base portion when in the stowed position. The sheet product dispenser further includes a first dispensing mechanism. The first dispensing mechanism comprises a first nip roller and a first drive roller. The first dispensing mechanism is configured to receive sheet product of the first product roll between the first nip roller and the first drive roller. The sheet product dispenser further includes a second dispensing mechanism. The second dispensing mechanism comprises a second nip roller and a second drive roller. The second dispensing mechanism is configured to receive sheet product of the second product roll between the second nip roller and the second drive roller. The sheet product dispenser further includes at least one motor configured to perform at least one of the following: rotate the first drive roller to cause a portion of the sheet product of the first product roll to dispense from the sheet product dispenser, rotate the second drive roller to cause a portion of the sheet product of the second product roll to dispense from the sheet product dispenser, or selectively rotate the first drive roller or the second drive roller to cause the portion of the sheet product of the first product roll or the portion of the sheet product of the second product roll to dispense from the sheet product dispenser. The sheet product dispenser further includes a controller configured to operate the at least one motor to cause the portion of the sheet product of the first product roll or the portion of the sheet product of the second product roll to dispense. When the first product roll is supported by the first roll holder and sheet product of the first product roll is received in the first dispensing mechanism, a first web path is formed from the first product roll to the first dispensing mechanism. When the second product roll is supported by the second roll holder and sheet product of the second product roll is received in the second dispensing mechanism, a second web path is formed from the second product roll to the second dispensing mechanism. The partition is configured to separate the first web path from the second web path when the partition is in the stowed position.

In some embodiments, the partition may be configured to be moved to the unstowed position to enable a user to load the first product roll into the first roll holder and the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, when the partition is in the stowed position, a user is able to load the second product roll into the second roll holder and the sheet product of the second product roll into the second dispensing mechanism. When the partition is in the unstowed position, the user is able to load the first product roll into the first roll holder and the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, when the partition is in the stowed position, the user is unable to load the first product roll into the first roll holder or the sheet product of the first product roll into the first dispensing mechanism. When the partition is in the unstowed position, the user is unable to load the second product roll into the second roll holder or the sheet product of the second product roll into the second dispensing mechanism.

In some embodiments, the sheet product dispenser further comprises a nip cover movable between a first nip cover position and a second nip cover position. The nip cover may be configured to move between the first nip cover position and the second nip cover position with movement of the partition between the stowed position and the unstowed position. The nip cover may be configured to prevent access to the first dispensing mechanism by a user when in the first nip cover position. The nip cover may be configured to prevent access to the second dispensing mechanism by the user when in the second nip cover position.

In some embodiments, the second roll holder may comprise a retention mechanism that is configured to prevent removal of an installed second product roll when the partition rotates to the unstowed position.

In some embodiments, the retention mechanism may comprise an engagement portion of the second roll holder that is configured to rotate to maintain a generally upward orientation as the partition rotates to the unstowed position such that the installed second product roll is maintained within the second roll holder.

In some embodiments, the base portion may define a receptacle feature. The retention mechanism may further comprise a linkage that includes a first pin and a second pin. The first pin is connected to the engagement portion. The receptacle feature is configured to receive the second pin when the partition is in the stowed position. As the partition rotates toward the unstowed position, connection of the second pin of the linkage within the receptacle feature may cause the engagement portion to rotate with respect to the partition so that the engagement feature maintains the generally upward orientation.

In some embodiments, the sheet product dispenser may further include a first chute positioned proximate the bottom of the base portion and a second chute positioned proximate the bottom of the base portion and proximate the first chute.

In some embodiments, the first dispensing mechanism may be positioned proximate the bottom of the base portion and adjacent to the second dispensing mechanism and closer to a rear wall of the base portion than the second dispensing mechanism. The first chute may define a first dispense surface that extends downwardly and outwardly from the first dispensing mechanism. The second chute may define a second dispense surface that extends downwardly and outwardly from the second dispensing mechanism. The first dispense surface is longer than the second dispense surface such that, when the portion of the first product roll is dispensed, the portion of the first product roll is positioned proximate to where the portion of the second product roll is positioned when the portion of the second product roll is dispensed.

In some embodiments, the partition may comprise an attachment feature that is configured to removably attach to the base portion of the housing when the partition is in the stowed position.

In some embodiments, the partition and the base portion of the housing may be configured such that attachment of the attachment feature to the base portion of the housing or detachment of the attachment feature from the base portion of the housing creates an audible noise to indicate occurrence of attachment or detachment.

In some embodiments, the sheet product dispenser may further include at least one nip sensor positioned proximate at least one of a first nip of the first dispensing mechanism or a second nip of the second dispensing mechanism. The at least one nip sensor may be configured to sense the presence of the sheet product of the first product roll proximate the first nip or sense the presence of the sheet product of the second product roll proximate the second nip. The controller may be configured to cause actuation of the at least one motor to cause rotation of the first drive roller in an instance in which the nip sensor senses the presence of the sheet product of the first product roll to assist a user with loading the first dispensing mechanism with the sheet product of the first product roll. The controller may be further configured to cause actuation of the at least one motor to cause rotation of the second drive roller in an instance in which the nip sensor senses the presence of the sheet product of the second product roll to assist the user with loading the second dispensing mechanism with the sheet product of the second product roll.

In some embodiments, the sheet product dispenser may further include at least one chute sensor positioned within at least one of a first chute or a second chute. The at least one chute sensor is configured to sense the presence of the sheet product of the first product roll within the first chute or sense the presence of the sheet product of the second product roll within the second chute. The controller may be configured to cause the at least one motor to cease operation in an instance in which the chute sensor senses the presence of the sheet product of the first product roll within the first chute or senses the presence of the sheet product of the second product roll within the second chute.

In some embodiments, the controller may be configured to automatically switch from operating the at least one motor to cause dispense from the first product roll to operating the at least one motor to cause dispense from the second product roll in an instance in which the first product roll becomes unavailable or empty.

In some embodiments, the controller may be configured to determine which of the first product roll or second product roll has less product remaining and operate, in an instance in which the first product roll has less product remaining than the second product roll, the at least one motor to cause dispense from the first product roll or operate, in an instance in which the second product roll has less product remaining than the first product roll, the at least one motor to cause dispense from the second product roll.

In some embodiments, the sheet product dispenser may further include a first product level sensor configured to sense an amount of product remaining on the first product roll and a second product level sensor configured to sense an amount of product remaining on the second product roll. In some embodiments, at least one of the first product level sensor or the second product level sensor is an infrared product level sensor.

In some embodiments, the at least one motor may comprises a first motor and a second motor. The first motor may be configured to rotate the first drive roller to cause the portion of the sheet product of the first product roll to dispense from the sheet product dispenser. The second motor may be configured to rotate the second drive roller to cause the portion of the sheet product of the second product roll to dispense from the sheet product dispenser.

In some embodiments, the partition and the second roll holder may be configured to be movable separately from the cover.

In yet another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The sheet product dispenser further includes a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser includes a partition movable relative to the base portion between a stowed position and an unstowed position. The second roll holder is attached to the partition. The sheet product dispenser includes a first dispensing mechanism that is configured to receive sheet product of the first product roll. The first dispensing mechanism is configured to operate to cause a portion of the sheet product of the first product roll to dispense from the sheet product dispenser. The sheet product dispenser further includes a second dispensing mechanism that is configured to receive sheet product of the second product roll. The second dispensing mechanism is configured to operate to cause a portion of the sheet product of the second product roll to dispense from the sheet product dispenser. The sheet product dispenser further includes an actuation sensor configured to sense presence of a user. The sheet product dispenser includes a controller configured to, in response to the actuation sensor sensing the presence of the user, operate either the first dispensing mechanism to cause the portion of the sheet product of the first product roll to dispense or the second dispensing mechanism to cause the portion of the sheet product of the second product roll to dispense. When the first product roll is supported by the first roll holder and the sheet product of the first product roll is received in the first dispensing mechanism, a first web path is formed from the first product roll to the first dispensing mechanism. When the second product roll is supported by the second roll holder and the sheet product of the second product roll is received in the second dispensing mechanism, a second web path is formed from the second product roll to the second dispensing mechanism. The partition is configured to separate at least a portion of the first web path from at least a portion of the second web path when the partition is in the stowed position.

In some embodiments, the partition may be configured to be moved to the unstowed position to enable the user to load the first product roll into the first roll holder and the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, the sheet product dispenser may further include a nip cover movable between a first nip cover position and a second nip cover position. The nip cover may be configured to move between the first nip cover position and the second nip cover position with movement of the partition between the stowed position and the unstowed position. The nip cover may be configured to prevent access to the first dispensing mechanism by the user when in the first nip cover position. The nip cover may be configured to prevent access to the second dispensing mechanism by the user when in the second nip cover position.

In some embodiments, the second roll holder may comprise a retention mechanism that is configured to prevent removal of an installed second product roll when the partition rotates to the unstowed position.

In some embodiments, the controller may be configured to automatically switch from operating the first dispensing mechanism to dispense from the first product roll to operating the second dispensing mechanism to dispense from the second product roll in an instance in which the first product roll becomes unavailable or empty.

In yet another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The sheet product dispenser includes a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a partition movable relative to the base portion between a stowed position and an unstowed position. The second roll holder is attached to the partition. The sheet product dispenser further includes a first dispensing mechanism that is configured to receive sheet product of the first product roll. The first dispensing mechanism is configured to operate to cause a portion of the sheet product of the first product roll to dispense from the sheet product dispenser. The sheet product dispenser further includes a second dispensing mechanism that is configured to receive sheet product of the second product roll. The second dispensing mechanism is configured to operate to cause a portion of the sheet product of the second product roll to dispense from the sheet product dispenser. The sheet product dispenser further includes an actuation sensor configured to sense presence of a user. The sheet product dispenser further includes a controller configured to, in response to the actuation sensor sensing the presence of the user, operate either the first dispensing mechanism to cause the portion of the sheet product of the first product roll to dispense or the second dispensing mechanism to cause the portion of the sheet product of the second product roll to dispense. When the partition is in the stowed position, the user is able to load the second product roll into the second roll holder and the sheet product from the second product roll into the second dispensing mechanism. When the partition is in the unstowed position, the user is able to load the first product roll into the first roll holder and the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, the partition may be configured to be moved to the unstowed position to enable the user to load the first product roll into the first roll holder and the sheet product of the first product roll into the first dispensing mechanism.

In some embodiments, the sheet product dispenser may further include a nip cover movable between a first nip cover position and a second nip cover position. The nip cover may be configured to move between the first nip cover position and the second nip cover position with movement of the partition between the stowed position and the unstowed position. The nip cover may be configured to prevent access to the first dispensing mechanism by the user when in the first nip cover position. The nip cover may be configured to prevent access to the second dispensing mechanism by the user when in the second nip cover position.

In some embodiments, the second roll holder may comprise a retention mechanism that is configured to prevent removal of an installed second product roll when the partition rotates to the unstowed position.

In some embodiments, the controller may be configured to automatically switch from operating the first dispensing mechanism to dispense from the first product roll to operating the second dispensing mechanism to dispense from the second product roll in an instance in which the first product roll becomes unavailable or empty.

In yet another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The sheet product dispenser includes a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a first dispensing mechanism configured to receive sheet product of the first product roll and dispense a portion of the sheet product of the first product roll. The sheet product dispenser further includes a second dispensing mechanism configured to receive sheet product of the second product roll and dispense a portion of the sheet product of the second product roll. The sheet product dispenser further includes a controller that is configured to determine which of the first product roll or second product roll has less product remaining and operate, in an instance in which the first product roll has less product remaining than the second product roll, the first dispensing mechanism to dispense the portion of the sheet product of the first product roll or operate, in an instance in which the second product roll has less product remaining than the first product roll, the second dispensing mechanism to dispense the portion of the sheet product of the second product roll.

In some embodiments, the controller may be configured to automatically switch from operating the first dispensing mechanism to dispense from the first product roll to operating the second dispensing mechanism to dispense from the second product roll in an instance in which the first product roll becomes unavailable or empty.

In some embodiments, the sheet product dispenser may further include a first product level sensor configured to sense an amount of product remaining on the first product roll. In some embodiments, the first product level sensor may be an infrared product level sensor. In some embodiments, the first product level sensor may be a mechanical-based product level sensor that is configured to contact an outer circumference of the corresponding first product roll.

In some embodiments, the sheet product dispenser may further include a first product roll rotational sensor configured to sense rotation of the first product roll and a second product roll rotational sensor configured to sense rotation of the second product roll. The controller may be configured to determine which of the first product roll or the second product roll has less sheet product remaining based on a comparison of rotational data received from the first product roll rotational sensor and the second product roll rotational sensor.

In some embodiments, the sheet product dispenser may further include a first drive roller rotational sensor configured to sense rotation of a first drive roller of the first dispensing mechanism. Rotation of the first drive roller may cause dispensing of sheet product from the first product roll. The sheet product dispenser may further include a second drive roller rotational sensor configured to sense rotation of a second drive roller of the second dispensing mechanism. Rotation of the second drive roller may cause dispensing of sheet product from the second product roll. The controller may be configured to determine which of the first product roll or the second product roll has less sheet product remaining based on a comparison of rotational data received from the first product roll rotational sensor, the first drive roller rotational sensor, the second product roll rotational sensor, and the second drive roller rotational sensor.

In some embodiments, the controller may be configured to determine which of the first product roll or the second product roll has less sheet product remaining based on a comparison of a first rotational ratio with a second rotational ratio. The first rotational ratio may comprise a time period for a rotation cycle of the first product roll over a time period for a rotation cycle of the first drive roller. The second rotational ratio may comprise a time period for a rotation cycle of the second product roll over a time period for a rotation cycle of the second drive roller.

In some embodiments, the controller may be configured to determine an amount of product remaining on the first product roll based on a comparison of rotational data received from the first product roll rotational sensor and the first drive roller rotational sensor. The controller may be further configured to determine an amount of product remaining on the second product roll based on a comparison of rotational data received from the second product roll rotational sensor and the second drive roller rotational sensor.

In some embodiments, the controller may be configured to determine, in an instance in which the first product roll and the second product roll have substantially the same amount of product remaining, which of the first product roll or the second product roll has been installed for a longer period of time. The controller may be further configured to operate the first dispensing mechanism in an instance in which the first product roll has been installed for a longer period of time than the second product roll or operate the second dispensing mechanism in an instance in which the second product roll has been installed for a longer period of time than the first product roll.

In some embodiments, the sheet product dispenser may further include a chute configured to direct the portion of the first product roll being dispensed. The sheet product dispenser may further include a first sensor positioned within the chute and configured to sense the presence of the sheet product of the first product roll within the chute. The controller may be configured to cause operation of the first dispensing mechanism to cease and operation of the second dispensing mechanism to begin in an instance in which the chute sensor does not sense the presence of the sheet product of the first product roll within the chute and the controller determines that that the first dispensing mechanism is operating. In some embodiments, the first sensor is an infrared sensor. In some embodiments, the first sensor is reflective.

In some embodiments, the sheet product dispenser may further include a first sensor positioned proximate a nip of the first dispensing mechanism and configured to sense the presence of the sheet product of the first product roll. In some embodiments, the sheet product dispenser may further include a light pipe positioned on a first side of the nip of the first dispensing mechanism. The first sensor may comprise an emitter and at least one receiver. The emitter may be positioned on a second side of the nip of the first dispensing mechanism and aimed to emit light across the nip toward the light pipe at a first position. The light pipe may be configured to receive the emitted light and redirect the light across the nip at a second position. The receiver may be positioned on the second side of the nip of the first dispensing mechanism and configured to receive the redirected light from the light pipe. The first position is spaced apart from the second position. The first sensor may sense the presence of sheet product in an instance in which the receiver does not receive the redirected light.

In some embodiments, the light pipe may be further configured to split the light received from the emitter. The light pipe may be further configured to redirect a first portion of the light across the nip at the second position and redirect a second portion of the light across the nip at a third position. The third position is spaced apart from the second position and the at least one receiver is a first receiver. The first sensor may comprise a second receiver that is positioned on the second side of the nip of the first dispensing mechanism and configured to receive the second portion of the redirected light from the light pipe. The first sensor may sense the presence of sheet product in an instance in which at least one of the first receiver or the second receiver do not receive the redirected light.

In yet another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The sheet product dispenser further includes a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a first dispensing mechanism configured to receive sheet product of the first product roll and dispense a portion of the sheet product of the first product roll. The sheet product dispenser further includes a second dispensing mechanism configured to receive sheet product of the second product roll and dispense a portion of the sheet product of the second product roll. The sheet product dispenser further includes a first product roll rotational sensor configured to sense rotation of the first product roll and a second product roll rotational sensor configured to sense rotation of the second product roll. The sheet product dispenser further includes a controller that is configured to determine which of the first product roll or second product roll has less product remaining based on a comparison of rotational data received from the first product roll rotational sensor and the second product roll rotational sensor and operate, in an instance in which the first product roll has less product remaining than the second product roll, the first dispensing mechanism to dispense the portion of sheet product of the first product roll or operate, in an instance in which the second product roll has less product remaining than the first product roll, the second dispensing mechanism to dispense the portion of the sheet product of the second product roll.

In some embodiments, the sheet product dispenser may further include a first drive roller rotational sensor configured to sense rotation of a first drive roller of the first dispensing mechanism. Rotation of the first drive roller may cause dispensing of sheet product from the first product roll. The sheet product dispenser may further include a second drive roller rotational sensor configured to sense rotation of a second drive roller of the second dispensing mechanism. Rotation of the second drive roller may cause dispensing of sheet product from the second product roll. The controller may be configured to determine which of the first product roll or the second product roll has less sheet product remaining based on a comparison of rotational data received from the first product roll rotational sensor, the first drive roller rotational sensor, the second product roll rotational sensor, and the second drive roller rotational sensor.

In some embodiments, the controller is configured to determine which of the first product roll or the second product roll has less sheet product remaining based on a comparison of a first rotational ratio with a second rotational ratio. The first rotational ratio may comprise a time period for a rotation cycle of the first product roll over a time period for a rotation cycle of the first drive roller. The second rotational ratio may comprise a time period for a rotation cycle of the second product roll over a time period for a rotation cycle of the second drive roller.

In some embodiments, the controller may be configured to determine an amount of product remaining on the first product roll based on a comparison of rotational data received from the first product roll rotational sensor and the first drive roller rotational sensor.

In yet another example embodiment, a sheet product dispenser is provided. The sheet product dispenser comprises a housing including a base portion and a cover. The cover is movable relative to the base portion to define an open position and a closed position. The sheet product dispenser further includes a first roll holder configured to support a first product roll and a second roll holder configured to support a second product roll. The sheet product dispenser further includes a first dispensing mechanism configured to receive sheet product of the first product roll and dispense a portion of the sheet product of the first product roll. The sheet product dispenser further includes a second dispensing mechanism configured to receive sheet product of the second product roll and dispense a portion of the sheet product of the second product roll. The sheet product dispenser further includes a chute configured to direct the portion of the first product roll being dispensed. The sheet product dispenser further includes a chute sensor positioned within the chute and configured to sense the presence of the sheet product of the first product roll within the chute. The sheet product dispenser further includes a controller that is configured to operate the first dispensing mechanism and automatically switch from operating the first dispensing mechanism to dispense from the first product roll to operating the second dispensing mechanism to dispense from the second product roll in an instance in which the chute sensor does not sense the presence of the sheet product of the first product roll within the chute and the controller determines that that the first dispensing mechanism is operating.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout.

As used herein, a “user” of example product dispensers may be a maintainer (e.g., a maintenance person, a janitor, a facility manager, etc.) or a consumer (e.g., a person receiving a dispensed portion of the product).

Overview

Some embodiments of the present invention described herein are designed to maximize efficiency of maintenance, usage, and operation for product dispensers. In this regard, some of the embodiments are designed to provide for easy and intuitive loading of sheet product (e.g., paper towel) to aid a maintainer during loading. Additionally, some embodiments of the present invention seek to avoid a completely empty scenario and maximize usage of the sheet product, such as by avoiding the scenario where the maintainer throws away unused sheet product. Further, some embodiments of the present invention seek to provide easy-to-use operation of the sheet product dispenser that seamlessly switches to dispensing from a second, full paper towel roll upon depletion of the first paper towel roll. Additional benefits sought by various embodiments of the present invention include avoidance of jamming scenarios, providing automatic or assisted loading through the dispensing mechanism, efficient management of web paths of the sheet product within the dispenser, among many other benefits that are evident to one of ordinary skill in the art based on the disclosure herein.

General Structure

FIG. 1illustrates an example sheet product dispenser10according to some embodiments of the present invention, such as in accordance with the sheet product dispenser105and its corresponding components described with respect toFIG. 2. The sheet product dispenser10includes a housing defined by a base portion12and a cover14. The sheet product dispenser10includes at least one dispensing slot11where the sheet product (e.g., paper towel) is provided to the user. Such sheet product may, such as described herein, be dispensed in response to user input being provided to an activation sensor20(e.g., in the circumstance where the sheet product dispenser is automated).

As used herein, the term “sheet product” may include a product that is relatively thin in comparison to its length and width. Further, the sheet product may define a relatively flat, planar configuration. In some embodiments, the sheet product is flexible or bendable to permit, for example, folding, rolling, stacking, or the like. In this regard, sheet product may, in some cases, be formed into stacks or rolls for use with various embodiments described herein. Some example sheet products include towel, bath tissue, facial tissue, napkin, wipe, wrapping paper, aluminum foil, wax paper, plastic wrap, or other sheet-like products. Sheet products may be made from paper, cloth, non-woven, metallic, polymer or other materials, and in some cases may include multiple layers or plies. In some embodiments, the sheet product (such as in roll or stacked form) may be a continuous sheet that is severable or separable into individual sheets using, for example, a tear bar or cutting blade. Additionally or alternatively, the sheet product may include predefined areas of weakness, such as lines of perforations, that define individual sheets and facilitate separation and/or tearing. In some such embodiments, the lines of perforations may extend along the width of the sheet product to define individual sheets that can be torn off by a user.

In some embodiments, the sheet product dispenser10is sized to support two full sheet product (e.g., paper towel) rolls and two separate web paths, each one leading to separate dispensing mechanisms. For example, with reference toFIG. 3, the sheet product dispenser10comprises a first set of roll holders31to hold a first sheet product roll51(e.g., first product roll151ofFIG. 2) near the top of the dispenser10. A first web path52leads from the first sheet product roll51to a first dispensing mechanism21(e.g., first dispensing mechanism121ofFIG. 2). Upon activation and after completing a dispense (using the first dispensing mechanism21), a portion of the first sheet product roll51extends out of a first chute43below the first dispensing mechanism21and is available for a user. The sheet product dispenser10further comprises a second set of roll holders36to hold a second sheet product roll56(e.g., second product roll156ofFIG. 2) near the bottom of the dispenser10. A second web path57leads from the second sheet product roll56to a second dispensing mechanism26(e.g., second dispensing mechanism126ofFIG. 2). Upon activation and after completing a dispense (using the second dispensing mechanism26), a portion of the second sheet product roll56extends out of a second chute48below the second dispensing mechanism26and is available for a user.

In some embodiments, the housing and roll holders are designed to enable the product roll to be installed in either a front loading or a back loading orientation, while still operate effectively in either loading orientation. For example, the product roll may be front loaded when the leading edge of the product roll that extends toward the dispensing mechanism comes in front of the product roll. Likewise, the product roll may be back loaded when the leading edge of the product roll that extends toward the dispensing mechanism comes from behind the product roll. Such embodiments offer versatility in loading for the maintainer.

FIG. 3Ashows a close up view of the first and second dispensing mechanisms21,26. With reference toFIG. 3A, each dispensing mechanism may include components that enable dispensing of the portion of the corresponding sheet product roll. For example, the first dispensing mechanism21includes a first nip61that is formed between a first pinch roller63and first drive roller62and covered by a first funnel cover44. The first drive roller62is driven by a motor (e.g., the first motor122ofFIG. 2). The second dispensing mechanism26includes a second nip66that is formed between a second pinch roller68and second drive roller67and covered by a second funnel cover49. The second drive roller67is driven by a motor (e.g., the second motor127ofFIG. 2). In some embodiments, the dispensing mechanisms may each include more or less components depending on the configuration. Further, in some embodiments, certain components may be shared between two dispensing mechanisms such that each dispensing mechanism has its own set of some components and there is one or more shared additional components. For example, each dispensing mechanism may include a pinch roller, but may share a drive roller. Likewise, depending on the configuration, other components may be shared such as, a pinch roller, a motor, etc. In such embodiments, the shared components (or the components of each dispensing mechanism) may be configured to selectively engage each other depending on which dispensing mechanism is operating.

In some embodiments, such as the depicted embodiment, the sheet product dispenser can include color coded components to aid in easy and intuitive loading. For example, the first funnel cover44may be green, which matches the color of corresponding roll holders for the first product roll. Likewise, the second funnel cover49may be blue, which matches the color of corresponding roll holders for the second product roll. In this manner, the maintainer can intuitively follow the color coding to ensure that the product rolls are properly loaded into the proper dispensing mechanisms.

In some embodiments, the product dispenser may be designed to hold two different product rolls, each with different properties (one in the first roll holder and the other in the second roll holder). For example, different quality product rolls could be used for expensive and inexpensive situational dispensing. Likewise, a product roll with special absorbency or other attributes could be set in a roll holder and used for special circumstances. In this regard, some embodiments of the present invention utilize web management to maintain separation of the product rolls, which could be useful for such example embodiments that enable two different types of product rolls. Further, in such embodiments with two distinct dispensing mechanisms, the product dispenser may be configured to enable dispensing from either product roll. This may be achieved by providing an input capability for the consumer and/or maintainer to choose which product roll to dispense from.

In some embodiments, the dispenser is an automatic dispenser. In such an embodiment, the dispenser may include an activation sensor (e.g., activation sensor120ofFIG. 2) that is configured to detect a user command, such as placement of the user's hand in a designated area or pulling on a leading edge of the paper towel roll. Upon sensing the user command, a controller (e.g., controller110ofFIG. 2) in the dispenser may automatically cause the sheet product dispenser to dispense sheet product from either one of the dispensing mechanisms using one or more motors to operate the corresponding drive roller (and, thus, the corresponding dispensing mechanism). The sensor may be a contact sensor, a non-contact sensor, or other suitable sensor. Alternatively, in some embodiments, the sheet product dispenser may be configured as a non-automated dispenser.

In some embodiments, the dispenser may include one or more chutes for guiding the dispensed portion of the product to user. In some embodiments where there are two dispensing mechanisms, the dispenser housing may define two chutes (one for each dispensing mechanism). For example, with reference toFIG. 3B, the dispenser housing may define a first chute43for the first dispensing mechanism21and a second chute48for the second dispensing mechanism26. One of the goals of the present invention may be to provide a product dispenser that enables a user to interact with a single activation sensor, but possibly receive dispensed product from either dispensing mechanism without much difference realized by the user. In this regard, it may be desirable to have the dispensed product provided to the user in a common area no matter which dispensing mechanism is used. In order to accomplish this, some embodiments of the present invention provide a front chute (e.g., the second chute48) and a rear chute (e.g., the first chute43) that each define a geometry that guides the dispensed product to the common area. Notably, in order to achieve this due to the extra space required for the rear dispensing mechanism21, the rear chute43may define a wall43athat extends at a greater length than the wall48aof the front chute48. Further, a different angle43bis used to guide the dispensed product through the rear chute43than the angle48bused to guide the dispensed product through the front chute48. In some embodiments, additional static electricity is built-up due to the extended length of the wall43aof the rear chute43. In some such embodiments, the present invention may employ various static management techniques, such as described in greater detail herein.

In some embodiments, the housing of the sheet product dispenser is designed such that the roll holders may each receive a full-sized (e.g., full-diameter) product roll. In this regard, when the cover is in the closed position, the housing is sized such that both a first roll holder and a second roll holder are configured to each hold a full size sheet product roll in a substantially vertical orientation with respect to each other (including a slightly offset vertical orientation). For example, one product roll may be generally positioned above the other product roll. Additional information and example embodiments of various dispensers configured for use of two full sized paper towel rolls can be found in U.S. application Ser. No. 13/998,753, entitled “System and Method for Reducing Waste Using a Sheet Product Dispenser”, filed Dec. 2, 2013, and U.S. Application No. 61/731,812, filed Nov. 30, 2012, both of which are owned by the Assignee of the present application and hereby incorporated by reference in their entireties.

Another example sheet product dispenser10′ that is configured to hold two full size rolls in a vertical relationship with respect to each other is shown inFIGS. 3C-3E. In the depicted embodiment, a first product roll51′ may be received in a first roll holder31′ and a second product roll56′ may be received in a second roll holder36′ (seeFIG. 3D). Notably, the first dispensing mechanism21′ is positioned proximate the first roll holder31′ near a top portion of the dispenser10′, while the second dispensing mechanism26′ is positioned proximate the second roll holder36′ near a bottom portion of the dispenser10′. In such a manner, the product rolls and their corresponding web paths are separated, with the first dispensing mechanism21′ delivering sheet product to a user near the top of the dispenser10′ and the second dispensing mechanism26′ delivering sheet product to a user near the bottom of the dispenser10′. Further, in some embodiments, one or more tucker fingers97a′,97b′ may be provided on the cover12′. In such an example, the tucker fingers97a′,97b′ may be aligned with the corresponding nips41′,46′ of the first and second dispensing mechanisms21′,26′. With this configuration, a maintainer may only need to lay the leading edge of the sheet material over the nip41′,46′ and the tucker fingers97a′,97b′ may automatically push the sheet product52′,56′ into the corresponding nip41′,46′ as the cover12′ closes—thereby loading the dispensing mechanisms. This avoids the need for the maintainer to feed the leading edge of the sheet product into the dispensing nips.

Although the above described multi-roll dispenser includes two roll holders, some embodiments of the present invention are not meant to be limited to two roll holders, as any number of roll holders may be utilized with the present invention. For example, the housing may be sized to include only one full size roll or one full size roll and one partially depleted roll (e.g., stub roll). Along these lines, various embodiments described herein may be utilized with other various configurations including for example one dispensing mechanism (and, in some cases, a transfer mechanism—such as depending on how many rolls are utilized).

Similarly, housing configurations other than exterior wall mounted may be utilized with various embodiments of the present invention. For example,FIGS. 4A and 4Beach show example recessed mounted housings that may be employed with various embodiments of sheet product dispensers described herein. In some such embodiments, a portion19′,19″ of the housing of the sheet product dispenser10′,10″ may be configured to be positioned in a recess or other receptacle of the wall for mounting purposes. Such a recessed design may provide a “sleek” look.

General Refilling and Roll Holder Articulation Example

An example embodiment of the contemplated dispenser operates as described below.FIG. 5illustrates the example dispenser200in a condition that is ready to be serviced when a maintainer (e.g., janitor, maintenance personnel, user, etc.) may approach it. In particular, there is a partially-used first product roll251which includes a portion (e.g., leading edge) of the first product roll that extends from the first product roll behind the cover roller272and into the first nip funnel261of the first dispensing mechanism221(thereby defining a first web path252). At this point, the first drive roller and first pinch roller of the first dispensing mechanism221may rotate upon command to dispense a portion of first product roll251.FIG. 5also shows a depleted empty product roll259in the second roll holder236that is ready to be replaced with a new product roll.

FIG. 6shows the dispenser200when the maintainer is opening the cover214. As the cover214opens, the cover214pivots about the cover hinge213away from the rear housing212and also draws the cover roller272away from contact with the portion of the first product roll along the first web path252. As the cover214opens, one or more of gravity, a spring (not shown), intentional contact with the cover214(not shown), user interaction, or the like urges the second roll holder236(or an intermediate roll partition as described in some embodiments herein) to pivot about a hinge241. In the illustrated embodiment, the cover214includes a cover contact surface219that contacts a second roll holder contact surface242and limits how far the second roll holder236pivots.

FIG. 7shows the dispenser200once the cover214has been opened further to a point that a right portion of the cover contact surface219is beginning to contact a right portion of the second roll holder contact surface242. The cover contact surface242is designed such that if the cover is opened further than shown inFIG. 7, the cover contact surface242prevents the second roll holders from pivoting further downward, which helps the maintainer avoid bending uncomfortably low to access the second roll holders236. As shown inFIG. 7, a maintainer has sufficient access to remove the depleted second product roll259and replace it with a full second product roll (preferred), or even a second product roll that has already had some paper product removed. If the cover214is opened further than shown inFIG. 7(such as shown inFIG. 8), the left portion of the cover contact surface219no longer is in contact with the left portion of the second roll holder contact surface242. The left and right portions of the cover contact surface219and the second roll holder contact surface242are used for example description, and either contact surface may be a continuous surface without interruption or separation. Likewise, other means or structures can be used to accomplish the same or similar task of controlling the position of the second roll holders as they articulate out of the dispenser housing when the cover is opened.

FIG. 8is a section view of the dispenser200that shows that the cover214has opened further, yet as previously described the cover contact surface219and the second roll holder contact surface242have maintained a position of the second roll holders236that is easy for the maintainer to access.FIG. 8shows that a maintainer has removed the depleted second product roll, replaced it with a full second product roll256, and reached over the full second product roll to load the leading edge of the second product roll into the second dispensing mechanism226. The dispenser200is now ready for the maintainer to close the cover214as shown inFIG. 8.

FIG. 9shows the dispenser200replenished with a full second product roll256and with the cover214closed. In the depicted embodiment, the cover contact surface219is contacting, or at least in close proximity with, the second roll holder contact surface242, which is designed to maintain a clearance between the cover214and the second product roll256in order to prevent interference as the second product roll256rotates during dispensing. InFIG. 9, the leading edge253of the first product roll251is loaded into the first nip funnel (not shown) of the first dispensing mechanism221, and the leading edge258of the second product roll256is loaded into the second nip funnel (not shown) of the second dispensing mechanism226. Therefore, the dispenser200has the option of satisfying a dispense request by dispensing from either the first dispensing mechanism221or the second dispensing mechanism226. As shown inFIG. 9, the first product roll251is smaller and contains less product than the second product roll256, so in an example preferred embodiment the dispenser200would dispense from the first product roll251until it was depleted. The advantage is that, for any total fixed quantity of total product within the dispenser, dispensing from the smaller product roll first will preserve the larger product roll as a reserve and also create the soonest opportunity for the smaller product roll to deplete so that a maintainer may again replenish the dispenser. Giving the maintainer the soonest opportunity to replenish the dispenser will maximize the amount of product the dispenser contains between maintainer visits, which helps ensure the dispenser is stocked enough to meet user demands and helps reduce the frequency with which a maintainer must visit the dispenser to check product level. As described in greater detail herein, some embodiments of the present invention utilize product level sensors (e.g., fuel gauges, product remaining sensors, low product indicator sensors, etc.) and other sensors to help accomplish such a feature.

FIG. 9also shows that when the cover214is closed, the cover roller272moves the webbing252leading from the first product roll251to the first dispensing mechanism221toward the rear housing212(e.g., the cover roller272acts as a web guide structure that guides the first web path252). This helps prevent the first product roll web252from contacting the second product roll256or the second product roll web (e.g., the leading edge258). It is beneficial to avoid contact, for example, if the first product roll web252contacted the second product roll256, the first product roll web252may rotate the second product roll256when the first drive roller of the first dispensing mechanism221is energized to dispense a portion of product from the first product roll251. If the second product roll256rotates without the second drive roller of the second dispensing mechanism226being energized, the second product roll web might accumulate and require increasing space within the dispenser until it encroaches on the first product roll web252and is drawn into the first nip of the first dispensing mechanism221, at which time the second product roll web would be captured by both the first dispensing mechanism221and the second dispensing mechanism226. This condition could prevent either dispensing mechanism from delivering product and may cause a failure (e.g., a jam scenario).

Other web guide structures are also contemplated by some embodiments of the present invention. For example, the illustrated dispenser also includes a cover divider plate273that separates the first product roll251from the second product roll256to further help avoid the product rolls or webs from contacting each other.

As previously mentioned, in an example embodiment, such as by using product level monitoring, the dispenser controller (e.g., controller110ofFIG. 2) may cause dispensing to occur firstly from the smaller product roll (e.g., the first product roll251inFIG. 9) until the smaller product roll is depleted, at which time the dispenser satisfies user commands for product by dispensing from the reserve product roll (e.g., the second product roll256inFIG. 9). This subsequent condition is depicted inFIG. 10. The dispenser200shown inFIG. 10is in a condition in which it is ready to be serviced again, as withFIG. 5. However, unlikeFIG. 5, the first product roll251is depleted, and the second product roll256is a partial product roll with a second product roll web257that is fed into the second nip funnel266and the second nip of the second dispensing mechanism226for dispensing.

FIG. 11shows the dispenser after a maintainer has opened the cover214to service the dispenser200. The second product roll256and second product roll web257have lowered out of the way of the maintainer, so that the maintainer is unobstructed to remove the depleted first product roll from the first roll holder231.

FIG. 12shows the dispenser200after the maintainer has removed the depleted first product roll and replaced it with a full first product roll251′ and loaded the leading edge253′ of the first product roll into the first dispensing mechanism221. Since the second roll holder236moved out from the inner volume of the dispenser200, the maintainer was able to access the first web path252unobstructed by the second web path—thereby enabling loading of the leading edge253′ into the first dispensing mechanism221.

FIG. 13shows the dispenser200replenished with a full first product roll251′ and with the cover214closed. The first product roll web252is loaded into the first nip funnel261of the first dispensing mechanism221and the second product roll web257is loaded into the second nip funnel266of the second dispensing mechanism226. Since the second product roll256is smaller and contains less product than the first product roll251′, for the same principles that were previously described, in a preferred embodiment the dispenser200may initially satisfy user commands for product by dispensing from the second product roll256until it was depleted. After that, the dispenser may resume satisfying user commands for product by dispensing from the first product roll251′ and the dispenser200could be the condition shown inFIG. 5in which the depleted product roll is available for a maintainer to replace.

FIG. 13also shows that when the cover214is closed, the cover roller272moves the first product roll web252toward the rear housing212.FIG. 13further shows the cover divider plate273that separates the first product roll251′ from the second product roll256. As previously described, both of these features may help prevent the product rolls and roll webs from contacting each other and potentially causing the dispenser to fail.

In some embodiments, a beneficial feature of the dispenser is that the roll holders for one of the product rolls moves out of the dispenser when the cover is open. This allows a user to replace and load either product roll into the dispensing mechanism without disturbing or being obstructed by the other product roll, the other product roll web, or any dispenser components. This also enables a maintainer to service the dispenser without confusion or unnecessary effort. Further, the dispenser may be a compact size while still containing up to two full-sized rolls.

Movable Roll Holders

Some embodiments of the present invention provide movable roll holders to enable the benefits of a compact-sized dispenser that contains up to 2 full-size rolls while still enabling the maintainer to have easy access to replace and load either roll without disturbing or being obstructed by the other product roll, the other product roll web, or dispenser parts. The example dispenser illustrated inFIGS. 5-13includes a second roll holder that moves by pivoting about a stationary pivot point connected to the rear housing. There are many additional embodiments of movable roll holders that enable convenient access to either roll, some of which are described herein.

Stationary Mounted Movable Roll Holder Via the Cover

FIG. 14shows a first example embodiment of “roll-in-lid” dispenser. The illustrated dispenser300includes a cover314that is pivotally connected to the rear housing312with a cover hinge313. Further, the second roll holder336is mounted to the inside of the cover314(thus called “roll-in-lid”). The second roll holder336is also pivotally connected to the rear housing312via the cover hinge313.FIG. 14shows that a maintainer may replace and load either product roll and roll web without disturbing the other product roll or roll web.

FIG. 15shows the dispenser300with the cover314closed. With the cover314closed, the cover roller372restricts the first roll web352toward the rear housing312, helping separate the first roll web352from contacting the second roll356or second roll web357. The cover divider plate373further helps separate the first roll web352from the second product roll356and second roll web357.

FIG. 16shows a second example embodiment of the “roll-in-lid” concept in which the dispenser300′ includes a cover314′ that is pivotally connected to the rear housing312′ with a cover hinge313′. However, instead of the second roll holder336′ being mounted to the inside of the cover314′, the first roll holder331′ is mounted to the cover. In the depicted embodiment, the position of the cover roller372′ is converted to be attached to and extending from the rear housing (e.g., base portion)312′. Likewise, the first web path352′ is proximate the front of the dispenser housing and interacts with the first dispensing mechanism321′, which is located near the front of the dispenser300′.FIG. 16shows that a maintainer may replace and load either product roll and roll web without disturbing the other roll or roll web when the cover is open. Such an example embodiment may enable low complexity and still allow for easy loading of either product roll by the maintainer.

FIG. 17shows the second embodiment of the “roll-in-lid” concept in which the maintainer has closed the cover314′. With the cover314′ closed, the cover roller372′ restricts the first product roll web352′ toward the cover314′, helping separate the first product roll web352′ from contacting the second product roll356′ or second product roll web357′. The housing divider plate373′ further helps separate the first product roll web352′ from the second product roll356′ and second product roll web357′.

Bottom Roll Holder and Dispensing Mechanism Pivotally Attached

FIG. 18shows another example embodiment of a dispenser400that holds a first product roll451and a second product roll456. A first web path452leads to a first dispensing mechanism421and a second web path457leads to a second dispensing mechanism426. Notably, the second dispensing mechanism426(or a portion thereof) is disposed on a chassis490that is pivotally coupled to the rear housing412with a chassis hinge491. In the depicted embodiment, and the dispenser400further includes second roll holders436that are pivotally coupled to the chassis490with a second roll holder hinge437. With reference toFIG. 18, when the cover414is opened, the maintainer may pivot the chassis490out of the housing, such as around the chassis hinge491to provide better access for loading sheet product into the first dispensing mechanism421. Additionally, when the cover414is opened, the chassis490may remain inside the housing to enable the maintainer to easily load sheet product into the second dispensing mechanism. In this regard, when the cover414is open, a maintainer may decide whether to pivot the chassis out of the housing and, thus, replace and load either product roll and roll web. In some embodiments, the chassis may be configured to automatically pivot out of the housing as the cover is opened. In such an embodiment, the maintainer may replace and load either product roll and roll web without disturbing the other roll or web. In some embodiments, the chassis may be configured to automatically pivot out of the housing as the maintainer pivots the second roll holders436out of the rear housing412(e.g., the second roll holders436and chassis may be connected to pivot together or in response to one or the other being pivoted). In such an embodiment, the maintainer may likewise replace and load either product roll and roll web without disturbing the other roll or web.

FIG. 19shows the embodiment of the dispenser400shown inFIG. 18with the cover414closed. With the cover414closed, the cover roller472restricts the first roll web452toward the housing412, helping separate the first roll web452from contacting the second product roll456or second roll web457. The cover divider plate473further helps separate the first roll web452from the second product roll456and second roll web457. The depicted embodiment also includes a nesting arm480that further helps separate the first roll web452from the second roll web457. Indeed, with reference toFIG. 19, the nesting arm480has a length that causes it to, when positioned vertically in the dispenser housing, extend upwardly such that a web path is created that leads the first roll web452around a cover roller472and on the side of the nesting arm480opposite the second product roll456. A hole within the nesting arm480enables the first roll web452to then be directed around the second product roll456and into the first dispensing nip421. By enabling the chassis490to pivot out of the housing, the nesting arm480may have sufficient length to separate the two roll webs, as the nesting arm480is also enabled to pivot, at least, partially out of the footprint of the housing. To explain, with reference toFIG. 18, the nesting arm480extends at a length that would cover the nip of the second dispensing mechanism426if the chassis490did not otherwise pivot forward out of the dispenser housing. However, by pivoting the chassis490forward, the maintainer still has access to load the sheet product from the second product roll456into the second dispensing mechanism426. In some example embodiments, a cover contact surface, a second roll holder contact surface, or other suitable means (not shown) may be provided to urge the second roll holder and the chassis to pivot toward the rear housing when the cover is closed.

Bottom Roll Holder Pivotally Attached to Base Portion and Separate from Cover

As noted herein, some embodiments of the present invention contemplate different ways to manage two separate web paths and still enable a maintainer (or other user) to easily load either product roll and load the corresponding leading edge into the proper dispensing mechanism. In this regard, some embodiments utilize a configuration where the second (e.g., bottom) roll holder is pivotally attached to the base portion (e.g., rear housing) and separate from the cover. In this regard, the movement of the second roll holder can be distinct from the cover even if not (in some cases) independent from movement of the cover. The following description details a number of different embodiments that utilize such a configuration.

FIGS. 20A-20Dillustrate an example embodiment of a dispenser with a movable roll holder. In particular, the dispenser includes a pivoting second (bottom) roll holder that “flips” out when the cover is opened. The dispenser500shown inFIG. 20Aholds a first product roll551and a second product roll556. Further, the dispenser500includes a second roll holder536that is attached to the base portion512with a pivot arm590and configured to move between a first position (shown inFIG. 20C) and a second position (shown inFIG. 20B). Notably, the second roll holder536is separate from the cover514, but still moves out of the way when the cover514is in the open position such that the maintainer can load either the top or bottom product roll and can easily load the leading edge of either the first (top) product roll551(e.g., web path552) into the first dispensing mechanism521or second (bottom) product roll556(e.g., web path557) into the second dispensing mechanism526. With reference toFIG. 20C, two rollers572a,572bnear the rear housing512(one in the middle and one near the bottom) are used to guide the first web path552around the second (bottom) roll556. Such rollers (e.g., web guide structures) can be either attached to the cover or pivotally attached to the second roll holder536such that they move out of the way when the cover514is open, but back into position to separate the web paths when the cover514is closed. For example, the second roller572bmay be attached to a link arm577that is connected with the second roll holder536and configured to move as prescribed by a slot573and along with rotation of the second roll holder536. The link arm577may be configured to rotate out of the way of a nip561for the first dispensing mechanism521when the second roll holders536are rotated out of the dispenser housing. In this regard, a maintainer may have access to load the leading edge of the first product roll551into the first dispensing mechanism521.

FIG. 20Dillustrates another example embodiment that is similar to the embodiment shown and described with respect toFIGS. 20A-20C, however, the link arm577′ is attached to a web guide roller572b′ that is attached to two web dividers578that are fixed to the dispenser chassis and configured to extend and retract with movement of the link arm577′. In some embodiments, the web dividers578are designed to separate the web paths for the first product roll551and the second product roll556. For example, though not shown inFIG. 20D, the web dividers578may be positioned in between sheet product from the first product roll551extending from the roll into the nip561of the first dispensing mechanism521and sheet product from the second product roll556extending from the roll into the nip566of the second dispensing mechanism526. Additionally, in some embodiments, the web dividers578may be force springs that are biased to pull the web guide roller572bforward. Additionally or alternatively, the web dividers578may be formed of electrically conductive material and may provide a path to ground for static buildup that occurs as the paper towel contacts the web dividers578.

Additionally, in the depicted embodiment, the link arm577′ comprises a piston that is configured to extend the range of travel of roll holders536′ while still enabling retraction within the dispenser housing when the cover is closed. In this regard, the designed motion of the link arm577′ and web guide roller572b′ can be maintained while still enabling the roll holders536′ to extend and retract as needed.

FIGS. 21-24Billustrates an example embodiment with dispenser that includes a movable roll holder and movable web management structure. The dispenser600shown inFIG. 21holds a first product roll651and a second product roll656and includes a second roll holder636. The second roll holder636, like the embodiment described with respect toFIGS. 20A-D, is pivotally mounted to the base portion612such that it can pivot out of the housing in a suitable manner when the cover614is opened. The embodiment inFIG. 21, however, further includes a pivoting arm680that is pivotally coupled to the base portion612at a location between the first dispensing mechanism621and the second dispensing mechanism626. When the cover614is opened, the pivoting arm680pivots away from the base portion (rear housing)612to a position such as shown inFIG. 21, at which point a maintainer may load a first roll web652from a first product roll651into a first dispensing mechanism621and/or may load a second roll web657from a second product roll656into a second dispensing mechanism626. Since the pivoting arm680is pivotally coupled to the housing at a point between the first dispensing mechanism621and the second dispensing mechanism626, it is not practical for the maintainer to erroneously load a roll web into the wrong dispensing mechanism (e.g., the maintainer must load the appropriate leading edge of the product roll into the appropriate dispensing mechanism on either side of the pivoting arm).

Once the dispenser is loaded, the maintainer may subsequently close the cover614which thereby moves the second roll holder636toward the rear housing612. Furthermore, closing the cover614causes the pivoting arm680to be urged toward the rear housing612, as shown inFIG. 22. The pivoting arm680may be urged toward the rear housing612by one or more means such as contact between the second roll656and the pivoting arm680; contact between the second roll holders636and the pivoting arm680; contact between the cover614and the pivoting arm680; or other suitable coupling.FIG. 22illustrates that once the cover614is closed, the pivoting arm680separates the first roll web652from the second product roll656and second roll web657, thereby mitigating the risk of dispenser failure due to such contact.

As shown inFIG. 23, the pivoting arm680allows the maintainer access to reach around either side of the pivoting arm680to load the first roll web652into the first dispensing mechanism621or to load the second roll web657into the second dispensing mechanism626.FIG. 23shows the pivoting arm680both in the extended position during loading, as well as in outline form while in the retracted position when the cover614is closed.

A similar example embodiment is illustrated with the dispenser600′ shown inFIGS. 24A and 24B. The depicted embodiment is similar to the embodiment shown and described with respect toFIGS. 21-23, but uses a simple structure in the form of a tongue681instead of the pivoting arm680shown inFIGS. 21-23. Like the pivoting arm680, the tongue681is positioned between the two dispensing mechanisms. With reference toFIG. 24B, the tongue separates the two web paths (652and657) leading into the dispensing mechanisms (621and626). When the cover614opens, the tongue flips out (such as due to a bias, pulling, or pushing force), which forces the maintainer to properly distinguish the two web paths for installing the leading edges of the rolls in the proper dispensing mechanisms (such as on either side of the tongue).

FIGS. 25-28illustrate another example embodiment where the dispenser includes a movable roll holder, a movable chassis, and a movable web management structure. A similar example embodiment was shown and described with respect toFIGS. 18-19. The dispenser700shown inFIG. 25holds a first product roll751and a second product roll756and includes a second roll holder736.FIG. 25shows that the dispenser utilizes a second product roll756that is mounted upon second roll holders736that pivot about a second roll chassis790. The second roll chassis790is pivotally coupled to the rear housing712. As such, the second roll holders736pivot and move away from the rear housing712as the cover714is opened in a suitable manner. The embodiment shown inFIG. 25includes a nesting arm780that is pivotally coupled (e.g., at781) to the rear housing712at a location between the rear housing and the first dispensing mechanism721. When the cover714is opened, the nesting arm780pivots away from the rear housing712to a position such as shown inFIG. 25, in which the nesting arm780is positioned above the first dispensing mechanism721and the second dispensing mechanism726such that a maintainer may load a leading edge of the second product roll756into the second dispensing mechanism726. Furthermore, the nesting arm780includes a nesting arm opening783(more clearly shown inFIGS. 27 and 28) through which the maintainer may load a leading edge of the first product roll751into the first dispensing mechanism721.

Once the dispenser is loaded, the maintainer may subsequently close the cover714which thereby moves the second roll holders736towards the rear housing712. Closing the cover714also urges and pivots the second roll chassis790towards the rear housing712, as shown inFIG. 26. The nesting arm780and the second roll chassis790may be urged toward the rear housing712by one or more means such as contact between the second roll holders736and the nesting arm780; contact between the second roll holders736and the second roll chassis790; contact between the cover714and the nesting arm780; contact between the cover714and the second roll chassis790; or other suitable coupling.FIG. 26illustrates that once the cover714is closed, the nesting arm780separates the first roll web752from the second product roll756and second roll web757, thereby mitigating the risk of dispenser failure due to such contact. In the depicted embodiment, the dispenser700uses a cover roller772and a cover divider plate773to further separate the first roll web752from the second roll756and second roll web757as has been previously described.

FIG. 27shows the dispenser embodiment with the cover714open and a maintainer loading the first roll web752through the nesting arm opening783into the first dispensing mechanism721.FIG. 28shows the dispenser700with the cover714closed and the nesting arm780, cover divider plate773, and cover roller772helping prevent the first roll web752from contacting the second roll756.

FIGS. 29A-29Cillustrates example embodiments of a dispenser that includes a movable roll holder and a linkage structure that aids in web management. The dispenser800shown inFIG. 29Aholds a first product roll851and a second product roll856and includes a second roll holder836. Similar to the embodiment described with respect toFIGS. 20A-D, the dispenser includes a second roll holder836that pivots out of the dispenser800to enable easy loading (seeFIG. 29B). Additionally, however, the depicted embodiment ofFIGS. 29A-Cincludes a web guide structure880that also pivots out of the dispenser800with the second roll holder836. With reference toFIG. 29B, the web guide structure880includes linkages880a,880bthat are designed to move as the cover814is opened to enable a maintainer easy access to load either product roll and either leading edge of a loaded product roll into the appropriate dispensing mechanism821,826(shown inFIG. 29C). To explain, the cover814includes a divider plate814athat acts as a web management feature (such as described herein). A first linkage880ais rotatably connected to the divider plate814aat a first end. A second linkage880bis rotatably connected at a first end to the second end of the first linkage880a. The second end of the second linkage880bis fixedly attached to the chassis890. Due to the various sizes and rotatable connections, as the cover814is opened the linkages880a,880bmove relative to each other and generally cause the first linkage880ato rotate around the second product roll856to the position shown inFIG. 29B. In this position, the nips of the dispensing mechanisms of the chassis890are exposed and available for loading of sheet product from either or both of the first or second product roll respectively.

FIG. 29Cillustrates another example embodiment of a sheet product dispenser that includes a web guide structure880′ that is similar to the web guide structure880shown and described with respect toFIGS. 29A-B.FIG. 29Cillustrates that the web guide structure880′ is designed to form a web guide structure that separates the first web path852from either the second product roll856or the second web path857to prevent jamming or other complications. Notably, the web guide structure880′ includes a second linkage881that is connected to the second roll holder836(e.g., instead of being connected to the chassis as shown inFIGS. 29A-B), and the second roll holder836is coupled to the cover814. Depending on the configuration, such embodiments may provide an advantageous motion path that enables the web guide structure880′ to somersault high enough to vault over the second roll856as the cover814opens. In this regard, the depicted embodiment ofFIG. 29Cprovides for an advantageous motion path because the second roll holder836is simultaneously moving the second roll856(along with the web guide structure880′) out of the dispenser housing as the cover814opens.

FIGS. 30A-30Cillustrate an example embodiment of a dispenser that includes a movable roll holder and a web management structure. The dispenser900shown inFIG. 30Aholds a first product roll951and a second product roll956and includes a second roll holder936. Like the example embodiment described with respect toFIGS. 20A-D, the dispenser includes a second roll holder936that pivots out of the dispenser to enable easy loading (seeFIG. 30A). In this position, the maintainer is free to replace a depleted second product roll with a new second product roll and feed the leading edge of the second roll956into the second dispensing mechanism926(e.g., through the second nip). Additionally, however, the dispenser900includes an intermediate shell940(e.g., a roll partition and/or web management structure) that includes a gap941. If a maintainer chooses to replace a depleted first product roll with a new first product roll, the maintainer may reach through the gap941to pull the leading edge of the first product roll951along the rear-facing surfaces of the intermediate shell940until the leading edge enters the first nip of the first dispensing mechanism921. The intermediate shell940separates the first roll web952from the second product roll956and second roll web957. The maintainer may then close the cover914, after which the dispenser900may resume dispensing product to users from the smaller roll.

FIG. 30Bshows the dispenser900as configured once the cover914is closed.FIG. 30Cshows the dispenser900with the cover914in the closed position and illustrates that the intermediate shell940helps separate the first roll web952from the second roll956and second roll web957so that the webs do not interact and cause the dispenser to jam.

FIGS. 31A-31Dillustrate another example embodiment of a dispenser that includes a movable roll holder and a movable web management structure. The dispenser1000shown inFIG. 31Aholds a first product roll1051and a second product roll1056and includes a second roll holder1036. With reference toFIG. 31A, the second roll1056is mounted upon second roll holders1036that are pivotally coupled to the rear housing1012. The second roll holders1036rotatably support a roll shroud1040. The roll shroud1040is coupled with a roll shroud linkage1041(shown inFIG. 31B) to the second roll holders1036and to the rear housing1012such that when the cover (not shown) opens, the second roll holders1036pivot to the loading position and the roll shroud1040rotates counter-clockwise (as viewed from the perspective ofFIG. 31B) about the second roll holders1036to provide access for a maintainer to load the second product roll into the second roll holders1036and further to load the leading edge1057of the second product roll1056into the second dispensing mechanism1026. Once the dispenser1000is loaded, the maintainer may subsequently close the cover which thereby pivots the second roll holders1036towards the rear housing1012. As the second roll holders1036pivot towards the rear housing1012, the roll shroud linkage1041urges the roll shroud1040to rotate clockwise (as viewed from the perspective ofFIG. 31B) about the second roll holders1036into the position shown inFIG. 31B, in which orientation the roll shroud1040separates the first roll web1052from the second product roll1056and second roll web1057, thereby mitigating the risk of dispenser failure due to such contact.

FIG. 31Cshows a perspective view of an instance in which the second roll holders1036are in the loading position and the roll shroud linkage1041prescribes the roll shroud1040to be in the open-access loading position.FIG. 31Dshows a perspective view of an instance in which the second roll holders1036are in the dispensing position and the roll shroud linkage1041prescribes the roll shroud1040to be in the dispensing position that separates the first roll web1052from the second product roll1056and second roll web1057.

FIGS. 32A-Eillustrate another example embodiment of a dispenser that includes a floating cover. The dispenser1100shown inFIG. 32Ais configured to hold a first product roll (not shown) within a first roll holder1131and a second product roll (not shown) and includes a second roll holder1136. In this illustrated embodiment, the second roll holders1136are pivotally coupled to the rear housing1112with a second roll holder hinge1137and the cover1114is coupled to the second roll holders1136with a cover hinge1113. This cover hinge1113is in place of a typical cover hinge that attaches to the rear housing. In this regard, when the cover1114opens, it give the appearance of “floating.” SeeFIG. 32C.

With reference toFIG. 32A, the cover1114closes flush against the rear housing1112without revealing any unsightly hinge. When a user pulls open the cover1114from the position shown inFIG. 32A, the cover1114and the second roll holders1136remain in the same position relative to each other due to suitable urging such as gravity urging the second roll holders1136toward the cover1114, a spring force urging the second roll holders1136towards the cover1114, or any other suitable means. As such, when a user pulls the cover1114open, the cover1114does not pivot about the cover hinge1113, although both the cover1114and the second roll holders1136pivot together about the second roll holder hinge1137. For example, the cover1114and second roll holder1136pivot to the position shown inFIG. 32B.

As shown inFIG. 32B, the second roll holders1136have descended until they rest upon a chassis hinge1183and can descend no further (seeFIG. 32Efor a more detailed illustration). InFIG. 32B, the second roll holders1136are in a position to allow a maintainer to change product rolls. The cover1114has maintained its position relative to the second roll holders1136. However, the cover1114may descend further if it overcomes the means that urges the cover1114to maintain position with the cover1114. For example, the weight of the cover1114might overcome a spring force urging the cover1114towards the second roll holders1136, in which case the cover1114may pivot about the cover hinge1113to a lower position depicted inFIG. 32C. The position shown inFIG. 32Cmay offer advantages such as increased access to change a product roll. Further, the pivoting cover inFIG. 32Chelps to reduce shock, stress, and potential for resulting damage upon the dispenser1100that may occur if a maintainer were to allow the cover and lower roll holders to freely fall to the position shown inFIG. 32B.

In some embodiments, the chassis1190may be configured to pivot upwardly for easier access. For example, as the cover1114and second roll holders1136pivot out of the dispenser betweenFIGS. 32A and 32B, a suitable mechanism pivots the chassis1190upwards about a chassis hinge1183. This mechanism is further shown inFIGS. 32D and 32E. In this embodiment, a chassis link1194connects the second roll holders1136to the pivoting chassis1190via a second link hinge1197and a first link hinge1198, respectively. When the second roll holders1136pivot to allow a product roll to be serviced, the second roll holders1136move the chassis link1194, which further urges the chassis1190to pivot upwards to a raised position inFIG. 32E. Both the first nip of the first dispensing mechanism1121and the second nip of the second dispensing mechanism1126are affixed to the chassis and likewise both pivot with the chassis1190. As such, the chassis1190is in a “home” position during dispensing, and in a “raised” position during maintenance. The “home” position is advantaged for dispensing because product dispenses from the first nip in a location that is lower than, and not obstructed by, the chute from the second nip. The “raised” position is advantaged for maintenance because it provides better access for a maintainer to reach the first nip to load product. Such advantages may be realized by such example embodiments described herein that enable pivoting or movement of the chassis to a raised position (e.g., the embodiments shown in and described with respect toFIGS. 18, 19, and 25-28).

Roll Partition

Another example embodiment of the present invention that provides, for example, a movable roll holder that is separately movable from the cover also includes a roll partition.FIGS. 33A-37Billustrate various example embodiments related to providing a movable (e.g., rotatable, pivotable, displaceable, slidable, etc.) roll partition for example dispensers.

With reference toFIGS. 33A and 33B, the example dispensers1200,1200′ are configured to hold a first product roll1251and a second product roll1256. In order to separate the web paths and provide for easy loading, among others things, the dispensers1200,1200′ each include a roll partition1240(e.g., an intermediate shell). In the depicted embodiment, the roll partition1240is configured to hold the second product roll1256, such as through the second roll holders1236which are attached to the roll partition1240. In some embodiments, the roll partition1240may define a first portion1247that is shaped (e.g., rounded) to cover at least a back portion of the second product roll1256(seeFIGS. 34B and 34C) to separate the first web path1252of the first product roll1251and the second product roll1256and second web path1257when the roll partition is in the closed position (shown inFIGS. 37A and 37B). Additionally or alternatively, in some embodiments, the roll partition1240may define a second portion1248that is shaped and configured to at least partially cover the first product roll1251. The second portion1248may be designed to cover the first product roll1251, but may also include one or more features (e.g., window1243) to aid in viewing the first product roll1251such as for visual confirmation of the amount of product remaining on the first product roll1251. Further, the roll partition1240may comprise a handle1242that can be utilized to cause rotation of the roll partition1240(e.g., to or from the closed position shown inFIGS. 33A and 33B).

FIG. 33Cshows another example roll partition1240′ that can be utilized with various embodiments of the present invention. The roll partition1240′ defines a first portion1247′ that is shaped to cover at least a back portion of the second product roll (seeFIGS. 34B and 34C). In the depicted embodiment, the first portion1247′ includes a transparent (or semi-transparent) section1247a′ that enables a maintainer to visually discern the amount of remaining sheet product on an installed second product roll (not shown)—such as through a side window (not shown) of the dispenser housing. Additionally, the roll partition1240′ defines a second portion1248′ that is shaped and configured to at least partially cover the first product roll (not shown). The second portion1248′ also includes an opening1243′ to aid in viewing the first product roll (not shown) such as for visual confirmation of the amount of product remaining on the first product roll. Further, the roll partition1240′ includes a handle1242′ that can be utilized to cause rotation of the roll partition1240′.

In some embodiments, with reference toFIG. 39, the roll partition1240amay include one or more side wall portions1299that is designed to fit between the rear housing1212and the cover1214when the cover1214is closed, such that the side wall portion of the roll partition1240aforms a part of the exterior of the dispenser1200. In some embodiments, the side wall portions1299may be formed of transparent or partially transparent material for aesthetics and/or to provide the maintainer or user the ability to visually assess the product level of the first or second product rolls.

FIGS. 33A and 33Beach illustrate the roll partition1240in the closed position. In the closed position, the maintainer is free to replace a depleted second (bottom) roll1256with a new second product roll and load the leading edge of the second (bottom) roll into the second dispensing mechanism1226, which has an exposed and accessible second nip1266. Notably, however, in some embodiments, when in the closed position, as will be described in greater detail herein, a nip cover1285may prevent access to the first dispensing mechanism1221. This forces the maintainer to properly install and load the leading edge of the second product roll1256into the second dispensing mechanism1226(as it is the only dispensing mechanism that is available for loading). The maintainer may then close the cover1214of the dispenser1200, after which the dispenser will resume dispensing product to users.

In some embodiments, the roll partition1240may be configured to rotate around the roll partition hinge1241, such as from a closed position (FIGS. 33A and 33B) to an open position (FIGS. 34A-34C). Notably, the cover1214may, in some embodiments, be configured to rotate separately from the roll partition1240. In this regard, the cover1214may have a separate hinge and/or may rotate around a separate axis than the roll partition1240. Alternatively, in some embodiments, the cover and roll partition may be configured to rotate around the same axis. Further, in some embodiments, the cover and roll partition may be configured to rotate around the same axis, but also may be configured to be able to rotate separately.

With reference toFIGS. 34A-34C, the roll partition1240has been rotated to the open position. In such an embodiment, the roll partition1240can fit within the cover1214(which is also in the open position). In this regard, the maintainer may have engaged the roll partition handle1242(shown inFIGS. 33A and 33B) and lowered the roll partition1240to the opened position. In some cases, such as shown inFIGS. 34A-34C, a second product roll1256may be already installed in the second roll holders1236of the roll partition1240. This may add significant weight to the roll partition1240. To aid in rotation of the roll partition1240and prevent damage (such as from the roll partition1240dropping under the influence of gravity into the opened cover1214), some embodiments of the present invention provide a dampening system for dampening the rotation of the roll partition1240. For example, a rotation dampener (e.g., a rotary vane dampener) may be positioned at the roll partition hinge1241to provide dampening during rotation. Additionally or alternatively, other dampening systems may be used, such as a frictional dampener located about the axis of rotation. For example,FIG. 36Aillustrates a frictional dampener1295located about the roll partition hinge1241.FIGS. 36B and 36Cillustrate another possible dampener. With reference toFIG. 36B, in some embodiments, the roll partition1240may comprise a linkage arm1244that, in some cases, may aid and/or control rotation of the roll partition1240around the roll partition hinge1241. For example, with reference toFIG. 36C, the linkage arm1244may house or cover a belt drive1296that moves along with rotation of the roll partition1240around the roll partition hinge1241. In some such embodiments, a linear dampener1295′ can be used in conjunction with the belt drive1296to provide dampening and/or control rotation of the roll partition1240. For example, the linear dampener1295′ may provide a resistance force to rotation of the belt drive1296, such as through interaction with one or more structures associated with the belt drive, such as structure1293′. Such a resistance force may be designed to provide for a slowed or controlled rotation of the belt drive1296. Further information regarding the belt drive may be found in the description corresponding to the embodiments shown and described with respect toFIG. 61.

With the roll partition1240in the opened position, the maintainer is free to replace a depleted first (top) product roll with a new first product roll and feed the leading edge of the first product roll into the first dispensing mechanism1221. In this regard, with reference toFIG. 34B, rotation of the roll partition1240(and, in some cases the nip cover1285) to the open position has revealed access to the rear housing1212and the first nip1261of the first dispensing mechanism1221. In particular, the maintainer may pull the leading edge of the first product roll1251along the rear housing1212and into the first nip1261.

The maintainer may then close the roll partition1240and close the cover1214, after which the dispenser1200will resume dispensing product to users. In some embodiments, the maintainer only needs to close the cover1214because the cover1214captures and in turn rotates the roll partition1240to a closed position. In some embodiments, the roll partition1240may be designed to attach to (e.g., snap into engagement with) the rear housing of the dispenser. In such embodiments, an audible snap may occur to provide confirmation to the maintainer that the roll partition1240has been properly re-installed inside the dispenser housing (into the closed position) for continued dispensing.FIGS. 35A-35Billustrate an example embodiment with a roll partition that includes a snap engagement with the dispenser housing. As shown inFIG. 35A, the roll partition1240includes a second roll holder1236that includes a pin1239. As the roll partition1240moves from the open position (as shown inFIG. 35A) to the closed position (shown inFIG. 35B), the pin1239snaps into a receiving portion1238of a protrusion1215that extends from the rear housing1214. Further information regarding how an example embodiment that utilizes the snap engagement works can be found herein, such as the example embodiments described and shown with respect toFIGS. 59A-I.

As detailed above, a benefit of using a roll partition is to provide separate web paths that limit contact between the product rolls and web paths. In this regard, with reference to FIGS.37A and37B, using a roll partition1240for example dispensers1200,1200′ enables separation of the first product roll1251and first web path1252from the second product roll1256and second web path1257. Indeed, in some embodiments, the shape of the first portion1247of the roll partition1240may cause it to act as a separator for web management purposes thereby creating a pathway for the web path1252leading to the first dispensing mechanism1221around the first portion1247. In some embodiments, rollers (e.g., rollers1240a,1240bshown inFIG. 35A) or other web management features can be added to the dispenser1200,1200′. For example, one or more rollers may be positioned on the first portion1247of the roll partition1240to help guide the web path1252. In some embodiments, the rollers or other web management features may reduce friction or static build-up due that would otherwise occur due to contact between the roll partition and the sheet product. Ultimately, the first product roll1251may be dispensed from a first chute1217and the second product roll1256may be dispensed from a second chute1219—maintaining separation between the product rolls during the entire dispensing process.

In the illustrated embodiments ofFIGS. 33A-37B, the second roll holders1236are fixed to the roll partition1240. Other embodiments of the present invention, however, contemplate providing other configurations, such as providing that the second roll holders1236are movable relative to and separately from the roll partition1240. For example, the second roll holders may separately pivot out of the roll partition or dispenser housing in a suitable manner as has been previously described in other concepts (such as in the example embodiment described above with respect toFIGS. 20A-D).

Another example configuration is shown inFIGS. 38A-38C. In the depicted embodiment, the dispenser1200″ includes a roll partition1240like prior described embodiments, however, the second roll holders1236in the depicted embodiment are attached directly to the cover1214(as opposed to the roll partition1240). As shown inFIG. 38B, the second roll holders1236will rotate with the cover1214to the open position even while the roll partition1240stays in the closed position. The maintainer can then load the new second product roll. Additionally, the maintainer has the option to rotate the roll partition1240to the open position (shown inFIG. 38C). Notably, with the second product roll1256attached to the cover1214, the weight of the roll partition1240is reduced, enabling easier rotation. In some embodiments, the cover1214may employ a dampening system, such as described above with respect to the roll partition.

Web Management

As has been described herein, the dispenser of various embodiments of the present invention might jam if the first drive roller draws the second roll web into the first nip, and the dispenser might likewise jam if the second drive roller draws the first roll web into the second nip. This tendency is described in further detail below with reference toFIGS. 40A-46. Further, the following description provides detail regarding possible web management features that can be used to avoid such issues. Though the following description focuses on web management features, various embodiments of the present invention described herein, including some embodiments previously described, employ some such web management features.

FIG. 40Ashows an embodiment of a dispenser1300that does not include any web management features. In the depicted embodiment, the dispenser1300is dispensing from a condition in which the first product roll1351is smaller than the second product roll1356, therefore the dispenser satisfies user commands for product by initially dispensing from the first product roll, which rotates the first product roll1251in a clockwise direction (FR).FIG. 40Aalso shows that the first roll web1352(dashed black line) contacts (at1399) the second product roll1356due to the geometry of the dispenser1300. Due to this contact, the first roll web1352may potentially cause the second product roll1356to rotate in a clockwise direction (SR) while the first dispensing mechanism1321dispenses the first roll web. Notably,FIG. 40Ashows that the second roll web1357(solid red line) is in a taught condition. However,FIG. 40Bshows the second roll web1357′ after the first roll web1352has rotated the second product roll1356and caused the second roll web1357′ to unwind and accumulate.FIG. 41shows that the accumulating second roll web is prone to accumulating near the first nip funnel1361, until the first dispensing mechanism1321catches the second roll web1357″ and pulls the second roll web1357″ into the first nip funnel1361and first dispensing mechanism1321as shown inFIG. 41. When this happens, the first dispensing mechanism1321draws the second roll web1357taught between the first dispensing mechanism1321and the second dispensing mechanism1326, which may render the dispenser1300unable to deliver product to a user from either roll, and may require a maintainer to service the dispenser (e.g., create a jam scenario).

One way to lessen the above noted problem is shown in an example embodiment inFIG. 42, in which the cover1314includes a cover roller1372configured such that as the user closes the cover1314, the cover roller1372displaces the first roll web1352towards the rear housing1312and away from contact with the second product roll1356or second roll web1357. Further, the cover1314includes a cover divider1373that further aids in separating the first product roll1351and the second product roll1351. Such web management features help avoid the likelihood of the second product roll1356rotating or accumulating the second roll web1357, thereby helping avoid the risk of the second roll web1357feeding into both dispensing mechanisms and causing the dispenser to fail.

Likewise, a form of web management, such as the web management features described above, may be useful to help prevent the second product roll1356from contacting the first roll web1352and unwinding the first product roll1351enough that the second dispensing mechanism1326might draw in the first roll web1352and cause the dispenser1300to fail.FIG. 43shows this type of failure with the first roll web1352(solid red line) captured by both the first dispensing mechanism1321and the second dispensing mechanism1326due to contact (at1399) between the second product roll1356and the first roll web1352.FIG. 44shows that a cover roller1372helps prevent such contact and avoid the dispenser failure.FIG. 44further shows that the cover1314may include a cover divider1373that prevents the first roll web1352from sagging below the cover roller1372and positively separates the first roll web1352from the second product roll1356, thereby further preventing the first roll web1352and second product roll1356from contacting each other and potentially causing related dispensing failures. In some embodiments, the cover roller and cover divider may be referred to as web guide structures or web management features.

FIG. 45shows yet another embodiment of web management in which the cover1314and second roll holders1336are coupled to a pivoting roller1380in a manner that nests the pivoting roller1380between the first nip funnel (not shown) of the first dispensing mechanism1321and the second nip funnel (not shown) of the second dispensing mechanism1326when the cover1314is open. This allows a maintainer to load either the first roll web1352(solid red line) into the first nip funnel and/or load the second roll web1356(dashed black line) into the second nip funnel without interference. Then the maintainer may close the cover as shown inFIG. 46which causes the pivoting roller1380to move (e.g., through a linkage or other means) to a position near the rear housing1312. For example, the cover1314may be pivotably connected to a first linkage1382a, such that the first linkage1382arotates as the cover1314closes. Additionally, the first linkage1382amay be connected to the second roll holders1336(or an associated arm thereof), such that the second roll holders1336rotate into the housing as the first linkage1382arotates. Further, the second roll holders1336may be connected to a second linkage1382b, such that the second linkage1382brotates into the housing as the second roll holders1336rotate. Finally, the second linkage1382bmay be connected to a third linkage1382cconnected to the pivoting roller1380, such that the third linkage1382cand the pivoting roller1380rotate into the housing as the second linkage1382brotates. As the pivoting roller1380moves towards the rear housing1312, it engages the first roll web1352and draws the first roll web1352towards the rear housing1312and away from contact with the second product roll1356that could potentially causing a dispensing failure.

As described above, some example embodiments of the present invention provide a dispenser that dispenses from the smaller product roll until it is depleted, after which time the dispenser dispenses from the remaining product roll. This preserves the larger product roll as a reserve to sustain the longest time between refills and also to create the soonest opportunity for the smaller product roll to deplete so that a maintainer may again replenish the dispenser. Although this principle is generally true, some embodiments of the dispenser may dispense several feet off the second product roll if the second product roll is full-size, even if the first product roll is the smaller roll. The purpose of firstly dispensing off of a full-size second product roll is to help prevent the risk of a pivoting arm or a nesting arm (such as in certain embodiments) from pressing the first roll web against the rear housing and thereby causing an obstruction to dispensing. By firstly dispensing several feet off of a full-size second product roll, the second product roll decreases in diameter enough for the pivoting arm or nesting arm to pivot away from the rear housing enough to avoid obstructing the first roll web when the first drive roller rotates to dispense product.

Color Coding

In some cases, it is possible for a maintainer to erroneously load the leading edge of the first product roll into the second dispensing mechanism, or alternatively to load the leading edge of the second product roll into the first dispensing mechanism. To help minimize the likelihood of this error, with reference toFIG. 47, some embodiments of the present invention provide a dispenser1400that uses color-coding to help the maintainer associate each roll holder with the proper nip funnel (of the proper dispensing mechanism).FIG. 47illustrates that the first roll holders1431and first nip funnel1461are green, while the second roll holders1436and second nip funnel1466are blue. In various other embodiments, other colors may be used to associate each roll holder with the proper nip funnel. In some embodiments, different textures, visual patterns, or other cues may be used to associate each roll holder with the proper nip funnel.

Roll Holders

Some embodiments of the present invention seek to provide a dispenser with one or more sets of roll holders that are configured to enable easy loading of new sheet product rolls. As used herein “a roll holder” may refer to a set of roll holders that are used to support a single product roll (e.g., “a roll holder for supporting a product roll” and “a set of roll holders for supporting a product roll” may be used interchangeably). In particular, some of the example roll holders are designed to provide a snap-in feature that emits a “click” to give the maintainer confidence that the product roll was loaded properly. Additionally, some example roll holders are designed to provide a drag force on the product roll to aid in preventing overspin of the product roll during dispensing. An additional benefit may include providing a resistance force or feature that prevents the product roll from unintentionally falling out of engagement with the roll holder. Further, some of the example roll holders may be designed to enable a maintainer to simply “drop” the product roll into the roll holder for proper loading. With reference to, for example,FIGS. 33A, 34A, and 34B, an example dispenser1200may include a first set of roll holders1231for receiving and holding a first product roll1251and a second set of roll holders1236for receiving and holding a second product roll1256. Notably, however, some embodiments of the present invention may have only one set of roll holders, such as for a dispenser that holds a single product roll for dispensing (whether full or partially depleted).

Some embodiments of the present invention contemplate a number of different configurations for roll holders that provide for easy and intuitive loading. For example,FIGS. 48-54Cillustrate example roll holders.

FIGS. 48-51Billustrate example roll holders that operate using a cantilever arm for enabling the product roll to be received and secured by the roll holder. For example, with reference toFIG. 48, the roll holder1531includes a stationary body portion1502and a cantilevered portion1505that are connected to the dispenser housing, such as the rear portion1512of the dispenser (although the roll holder could be connected to another portion of the dispenser, such as a movable roll partition). Notably, the cantilevered portion1505is designed to be flexible to deflect outwardly from the product roll (such as in a direction DRHthat is opposite the direction facing the opposed roll holder (not shown)). In this regard, the cantilevered portion1505of the roll holder1531may deflect along arrow DRHto enable a plug or core of the product roll (not shown) to be positioned within the center engagement portion1510of the roll holder1531. This deflection may occur automatically as the maintainer pushes the product roll through a receiving slot1503of the roll holder1531and over a tab1515. The depicted roll holder1531also includes guide tabs1517that help guide the plug or core of the product roll along a track toward the engagement feature1510. Due to the rigidity of the cantilevered portion1505, the cantilevered portion1505may be biased to return to its original position and securely engage the plug or core of the product roll with the engagement feature1510. Notably, the tab1515of the depicted roll holder1531may be designed to snap back into contact with the product roll (or a portion thereof) to create an audible noise—thereby providing an indication to the user that the product roll is properly loaded.

A slight variation of the depicted roll holder shown inFIG. 48is illustrated inFIG. 49. In particular, a larger portion of the roll holder1531′ defines the cantilevered portion1505′, as the stationary body portion1502′ is smaller and only extends part of the way down the length of the roll holder1531′.

Another similar embodiment of a roll holder can be seen inFIGS. 50A-50B. In the depicted embodiment, the roll holder1531″ includes a cantilevered portion1505″ with an engagement feature1510″ with a deep hole defined by a tab1515″. This deep hole provides a retention mechanism that makes it even more difficult to remove the product roll once it is loaded. Such a feature may be useful for roll holders that may be rotated into and out of the dispenser—as the retention mechanism may prevent the loaded product roll from unintentionally falling out of the roll holders during such rotation when the tab may align downward and retention is necessary to prevent gravity from causing the roll to drop out of the roll holder engagement feature1510″.

In some embodiments, the roll holder may include a drag feature that may provide a friction force against the product roll that helps to prevent overspin of the product roll after the motor ceases during dispensing. In this regard, once the motor stops pulling the product from the product roll there may be momentum that would cause the product roll to continue to spin. The friction force provided by the drag feature1507″ is designed to counteract that momentum and prevent or limit overspin. For example, the roll holder1531depicted inFIG. 48includes a drag feature1507that presses up against the side of the product roll or a feature of the product roll (e.g., a plug or the core of the product roll). Likewise, the roll holder1531″ includes a similar drag feature1507″ that presses up against the side of the product roll or a feature of the product roll (e.g., a plug or the core of the product roll).

Yet another example embodiment of a roll holder that utilizes a cantilever portion is shown inFIGS. 51A-51B. In the depicted embodiment, the roll holder1631includes a stationary body portion1602and a cantilevered portion1605that are connected, such as via a rear stationary portion1603, to the dispenser housing or a feature of the dispenser (such as a roll partition). The cantilevered portion1605includes an engagement feature1610that protrudes from the cantilevered portion1605toward the product roll (not shown). The engagement feature1610defines a tapered front edge1626that causes the cantilevered portion1605and the engagement feature1610to deflect in a direction opposite the product roll when the product roll is fed into the roll holder1631. This deflection is illustrated inFIG. 51Bwith the cantilevered portion deflecting from left to right as shown along arrow RH1631at different times1605,1605′, and1605″. Due to the rigidity of the cantilevered portion1605, the cantilevered portion1605may be biased to return to its original position and securely engage the plug or core of the product roll with the engagement feature1610. Notably, the engagement feature1610may also be designed with a back edge1627that is configured to abut against an internal circumferential surface of the product roll or a portion thereof (e.g., the plug or the core). The designed shape of the engagement feature1610may help maintain the product roll in engagement with the roll holder and prevent unintentional removal or release of the product roll.

FIGS. 52A-53Billustrate example roll holders that operate using a biased (e.g., spring-loaded) feature for enabling the product roll to be received and secured by the roll holder. For example, with reference toFIG. 52A, the roll holder1731includes a main body portion1702and an engagement portion1704that are connected to the dispenser housing or a feature of the dispenser (such as a roll partition). Notably, the engagement portion1704includes an engagement feature1710(e.g., a “button” or “latch”) that is configured to bias (e.g., through a spring1711shown inFIG. 52B) to protrude outwardly of the engagement portion1704. Similar to the engagement feature1610ofFIGS. 51A-51B, the engagement feature1710defines a tapered front edge1726and an opposing back edge1727. As the product roll is fed into the guide slot1703of the engagement portion1704, the product roll will interact with the tapered front edge1726of the engagement feature1710thereby forcing the engagement feature1710against the bias of the spring1711and into the roll holder1731(such as shown inFIG. 52Bwhich is a cross-sectional view taken along line52B inFIG. 52A, but with the engagement feature1710in a withdrawn position inside the roll holder). With the engagement feature1710inside the roll holder, the plug or core of the product roll may pass into the center of the engagement portion1704. Due to the bias, the engagement feature1710will return to its original position (shown inFIG. 52A) and securely engage the plug or core of the product roll with the engagement feature1710. The back edge1727of the engagement feature1710may be configured to abut against an internal circumferential surface of the product roll or a portion thereof (e.g., the plug or the core) to maintain the product roll in engagement with the roll holder and prevent unintentional removal or release of the product roll. Additionally, the raised portion1707of the engagement portion1704may provide additional support for maintaining the product roll within the roll holder. Likewise, as similar to described above, in some embodiments, the raised portion1707may act as a drag feature to help prevent overspin of the product roll.

Yet another example embodiment of a roll holder that utilizes a biased feature is shown inFIGS. 53A-53B. In the depicted embodiment, the roll holder1831includes an engagement portion1804and is connected to a feature of the dispenser (such as a roll partition), although the roll holder1831could, in some embodiments, be connected to the dispenser housing, such as the rear portion (e.g., via a stationary body portion). The engagement portion1804includes an engagement feature1810(e.g., a “center piece”) that is configured to bias (e.g., through a spring1811shown inFIG. 53B) to protrude outwardly of the engagement portion1804. As the product roll (or the plug1859thereof, such as shown inFIG. 53B) is fed into the guide slot1803of the engagement portion1804, the product roll will interact with a tapered front edge1826of the engagement feature1810thereby forcing the engagement feature1810against the bias of the spring1811and into the roll holder1831. With the engagement feature1810inside the roll holder, the plug (e.g., plug1859) or core of the product roll may pass into the center1819of the engagement feature1810. Due to the bias, the engagement feature1810will return to its original position (shown inFIGS. 53A and 53B) and securely engage the plug or core of the product roll with the engagement feature1810. The raised portion1807of the engagement feature1810may provide additional support for maintaining the product roll within the roll holder. Likewise, as similar to described above, in some embodiments, the raised portion1807may act as a drag feature to help prevent overspin of the product roll. Notably, a difference between the roll holder1831shown inFIGS. 53A-53Band the roll holder1731shown inFIGS. 52A-52Bis that that engagement feature1810(which is the biased portion) includes the raised portion1807such that it completely surrounds the plug or core of the product roll. This provides additional surface area that flexes with insertion of the product roll (e.g., the engagement feature1810(which deflects) is larger than the engagement feature1710(which also deflects)), providing an easier loading experience for the maintainer.

FIGS. 54A-54Cillustrate another example roll holder that operates using a linkage feature for enabling the product roll to be received and secured by the roll holder. For example, with reference toFIG. 54A, the roll holder1931includes a main body portion1902, an engagement portion1904, and a linkage1984. The roll holder1931may be connected to the dispenser housing or a feature of the dispenser (such as a roll partition). The engagement portion1904includes a guide slot1903defined to receive the product roll (e.g., a plug1959of the product roll). As will be described in greater detail herein with respect to various example retention mechanisms, the linkage1984may be configured to cause a tab1985to either protrude into the engagement portion1904to engage a wall1958of the plug1959(shown inFIGS. 54B and 54C) or retract from the engagement portion1904to enable easy insertion and removal of the plug1959(shown inFIG. 54A). In some embodiments, the tab1985may still protrude slightly into the engagement portion1904even when “retracted” so that it can create an audible “snap” noise when the plug1959passes over the tab1985during loading (e.g., insertion of the plug1959into the engagement portion1904). Such a “snap” noise gives an indication to the maintainer that the product roll was properly loaded.

As noted above, some embodiments of the present invention may provide a retention mechanism for one or more sets of roll holders for the dispenser. In this regard, as detailed herein, some embodiments of the present invention provide a dispenser that includes one or more sets of movable roll holders. For example,FIGS. 6-38Cprovide a number of various examples of dispensers that include movable roll holders. As a particular example,FIGS. 33A-38Cillustrate various configurations of dispensers that include a roll partition. In such example embodiments, with reference toFIG. 33A, a second set of roll holders1236for receiving and holding a second product roll1256are positioned on the roll partition1240and are movable by virtue of movement of the roll partition1240. Notably, as the roll holder (and, in some embodiments, the roll partition) moves, such as from a vertical orientation (shown inFIG. 33A) to a generally horizontal orientation (shown inFIG. 34), the installed product roll may fall out due to gravity and orientation of the guide slot of the roll holder. For example, with reference toFIG. 48, the guide slot1503may generally face upwardly and outwardly when the roll holder1531is in the first or vertical orientation (e.g., the roll holder is within the dispenser housing in the position to receive the replacement product roll). However, upon rotation of, for example, the roll partition and roll holders to the second or generally horizontal orientation (e.g., shown inFIG. 34) the guide slot1503may generally face downwardly. Thus, the force of gravity on the product roll along with the alignment of the guide slot1503to the downward direction may cause the product roll to fall out of the roll holders.

Some embodiments of the present invention seek to provide a retention mechanism for the roll holders that keep the product roll installed even during and after movement of the roll holders. In some embodiments, the retention mechanism is configured to retract or be removed from secure engagement with the product roll when the roll holder is in the stowed position or generally vertical orientation so as to enable easy removal and loading. Some embodiments of the present invention contemplate a number of different configurations for retention mechanisms for roll holders.

FIGS. 54A-56Billustrate some example embodiments of roll holders that use a trigger that forces a tab or similar feature into and out of engagement to secure the product roll in the roll holder. For example,FIGS. 54A-54Cillustrate an example roll holder1931with a retention mechanism in the form of a linkage. As noted above, with reference toFIG. 54A, the roll holder1931includes a main body portion1902, an engagement portion1904, and a linkage1984. Notably, the depicted embodiment is designed to be movable so as to move into and out of the dispenser housing. In this regard, the retention mechanism is designed to use the dispenser housing (not shown) to activate the retention mechanism for securing the product roll from removal. To explain, the main body portion1902defines a back edge1901that is configured to abut the dispenser housing (or a related portion thereof). Further, the roll holder1931includes a trigger1987that is biased to protrude outwardly from the back edge1901of the roll holder1931(shown inFIG. 54B).

With reference toFIG. 54A, when the roll holder1931is disposed inside the dispenser in the stowed position, the trigger1987is forced inside the main body portion1902by the force of the dispenser housing on the back edge1901of the roll holder1931. In this position, a tail1981of the linkage1984is disposed inside a hole1988of the trigger1987(this is due to a bias1983forcing the tail1981of the linkage1984generally toward the hole1988). With the tail1981inside the hole1988, a tab1985at the other end of the linkage1984is retracted from substantially blocking the wall1958of the product roll plug1959from removal—thereby enabling easier removal or loading (e.g., while the roll holder1931is in the stowed position in the dispenser—see e.g., the position of the roll holder1236shown inFIG. 33A).

With reference toFIG. 54B, when the roll holder1931is moved to an unstowed position (e.g., the roll partition1240containing the roll holder1236is rotated downwardly, such as shown inFIG. 34), the trigger1987is biased (e.g., through a spring1989a) and now free to extend outwardly from the back edge1901. However, as the trigger1987moves, a raised portion1989of the trigger1987forces the tail1981of the linkage1984to retract out of the hole1988against its bias. In response, the tab1985of the linkage1984protrudes into the engagement portion1904to engage the wall1958of the plug1959(shown inFIGS. 54B and 54C). This interaction between the tab1985and the product roll causes the product roll to be securely engaged within the roll holder1931including, for example, in an instance in which the roll holders1931have rotated to face generally downwardly such that gravity and the alignment of the guide slot1903may otherwise cause the product roll to fall out of engagement with the roll holder.

FIGS. 55A-55Cillustrate another example embodiment of roll holders that use a trigger that forces a tab or similar feature into and out of engagement to secure the product roll in the roll holder. For example, with reference toFIG. 55A, the depicted embodiment of the roll holder2031is designed to be movable so as to move into and out of the dispenser housing. In this regard, the retention mechanism is designed to use the dispenser housing (not shown) to activate the retention mechanism for securing the product roll from removal. To explain, the main body portion2002defines a back edge2001that is configured to abut the dispenser housing (or a related portion thereof). Further, the roll holder2031includes a trigger2087that is biased to protrude outwardly from the back edge2001of the roll holder2031(shown inFIG. 55A).

With reference toFIG. 55B, when the roll holder2031is disposed inside the dispenser in the stowed position, the trigger2087is forced inside the main body portion2002by the force of the dispenser housing pressing against the trigger2087. In this position, a blocking element2081of the trigger2087is positioned to hold a retention pin2085inside the main body2002of the roll holder2031in a retracted position (this is due to a bias forcing the retention pin2085generally toward the product roll). In the retracted position, the retention pin2085is retracted from substantially blocking the wall of the product roll plug2059from removal—thereby enabling easier removal or loading (e.g., while the roll holder2031is in the stowed position in the dispenser—see e.g., the position of the roll holder1236shown inFIG. 33A).

With reference toFIG. 55C, when the roll holder2031is moved to an unstowed position (e.g., the roll partition1240containing the roll holder1236is rotated downwardly, such as shown inFIG. 34), the trigger2087moves out of engagement with a portion of the dispenser housing. In this regard, the force being applied by the dispenser housing against the trigger2087is removed and a bias being applied to the trigger2087, such as a spring (not shown) inside the main body2002of roll holder2031, causes the trigger2087to extend outwardly from the back edge2001. As the trigger2087moves, the blocking element2081of the trigger2087moves out of engagement with a portion of the retention pin2085(which is otherwise retained within the main body2002by the blocking element2081). With the blocking element2081out of engagement with the retention pin2085, the bias of the retention pin2085(e.g., a spring attached to the retention pin2085) causes the retention pin2085to extend out of the main body2002and toward the product roll to engage with the product roll plug2059(e.g., the retention pin2085is shown retracted within the main body2002inFIG. 55Band extended in contact with the product roll plug2059inFIG. 55C). The interaction between the retention pin2085and the product roll causes the product roll to be securely engaged within the roll holder2031including, for example, in an instance in which the roll holders2031have rotated to face generally downwardly such that gravity and the alignment of the guide slot may otherwise cause the product roll to fall out of engagement with the roll holder. Upon return of the roll holder2031to engage with the dispenser (e.g., when the roll holder2031returns to the vertical position), the dispenser housing engages with and forces the trigger2087back into the main body2002. Further, however, the trigger2087and/or retention pin2085may include a ramp or other feature that causes the trigger2087to force the retention pin2085to retract back into the main body2002as the trigger2087itself is pushed back into the main body2002. In this manner, the retention pin2085releases from engagement with the product roll (such as to enable removal by a maintainer).

FIGS. 56A-56Billustrate another example embodiment of roll holders that use a trigger that forces a tab or similar feature into and out of engagement with the product roll to secure it within the roll holder. For example, with reference toFIG. 56A, the depicted embodiment of the roll holder2131is designed to be movable so as to move into and out of the dispenser housing. In this regard, the retention mechanism is designed to use the dispenser housing (not shown) to activate and/or deactivate the retention mechanism for securing the product roll from removal and/or freeing the product roll for removal. To explain, a main body portion2102of the roll holder2131defines a back edge2101that is configured to abut the dispenser housing (or a related portion thereof). Additionally, the roll holder2131includes a cantilevered portion2104that is configured to flex in a direction opposite to the product roll to enable loading of the product roll. Further, the roll holder2131includes a trigger2187that is biased to protrude outwardly from the back edge2101of the roll holder2131(shown inFIG. 56A).

With reference toFIG. 56B, when the roll holder2131is disposed inside the dispenser in the stowed position, the trigger2187is forced inside the main body portion2102by the force of the dispenser housing on the back edge2101of the roll holder2131. In this position, a blocking element2181(e.g., a wedge) of the trigger2187is positioned past an edge portion2105of the cantilevered portion2014such that the cantilevered portion2104is free to flex in the direction opposite the product roll (e.g., the cantilevered portion2014′ has deflected past the blocking element2181). This may be caused, for example, during insertion of a plug2159of the product roll over a tapered front edge2126of the engagement feature2185for holding the product roll. When the blocking element2181is positioned past the edge2105of the cantilevered portion2104, the product roll is more easily removed or replaced. This may occur, for example, while the roll holder2131is in the stowed position in the dispenser (see e.g., the position of the roll holder1236shown inFIG. 33A).

With reference toFIGS. 56A-56C, when the roll holder2131is moved to an unstowed position (e.g., the roll partition1240containing the roll holder1236is rotated downwardly, such as shown inFIG. 34), the trigger2187is free to extend outwardly from the back edge2101(such as due to a bias on the trigger2187). However, with reference toFIG. 56C, as the trigger2187moves, the blocking element2181moves to abut (e.g., underneath) the edge2105of the cantilevered portion2104. In this regard, the cantilevered portion2104is not free to deflect and, thus, the product roll is not freely removable, as the engagement feature2185is secure within the plug2159of the product roll. This interaction between the engagement feature2185and the product roll causes the product roll to be securely engaged within the roll holder2131including, for example, in an instance in which the roll holders2131have rotated to face generally downwardly such that gravity and the alignment of the guide slot may otherwise cause the product roll to fall out of engagement with the roll holder.

FIGS. 57A-59G and 61illustrate some example embodiments of roll holders that operate to change the orientation of the engagement feature of the roll holder to always remain generally upward (even when the roll holder is otherwise in a generally horizontal orientation, such as the roll holder1236inFIG. 34) in order to prevent the product roll from unintentionally falling out of the roll holder. For example,FIGS. 57A-57Billustrates an example dispenser2200with a set of roll holders2236that are attached to a roll partition2240. As detailed herein, the roll partition2240is configured to be rotated (such as around axis2241) between a stowed position within the dispenser housing (shown inFIG. 57A) to an unstowed position out of the dispenser housing (shown inFIG. 57B). In the depicted embodiment, the roll holder2236is attached to a linkage2295at connection point2292. The linkage2295is rotatably attached to the dispenser housing about axis2293. The connection point2292between the linkage2295and the roll holder2236is configured to ride within a track2297within the roll partition2240as the roll partition2240rotates. In this regard, as the roll partition2240rotates, the orientation of the roll holder2236stays substantially (or generally) constant (as the connection to the linkage2295causes the roll holder2236to rotate to maintain a generally upward and outward orientation of the guide slot2203). For example, the orientation of the guide slot2203of the roll holder2236is the same betweenFIGS. 57A and 57Bdespite the fact that the roll partition2240has rotated from a vertical orientation (FIG. 57A) to a horizontal orientation (FIG. 57B). Although the above example describes that the orientation of the guide slot is the same, in some embodiments, the orientation of the guide slot may not stay the same and may just maintain a generally upward and/or outward orientation as the roll holders rotate.

FIGS. 58A-58Dillustrate another example embodiment of roll holders that operate to change the orientation of the engagement portion to maintain the product roll within the roll holder. For example, with reference toFIG. 58A, the depicted embodiment of the roll holder2331is designed to be movable so as to move into and out of the dispenser housing. In this regard, the retention mechanism is designed to use the dispenser housing (not shown) to control orientation of the engagement portion2380for securing the product roll from unintentional removal as the roll holders2331rotate. To explain, the main body portion2302defines a back edge2301that is configured to abut the dispenser housing (or a related portion thereof). Further, the roll holder2331includes a trigger2387that is biased to protrude outwardly from the back edge2301of the roll holder2331(shown inFIG. 58C), such as due to a spring (not shown) that is positioned within the main body2302of the roll holder2331and configured to act on the trigger2387.

With reference toFIGS. 58A and 58B, when the roll holder2331is disposed inside the dispenser in the stowed position, the trigger2387is forced inside the main body portion2302by the force of the dispenser housing on the trigger2387. In this position, a track2389of the trigger2387engages with and forces a pin2382of the engagement portion2380to a stowed position (shown inFIG. 58B). In this position, the guide slot2303of the engagement portion2380faces generally outwardly and upwardly (e.g., see arrow A2331) enabling easy access for the maintainer for loading and unloading the product roll with respect to the engagement feature2385.

With reference toFIGS. 58C-58D, when the roll holder2331has rotated to an unstowed position (e.g., the roll partition1240containing the roll holder1236is rotated downwardly, such as shown inFIG. 34), the trigger2387is free to extend outwardly from the back edge2301(such as due to a bias on the trigger2387). However, as the trigger2387moves, the track2389forces the pin2382of the engagement portion2380to rotate about the roll holder2331such that the orientation of the engagement portion2380stays at least generally upward. For example, with the trigger2387in the fully extended position (such as may occur when the roll holder2331has rotated to the unstowed position), the engagement portion2380may be rotated such that it maintains a generally outward and upward orientation (e.g., see arrow A2331inFIG. 58C). In this manner, with the guide slot2303maintaining a generally upward orientation, the product roll may be prevented from falling out unintentionally during rotation of the roll holders (e.g., as the raised portion of the engagement portion2380may prevent the product roll from falling out of engagement).

FIGS. 59A-59Dillustrate another example embodiment of roll holders that operate to change the orientation of the engagement portion to maintain the product roll within the roll holder. For example, with reference toFIGS. 59A-B, the depicted embodiment of the roll holder5031is designed to be movable so as to move into and out of the dispenser housing. In this regard, the retention mechanism is designed to use the dispenser housing5014to control orientation of the engagement portion5080for securing the product roll from unintentional removal as the roll holder5031rotates. To explain, the main body portion5002defines a back edge5001that is configured to interact with the dispenser housing (or a related portion thereof). In the depicted embodiment, the dispensing housing5014defines a protrusion5015that fits within the main body portion5002of the roll holder5031through the back edge5001. When the roll holder5031is generally within the dispenser housing, the protrusion5015fits within the main body5002and contacts a linkage5087that is biased (such as due to spring5090) to protrude toward the back edge5001of the roll holder5031(shown inFIG. 59D).

The linkage5087defines a first pin5088that is connected to the engagement portion5080and travels within a first slot5038of the roll holder5031to define an orientation of the engagement portion5080with respect to the roll holder5031(e.g., an open position shown inFIG. 59Aand a retained position shown inFIG. 59C). The linkage5087also defines a second pin5089that travels within a second slot5039of the roll holder5031to guide movement of the linkage5087.

With reference toFIGS. 59A and 59B, when the roll holder5031is disposed inside the dispenser in the stowed position, the linkage5087is forced inside the main body portion5002by the force of the protrusion5015on the linkage5087. In this position, the second pin5089of the linkage5087is forced to the distal end of the second slot5039and the first pin5088is forced to the distal end of the first slot5038, thereby forcing a guide slot5003of the engagement portion5080to face generally outwardly and upwardly to enable easy access for the maintainer for loading and unloading the product roll. In the depicted embodiment, the guide slot5003aligns with a corresponding guide slot5006of the main body portion5002of the roll holder5031.

With reference toFIGS. 59C-59D, when the roll holder5031has rotated to an unstowed position (e.g., the roll partition1240containing the roll holder1236is rotated downwardly, such as shown inFIG. 34), the linkage5087is free to extend toward the back edge5001(such as due to a bias of the spring5090). However, as the linkage5087moves, the second pin5089of the linkage5087moves to the proximal end of the second slot5039and the first pin5088moves to the proximal end of the first slot5038such that the orientation of the engagement portion5080(and the guide slot5003) changes to block removal or release of the loaded product roll. In the depicted embodiment, the guide slot5003moves out of alignment with a corresponding guide slot5006of the main body portion5002of the roll holder5031and, instead, aligns with a wall portion5007to prevent removal of the installed product roll. In this manner, with the guide slot5003maintaining an orientation towards the wall portion5007, the product roll may be prevented from falling out unintentionally during rotation of the roll holders. In some embodiments, the engagement portion5080and guide slot5003maintain a generally upward orientation to further help prevent the product roll from falling out.

FIGS. 59E-59Iillustrate another example embodiment of roll holders that operate to change the orientation of the engagement portion to maintain the product roll within the roll holder. The depicted embodiment of the roll holder5031′ operates in the same manner as the roll holder5031shown inFIGS. 59A-D, except that the roll holder5031′ does not have a spring or other biasing element and the second pin5089′ of the linkage5087′ interacts with (e.g., snaps into and out of) a receptacle of the protrusion5015′ of the dispenser housing5014′ (example receptacles5016′,5016″ are shown inFIGS. 59G and 59H).

With reference toFIG. 59E, when the roll holder5031′ is disposed inside the dispenser in the stowed position, the linkage5087′ is held inside the main body portion5002′ by the connection of the second pin5089′ and the receptacle5016′ of the protrusion5015′. In this position, the second pin5089′ of the linkage5087′ is forced to the distal end of the second slot5039′ and the first pin5088′ is forced to the distal end of the first slot5038′, thereby forcing a guide slot of the engagement portion to face generally outwardly and upwardly to enable easy access for the maintainer for loading and unloading the product roll, such as shown inFIG. 59A.

With reference toFIGS. 59F and 59I, as the roll holder5031′ rotates to an unstowed position (e.g., the roll partition1240containing the roll holder1236is rotated downwardly, such as shown inFIG. 34), the receptacle5016′ retains the second pin5089′ (shown inFIG. 59I). Therefore, rotation of the roll holder5031′ causes the proximal end of the second slot5039′ to move toward the second pin5089′ that is retained in the receptacle5016′, which also causes the proximal end of the first slot5038′ to move closer to the first pin5088′, which causes the orientation of the engagement portion and the guide slot to change so that the guide slot aligns with a wall portion to prevent removal or release of the installed product (e.g., similar to the embodiment shown inFIG. 59C). In the specific embodiment shown, the orientation of the engagement portion and the guide slot stays at least generally upward, such as shown inFIG. 59C, to further help prevent the product from falling out of the engagement portion.

In some embodiments, at some point during the rotation of the roll holder5031′ toward the unstowed position, the second pin5089′ may disengage from the receptacle5016′ to enable full rotation of the roll holder5031′ to the unstowed position. In this regard, the receptacle5016′ may be shaped with a snap-fit (e.g., interference fit) design to hold engagement with the second pin5089′ until enough force is provided to overcome the snap-fit.

In some embodiments, at some point during rotation of the roll holder5031′ toward the stowed position (from the unstowed position), the second pin5089′ may contact the receptacle5016′, but not have enough force to overcome the snap-fit (e.g., to re-engage the second pin5089′ with the receptacle5016′). However, that contact may be enough force to cause the second pin5089′ of the linkage5087′ to move to the distal end of the second slot5039′ and the first pin5088′ to move to the distal end of the first slot5038′, thereby forcing a guide slot of the engagement portion to face generally outwardly and upwardly (e.g., as shown inFIG. 59A). Thereafter, to complete rotation of the roll holder5031′ within the dispenser housing5014′, a force sufficient enough to overcome the snap-fit may be applied to cause re-engagement of the second pin5089′ and the receptacle5016′. Such an action may cause an audible “snap” that may indicate proper re-engagement.

FIG. 59Hshows another embodiment of a protrusion5015″ that includes a differently shaped receptacle5016″. Notably, the depicted receptacle5016″ defines a pronounced snap-fit receptacle that requires additional force to disengage and/or engage the second pin5089′ with the receptacle5016″. The depicted protrusion5015″ also includes a cut-out portion5017″ that enables deflection of the receptacle5016″. Such an example embodiment may provide increased flexibility and a more audible “snap” to help a maintainer feel confident with proper positioning of the roll holder.

In some embodiments, the roll holder5031′ may be installed on a roll partition and may, in some cases, provide for an audible “snap” as the roll holder and roll partition are moved to their stowed position. For example,FIGS. 59J-59Oillustrate an example interaction between a roll partition5040′/roll holder5031′ and the rear dispenser housing5014′ as the roll partition5040′ (and the roll holder5031′) rotates from a stowed position to an unstowed position and back again.

FIG. 59Jshows the roll partition5040′ and roll holder5031′ in the stowed position, being held in engagement with the rear housing5014′ of the dispenser. In the depicted embodiment, the roll holder5031′ includes a linkage5087′ with a first pin5088′ and a second pin5089′. In the stowed position, the second pin5089′ is engaged with a receptacle5016′ of a protrusion5015′ that extends from the rear housing5014′ and the first pin5088′ is positioned at a distal end of a first slot5038′ (shown inFIG. 59F) such that the guide slot5003′ of the roll holder5031′ faces generally outwardly and upwardly.

FIG. 59Kshows the roll partition5040′ beginning to rotate toward the unstowed position. As shown, a proximal end of the first slot5038′ (shown inFIG. 59F) has moved to the first pin5088′ and a proximal end of the second slot5039′ (shown inFIG. 59F) has also moved to the second pin5089′. Notably, however, the second pin5089′ has not yet become disengaged from the receptacle5016′ due to the interference fit engagement. Further, due to movement of the roll holder5031′ away from the first pin5088′ within the first slot5038′, the guide slot5003′ of the roll holder5031′ has rotated to now be oriented generally upwardly (which helps with retaining an installed product roll as described herein).

FIG. 59Lshows that the roll partition5040′ has further rotated toward the unstowed position such that the second pin5089′ has disengaged from the receptacle5016′. In some cases, an audible “snap” may have occurred upon disengagement—thereby confirming detachment to the maintainer. Additionally or alternatively, a physical snap release may be felt by the maintainer to confirm detachment.

FIG. 59Mshows the roll partition5040′ beginning to rotate back toward the stowed position. As shown, the first pin5088′ is still at the proximal end of the first slot5038′ (shown inFIG. 59F) and the second pin5089′ is still at the proximal end of the second slot5039′ (shown inFIG. 59F). Notably, however, the second pin5089′ has not yet re-engaged with the receptacle5016′ since some amount of force is required to create the interference fit engagement.

FIG. 59Nshows the roll partition5040′ further rotated toward the stowed position. As shown, a distal end of the first slot5038′ (shown inFIG. 59F) has moved to the first pin5088′ and a distal end of the second slot5039′ (shown inFIG. 59F) has also moved to the second pin5089′, the first pin5088′ and second pin5089′ being restrained from movement by the contact between the second pin5089′ and receptacle5016′. Notably, however, the second pin5089′ still has not yet re-engaged with the receptacle5016′. Further, due to movement of the roll holder5013′ toward the first pin5088′ within the first slot5038′, the guide slot5003′ of the roll holder5031′ has rotated to now be oriented generally outwardly and upwardly (returning generally to its original orientation shown inFIG. 59J).

FIG. 59Oshows that the roll partition5040′ has further rotated into the stowed position such that the distal end of the first slot5038′ (shown inFIG. 59F) urged the first pin5088′, and thereby the second pin5089′, to move toward the rear housing5014′ until the second pin5089′ has re-engaged with the receptacle5016′. In some cases, an audible “snap” may have occurred upon re-engagement—thereby confirming proper engagement between the roll partition and dispenser housing to the maintainer. Additionally or alternatively, a physical snap force may be felt by the maintainer to confirm re-attachment.

FIGS. 60A-60Eillustrate another example embodiment of a roll holder that operates to retain the product roll within the roll holder as the roll holder rotates. However, the depicted roll holder6031is designed to prevent the engagement portion6080from retracting out of engagement with a plug6059of the product roll6051when the roll holder6031is rotated downwardly by using gravity and a blocking element (e.g., a steel ball6090).

FIG. 60Aillustrates the roll holder6031with a product roll6051installed. Further, the roll holder6031and the product roll6051are in the vertical, stowed position within the dispenser housing. In the stowed position, with reference toFIG. 60B, a blocking element (e.g., a steel ball6090) of the roll holder6031is positioned at a first end6097of a blocking element guide slot6095. In some embodiments, the blocking element guide slot6095may be designed such that it slopes at least partially downwardly toward the first end6097when the roll holder6031is in the stowed position. As such, the blocking element6090may be biased due to gravity to travel (e.g., roll) toward the first end6097as the roll holder6031rotates toward the stowed position.

With reference toFIG. 60C(which shows a dual cross sectional view of the roll holder and product roll engagement when in the stowed position), the blocking element6090is in a position near the first end6097and out of alignment with a stop element6083of the engagement portion6080. As such, the engagement portion6080is free to retract within the main body portion6002of the roll holder6031. This free movement enables loading and unloading of the product roll6051into and out of engagement with the engagement portion6080. The depicted example illustration ofFIG. 60Cshows a view orientation that shows the product roll directly above the roll holder. In this regard, the view orientation ofFIG. 60Cis shown for ease of explanation and is not meant to provide a limiting example of an orientation of the example roll holder embodiment.

FIG. 60Dillustrates the roll holder6031and the product roll6051in the horizontal, unstowed position within the dispenser housing (e.g., the roll holder6031and product roll6051have rotated downwardly around the axis6037). In the unstowed position, with reference toFIG. 60E, a blocking element (e.g., a steel ball6090) of the roll holder6031is positioned at a second end6096of a blocking element guide slot6095. In some embodiments, the blocking element guide slot6095may be designed such that it slopes at least partially downwardly toward the second end6096when the roll holder6031is in the unstowed position. As such, the blocking element6090may be biased due to gravity to travel (e.g., roll) toward the second end6096as the roll holder6031rotates toward the unstowed position.

With reference toFIG. 60C(which shows the roll holder6031in the stowed position), when the roll holder6031rotates toward the unstowed position, the blocking element6090moves (e.g., rolls) to the second end6096underneath the stop element6083of the engagement portion6080. As such, the engagement portion6080is prevented from retracting within the main body portion6002of the roll holder6031. This maintains engagement of the engagement portion6080with the product roll6051, such as through engagement of a wall6081of the engagement portion6080with a wall portion6058of the plug6059of the product roll6051. Since retraction of the engagement portion6080is prevented, the engagement with the product roll6051will be maintained even as the roll holder6031rotates to the unstowed position—thereby preventing the product roll from falling out of installed engagement.

FIG. 61illustrates another example embodiment of roll holders that operate to change the orientation of the engagement feature of the roll holder to always remain generally upward (even when the roll holder is otherwise in a generally horizontal orientation, such as the roll holder1236inFIG. 34) in order to prevent the product roll from unintentionally falling out of the roll holder. For example,FIG. 61illustrates an example dispenser2400with a set of roll holders2436that are attached to a roll partition2440. As detailed herein, the roll partition2440is configured to be rotated (such as around axis2441) between a stowed position within the dispenser housing (shown inFIG. 61) to an unstowed position out of the dispenser housing (not shown). In the depicted embodiment, the engagement portion2480of the roll holder2436is connected to one or more gears (as described herein) that are rotatably attached to a rotatably cogged pulley2444(e.g., upper pulley) that is attached to a belt2485at connection point2482. A stationary cogged pulley2443(e.g., lower pulley) is positioned at the axis2441of rotation. The belt2485wraps around and couples the stationary cogged pulley2443and rotatable cogged pulley2444. The rotatable cogged pulley2444is coupled to one or more gears2446that are affixed to the roll holder2436. As the roll partition2440rotates around its axis2441, the belt2485rotates to cause the orientation of the roll holder2436to stay constant (e.g., the rotation of the belt2485and the connection between the rotatable cogged pulley2444and the gear2446of the engagement portion2480causes the engagement portion2480of the roll holder2436to rotate to maintain a generally upward and outward orientation of the guide slot2403).

In some embodiments, one or more roll holders may be designed with one or more slopes, angles, or other wall shapes that are configured to help prevent an installed product roll from being removed or releasing unintentionally (e.g., during rotation of the roll holder). For example, with reference toFIG. 62A, an example roll holder9031includes a body portion9002with a slot9003that is configured to receive a core of the product roll (not shown). Notably, the slot9003includes a bend9004that changes the angle (e.g., 110 degrees) of the slot9003. A maintainer can insert the core of the product roll into the slot9003and “drop” it over the bend9004. An engagement feature9085can engage the core of the product roll to cause the product roll to be installed. In the depicted embodiment, the engagement feature9085is positioned on a cantilevered portion9087of the roll holder9031to enable deflection of the engagement feature9085for easier installation and/or formation of an audible “snap” confirmation during installation. With the bend9004and angle change, the slot9003includes walls that help retain the installation of the product roll even in the instance where the orientation of the roll holder9031changes, such as due to rotation of the roll holder9031(e.g., if the roll holder is attached to a roll partition or otherwise rotatable). In this regard, the angle change is sufficient enough to keep the angle of the wall with respect to the new orientation at a slope that prevents disengagement of the core of the product roll from the engagement feature9085(such as due to gravity keeping the core of the product roll within the angled portion of the slot9003). For example,FIG. 62Billustrates that the slope9004aof the slot9003before the bend9004prevents the product roll from falling out of the slot9003even when the roll holder9031is oriented downwardly as shown.FIGS. 62C and 62Dshow additional example roll holders9031′ and9031″ that have similar features to the roll holder9031shown in and described with respect toFIG. 62A.

Nip Cover

As detailed herein, some embodiments of the present invention provide a dispenser that is configured to hold two product rolls and provide corresponding dispensing mechanisms for each product roll. Notably, however, when such a dispenser is completely empty and the maintainer is loading a product roll a further goal may be to ensure that the product roll being installed is loaded into the proper dispensing mechanism. For example, with reference toFIG. 3, the dispenser10includes a first dispensing mechanism21and a second dispensing mechanism26. As noted herein, in order to avoid possible jam scenarios, web management is used to separate the web paths for each product roll. Thus, it is desirable for a first product roll51to be loaded into the first dispensing mechanism21and a second product roll56to be loaded into the second dispensing mechanism26. While color coding may be employed in some embodiments (see e.g.,FIG. 47and the corresponding description above), it may be desirable to force the maintainer to load the product roll into the proper dispensing mechanism.

As such, some embodiments of the present invention provide a nip cover that moves with the movable roll holder (e.g., a roll partition with a roll holder) to reveal the proper dispensing mechanism for loading the current product roll and, at the same time, block the improper dispensing mechanism to ensure that improper loading does not occur. For example, with reference toFIGS. 63A-63B, some embodiments of the present invention contemplate using a nip cover with movable roll holders, such as the roll partition1240shown inFIGS. 33A and 34. In the depicted embodiment, the example dispenser2500includes a roll partition2540.

When the roll partition2540is in the stowed position (vertical orientation), as shown inFIG. 63A, the maintainer may install the second product roll (not shown). The dispenser2500may include a nip cover2565that covers the nip (not shown) to the first dispensing mechanism2521when the roll partition2540is in the stowed position, as the second product roll should not be loaded into the first dispensing mechanism2521. However, the nip2566of the second dispensing mechanism2526is revealed and, thus, the maintainer may load the leading edge from the second product roll into the second nip2566, thereby causing the second product roll to be loaded into the proper second dispensing mechanism2526.

When the roll partition2540is in the unstowed position (e.g., horizontal orientation), as shown inFIG. 63B, the maintainer may install the first product roll (not shown). In this unstowed position, the nip cover2565moved (such as with the roll partition2540) so that it covers the nip (not shown) to the second dispensing mechanism2526, as the first product roll should not be loaded into the second dispensing mechanism2526. However, the nip2561of the first dispensing mechanism2521is revealed and, thus, the maintainer may load the leading edge from the first product roll into the first nip2561thereby causing the first product roll to be loaded into the proper first dispensing mechanism2521.

Some embodiments of the present invention contemplate various configurations for how the nip cover moves. For example,FIGS. 63C and 63Dillustrate an example nip cover that rotates with the roll partition to move between revealing the appropriate nip for loading purposes. For example, the dispenser2600may include a nip cover2665that is pivotally attached at a point between the first nip2661of the first dispensing mechanism2621and the second nip2666of the second dispensing mechanism2626(see e.g.,FIGS. 63A and 63B).

In some embodiments, the nip cover2665may be biased (e.g., spring biased) away from the rear housing2614of the dispenser2600. When the roll partition2640is being rotated towards the stowed position (shown inFIG. 63C), the roll partition2640may force the nip cover2665against the bias to cover the first nip2661and reveal the second nip2666. When the roll partition2640rotates to the unstowed position (shown inFIG. 63D), the nip cover2665may rotate forward (such as due to the bias) to cover the second nip2666and reveal the first nip2661. When the roll partition2640rotates back to the stowed position, the roll partition2640may interact with the nip cover2665to force it back toward the rear housing2614.

Additionally or alternatively, the nip cover2665may have one or more pins2669that are configured to be received within tracks that are formed into the roll partition2640. The tracks may be designed to “grab” the pins2669and pull the nip cover2665forward when the roll partition2640rotates forward such that the nip cover2665rotates forward to cover the second nip2666and reveal the first nip2661. Similarly, the tracks may be designed to “push” the pins2669and the nip cover2665backward when the roll partition2640rotates backward such that the nip cover2665rotates backward to cover the first nip2661and reveal the second nip2666. Along these same lines, other configurations may be contemplated for rotating the nip cover. For example, the nip cover may be pivotally attached to the roll partition (instead of the dispenser/dispensing mechanisms).

FIGS. 64A and 64Billustrate another example nip cover that slides within a track to move with the roll partition between revealing the appropriate nip for loading purposes. For example, the dispenser2700may include a nip cover2765that is slidably attached to selectively travel along a track2768defined in the dispenser housing over the first nip2761of the first dispensing mechanism2721(seeFIG. 64A) or over the second nip2766of the second dispensing mechanism2726(seeFIG. 64B) depending on the position of the roll partition2740.

In some embodiments, the nip cover2765may have one or more pins2769that are configured to be received within corresponding pin guide tracks that are formed into the roll partition2740. The pin guide tracks may be designed to “grab” the pins2769and pull the nip cover2765forward when the roll partition2740rotates forward such that the nip cover2765slides forward to cover the second nip2766and reveal the first nip2761. Similarly, the pin guide tracks may be designed to “push” the pins2769and the nip cover2765backward when the roll partition2740rotates backward such that the nip cover2765slides backward to cover the first nip2761and reveal the second nip2766.

In some embodiments, the nip cover2765may be biased (e.g., spring biased) away from the rear housing2714of the dispenser2700. When the roll partition2740is in the stowed position (shown inFIG. 64A), the roll partition2740may force the nip cover2765against the bias to cover the first nip2761and reveal the second nip2766. When the roll partition2740rotates toward the unstowed position (shown inFIG. 64B), the nip cover2765may slide forward (such as due to the bias) to cover the second nip2766and reveal the first nip2761. When the roll partition2740rotates back to the stowed position, the roll partition2740may interact with the nip cover2765to force it to slide backward toward the rear housing2714.

Some embodiments of the present invention contemplate other types of nip covers for selectively covering or revealing nips of dispensing mechanisms based on the position of the roll holder. For example, in some embodiments, the nip cover may be made of elastic material. The nip cover may be attached at one end between the first dispensing mechanism and the second dispensing mechanism and to the roll holder (or corresponding structure with the roll holder) at the other end. In this regard, the elastic nip cover may cover up the first nip when the roll holder is in the stowed position. However, as the roll holder rotates toward the unstowed position, the elastic nip cover may stretch and move generally forward to cover the second nip while revealing the first nip.

Although the above example embodiments illustrate and describe use of a nip cover with a roll partition, some embodiments of the present invention contemplate use of a nip cover with other configurations where the roll holders move (e.g., any of the embodiments described herein and shown in the various figures, such asFIGS. 14-32E).

Funnel Cover

Some embodiments of the present invention provide a funnel cover for a nip of the dispensing mechanism. The funnel cover may be designed to improve loading of the leading edge of product into the nip of the dispensing mechanism. In this regard, the funnel cover may provide a surface that physically and/or visually leads the maintainer to where to position the leading edge of the product roll for proper loading.

FIGS. 65A-65Billustrate an example funnel cover2875for a nip2861for a dispensing mechanism2821of a dispenser2800. The funnel cover2875is visually appealing to the maintainer and provides a visual attractant and structure that covers up much of the structure of the nip2861(e.g., the drive and nip rollers). Additionally, with reference toFIG. 65A, in the depicted embodiment, the funnel cover2875includes portions that define a color (e.g., light green) that can be used to help differentiate the corresponding nip2861and associate the nip2861with the proper roll holder for the proper product roll to be loaded into the nip2861. For example, the funnel cover2875can be utilized for color coding, such as described herein with respect toFIG. 47.

With reference toFIG. 65B, the funnel cover2875may define a front surface2879and a back surface2877that are angled so as to be parallel to the intended web paths (2852,2852′) from the installed full product roll2851to the nip2861such that the product web does not “touch” the funnel cover2875during dispensing. This is important to avoid static build-up and prevent unintended jamming. Moreover, the funnel cover2875may be designed to maintain the parallel nature of the surfaces2877,2879despite what orientation the product roll is loaded into the dispenser. For example, the web path2852from a front loaded product roll (e.g., the leading edge comes from the front of the product roll) leads into the nip2861without touching the front surface2879of the funnel cover2875. Further, the web path2852′ from a backward loaded product roll (e.g., the leading edge comes from the back of the product roll) leads into the nip2875without touching the back surface2877of the funnel cover2875.

Various Sensors, Product Roll and Dispensing Management

Some example embodiments of the present invention contemplate use of various sensors in the product dispenser. For example, as described herein, some embodiments contemplate a product dispenser with one or more funnel sensors, one or more chute sensors, one or more product level (e.g., fuel) gauges, one or more motor operation sensing systems, one or more tear bar detection mechanisms, an activation sensor, among other sensors. By utilizing the gathered information, example product dispensers (such as through the controller) may be configured to perform various functions (e.g., switch dispensing between product rolls, display information to the user/maintainer, automatic or assisted feed, etc.) and determine various scenarios (e.g., a jam scenario, out of paper scenario, etc.). The following describes various example sensors and functions or scenarios that can be performed or determined using the gathered information from the sensors.

Some embodiments of the present invention provide an activation sensor (e.g., activation sensor120ofFIG. 2) for the product dispenser, where the activation sensor is configured to sense a user's desire for the product dispenser to dispense a portion of the product. Depending on the configuration, the activation sensor may be configured in various forms. For example, in some embodiments, the activation sensor may be a capacitive sensor that is configured to sense the presence of a user (e.g., a user's hand). In other embodiments, the activation sensor may be an infrared sensor that is configured to sense the presence of a user (e.g., a user's hand). In response to sensing the presence of the user, the controller may be configured to cause the product dispenser to dispense a portion of the product, such as described herein.

In some embodiments, an IR activation sensor may be formed of a transmitter and a receiver. The transmitter may be configured to transmit one or more pulses of infrared light in a direction (e.g., an activation sensor space). In some embodiments, one or more light pipes may be used to direct light traveling from an LED on a printed circuit board toward a desired space. The receiver may be configured to sense a reflection of the transmitted infrared light, such as when it reflects off the hand of a user. Depending on the configuration, in some embodiments, the transmitter and receiver may be controlled separately such that they can be operated independently of each other. For example, the transmitter can be turned on and off (e.g., pulsed) and the receiver can be separately turned on and off. By operating the transmitter and receiver separately, overall power consumption can be reduced.

Depending on the location of the sheet product dispenser and general preferences of the maintenance personnel, having an adjustable sensing range can be desirable. For example, the range can be set to high, medium, or low (or other variations), and generally correlates to a distance away that a user's hand may be sensed. By using a lower setting, the IR activation sensor may be configured to avoid detecting passing objects (such as users) at distances further away than the desired distance from the IR activation sensor that are indicative of a user intentionally trying to activate the dispenser. In some embodiments, the IR activation sensor may be enabled with an adjustable sensing range. For example, with reference toFIG. 65C, some embodiments may utilize a circuit2890that includes an inductor2893. Such an inductor2893may be in series with a limiting resistor2894for the lighting emitting diode (LED)2895for the IR transmitter. In such example embodiments, the inductor2893may provide (such as through software implementation) for a controlled ramp up of power delivered to the IR LED transmitter (e.g., increasing current from 0%). By adjusting the “on” time of the IR LED transmitter, the controlled ramp can be de-energized once the IR activation sensor has had an opportunity to detect objects within the desired activation range, but before the IR activation sensor would be intense enough to detect objects at distances further away than the desired activation range. To explain further, with no inductor present, the IR LED transmitter would switch on to 100% immediately, and might detect objects at distances further away than desired. For example, prior circuits may have used several resistors and switches to allow the dispenser, user, and/or maintainer to optionally select configurations that would reduce the current through the LED to cause the IR activation sensor to only detect objects within shorter distances from the sensor. However, the additional resistors and switches can increase costs that may be avoided by utilizing an inductor. Further, such prior circuits are not adjustable with simple software changes, and in some embodiments require a more complex printed circuit board and more expensive microcontroller with more pins to control the resistors and switches. Therefore, the inductor embodiment inFIG. 65Cis simpler, lower-cost, and provides a more adjustable configuration to provide adjustment of the IR activation sensor range. For background, additional information regarding adjustability of IR LED activation sensors can be found in U.S. Pat. No. 7,793,882, entitled “Electronic Dispenser for Dispensing Sheet Products”, which is assigned to the owner of the current application, and which is incorporated by reference herein in its entirety.

Automatic/Assisted Feed, Funnel and Chute Sensors

Some example embodiments of the present invention contemplate a product dispenser that is configured to enable automatic or assisted loading of a leading edge of a product roll. For example, in some embodiments, the product dispenser may be configured to automatically energize a drive roller of the dispensing mechanism during loading of the leading edge of the product roll to make it easier for a maintainer to load the dispenser with the product roll. Such automatic energizing of the drive roller may occur in response to sensing the leading edge of the product roll. Further, some embodiments may sense that the product roll has successfully been loaded and, in response, may de-energize or stop rotation of the drive roller.

FIG. 66Ashows an example product dispenser2900that is configured to enable automatic or assisted feed (e.g., auto-loading or assisted loading) for loading the leading edge of a new product roll into the dispensing mechanism (although the product rolls are already loaded successfully inFIG. 66A). A first product roll2951is installed and includes a web path2952that passes through the first dispensing mechanism2921. The product dispenser2900includes a first funnel sensor2941proximate the nip2961of the first dispensing mechanism2921and a first chute sensor2942positioned within the first chute2943(see e.g.,FIG. 66B). A second product roll2956is installed and includes a web path2957that passes through the second dispensing mechanism2926. The product dispenser2900also includes a second funnel sensor2946proximate the nip2966of the second dispensing mechanism2926and a second chute sensor2947positioned within the second chute2948(see e.g.,FIG. 66B).

The funnel and chute sensors are each configured to detect whether or not product is present in the corresponding area. In the depicted embodiments ofFIGS. 66A and 66B, the funnel sensors and chute sensors are each infrared sensors that use a light beam directed down the width of the corresponding funnel or chute. Such a sensor is designed to be transmissive such that any break in the light triggers an indication that product is present. However, as provided in greater detail herein, some example embodiments contemplate other configurations for the funnel and/or chute sensors, such as the sensor directing light in a different direction or pattern and/or using a reflective sensor configuration.

In some embodiments other directions or configurations for the funnel and/or chute sensors can be used. For example,FIGS. 67A-68Billustrate an example embodiment that utilizes an IR sensor that emits light “across” the width of the funnel (e.g., nips3061,3066), although the same or similar design may be applied to the first and second chutes. Further, as will be described in greater detail herein, the illustrated embodiment employs a light pipe that enables a single IR transmitter to emit light that has three paths across each nip3061,3066. A break in any of the three paths indicates a detection of the product. Since the three paths are spread along the entire width of the nip3061,3066, more area is covered and, thus, there is a low likelihood that product may pass through the nip3061,3066without being detected. Additional example sensors include a single IR light emitted across the nip or chute in which a break in the light beam indicates the presence of product (see, for example, the funnel sensor3091ofFIG. 70A), a reflective IR sensor designed to reflect off the product and be detected by a receiver (see, for example, the funnel sensor3092ofFIG. 70B), and an IR sensor that emits light at a slight angle “down” (e.g., diagonally down) the width of the nip or chute (see, for example, the funnel sensor3093ofFIG. 70C). Along similar lines, non-IR sensors can be utilized, including, for example, a capacitive sensor3094that is attached to the dispenser near the nip3061and designed to sense the product when it is proximate the nip3061(see, for example,FIG. 70D) or a mechanical switch sensor3095that is designed to detect the presence of the product proximate the nip3061(see, for example,FIG. 70E).

FIG. 66Cshows that after loading a first roll2951into the first roll holders2931, the maintainer has pulled the leading edge2953from the product roll2951and begun to move the leading edge2953, or first roll tail, of the first product roll2951towards the first nip2961of the first dispensing mechanism2921. In some embodiments, loading guides2901, such as loading instructions in the form of arrows, text, or other indications suitable for helping a maintainer load the leading edge2953into the first nip2961may be utilized for additional guidance.

When the maintainer has pulled the leading edge2953of the first product roll2951to a position that is within a threshold distance of the nip2961of the first dispensing mechanism2921the first funnel sensor2941will detect the leading edge2953(e.g., the leading edge2953will cross and break the IR light2941aemitted down the width of the first nip2961). Though the first funnel sensor2941is shown as emitting an IR light2941adown the width of the nip2961, other IR sensors are contemplated (such as those described herein).

When the first funnel sensor2941detects the presence of the leading edge2953of the product roll, the controller may be configured to activate the first dispensing mechanism2921, such as by causing rotation of the drive roller of the first dispensing mechanism2921. As the drive roller and pinch roller of the first dispensing mechanism2921rotate, the maintainer may further lower the leading edge2953of the first product roll2951into contact with the drive roller and pinch roller such that the drive roller and pinch roller pull the leading edge2953of the first product roll2951and automatically feed the leading edge2953into the first dispensing mechanism2921to subsequently meet user commands for product.

In some embodiments, the controller may continue to operate the motor of the first dispensing mechanism2921for a pre-determined amount of time (e.g., 0.3 seconds, 2 seconds, etc.). Additionally or alternatively, in some embodiments, the controller may be configured to operate the motor of the first dispensing mechanism2921until the first chute sensor2942detects the presence of the leading edge2953signifying that the leading edge2953has successfully passed through the dispensing mechanism2921and into the first chute2943. Thereafter, the controller may deactivate the motor of the first dispensing mechanism2921and the product roll may be successfully loaded. The ability to automatically feed product into the dispensing mechanism is useful to the maintainer because it replaces the step in which the maintainer may need to press a button or otherwise manually activate the dispensing mechanism to feed the leading edge of the product roll into the appropriate dispensing mechanism.

Though the above description focuses on automatically loading a leading edge of a first product roll into a first dispensing mechanism, some embodiments of the present invention may also utilize similar features to enable automatic or assisted loading of a leading edge of a second product roll into a second dispensing mechanism. For example,FIG. 66Cshows an example second funnel sensor2946with emitted light2946athat can be used for automatic or assisted loading of the second dispensing mechanism2926. In some embodiments, one or more manual feed buttons (e.g., such as described with respect toFIG. 82) may be pressed to cause the corresponding dispensing mechanism to operate to feed the product through the dispensing mechanism—such as may be useful for loading the product, which may occur independently or in conjunction with various automatic/assisted loading example embodiments.

In some embodiments, the controller may be configured to cause the automatic or assisted feed operation to initiate slowly to make the experience more pleasant for the maintainer. To explain, the controller may operate the motor of the dispensing mechanism slowly at first and slowly ramp up speed. In this regard, the maintainer might not get scared or intimidated by the burst of motor operation (as their hand is nearby). Further, in some embodiments, the slow acceleration of the motor invites the maintainer to maneuver the leading edge of the product roll near the nip for loading.

In some embodiments, the controller may be configured to enable re-installation of the leading edge. For example, a maintainer may feel that the leading edge was awkwardly loaded. In this case, after the motor stops running (e.g., the controller sensed the leading edge in the chute), the maintainer may pull out the leading edge from above the dispensing mechanism (e.g., upward from within the dispensing mechanism). Instead of fighting, the motor may be configured to cooperate and enable the maintainer to remove the installed leading edge of product roll. Then, in some embodiments, the funnel sensor may detect the lack of presence of the leading edge (as it was pulled out) and the controller may reset the automatic or assisted feed operation and be ready to begin automatic or assisted feeding again.

In some embodiments, the product dispenser may include one or more light pipes to facilitate operation of one or more of the funnel sensor and/or chute sensor. In this regard, in some embodiments, a light pipe system may be configured to reduce parts and maximize the ability to accurately detect the presence or absence of the product roll in the corresponding funnel or chute.FIGS. 67A and 67Cillustrate two example light pipe systems that provide such advantages for both of two funnel sensors (e.g., when the product dispenser has two dispensing mechanisms and two corresponding funnel sensors).

FIG. 67Aillustrates a top view of an example light pipe system3000for an example product dispenser with two nips3061,3066(e.g., the product dispenser2900). The light pipe system3000includes a first printed circuit board (PCB)3011, a second printed circuit board (PCB)3016, a first light pipe3080a, and a second light pipe3080b. The first PCB3011and the second PCB3016are positioned on opposite sides of both nips3061,3066(e.g., on either side of the dispensing mechanisms). The first PCB3011includes a single transmitter3012and two receivers3013a,3013b. Likewise, the second PCB3016includes a single transmitter3017and two receivers3018a,3018b. Two light pipes3080a,3080bare positioned in between the two nips3061,3066, with the first light pipe3080afacing the first PCB3011and the second light pipe3080bfacing the second PCB3016.

The shape of the illustrated light pipes3080a,3080benable a single transmitter3012,3017to emit light for the IR sensor such that the IR sensor effectively covers the entire nip3061,3066to efficiently and effectively detect the presence or absence of the product in the nip3061,3066. To explain, with reference toFIG. 67A, the first light pipe3080aincludes an inlet3081that is positioned across the nip3061from the single transmitter3012(positioned on the first PCB3011). Light is emitted from the single transmitter3012across the nip3061into the inlet3081across Path PT. The light pipe3080aincludes a first splitting surface3082and a second splitting surface3087that are designed to split the received light, with a first portion of the light travelling toward a first deflecting surface3083and the second portion of the light travelling toward a second deflecting surface3088. The first portion of the light is deflected off the first deflecting surface3083out of the first outlet3084across the nip3061and toward the first receiver3013aacross PR1. The second portion of the light is deflected off the second deflecting surface3088out of the second outlet3089across the nip3061and toward the second receiver3013bacross PR2. In this manner, a single transmitter3012is capable of creating three distinct paths (PT, PR1, and PR2) across the nip3061, where breaking any one of the paths indicates the presence of product in the nip3061. Further, the light pipe3080acan be designed such that the paths can extend across the nip at various desirable points (such as proximate the ends of the nip) to maximize the potential to sense the presence of the product in the nip. In this regard, a compact system that minimizes parts is created that enables both funnel sensors.FIG. 67Billustrates a side view of the light pipe system3000in use with both nips3061,3066of a product dispenser.

FIG. 67Cillustrates another example light pipe system3100. Notably, the light pipe system3100is similar to light pipe system3000(shown inFIG. 67A), but the position of the second light pipe3180band the second PCB3116are switched.

FIGS. 68A-Bshow example light pipes that are usable for example embodiments, such as the examples described above with respect toFIGS. 67A-67C.

Although the above example light pipes are described for funnel sensors, some embodiments of the present invention contemplate use for one or more chute sensors. Along these same lines, some embodiments of the present invention contemplate other light pipe systems for the one or more chute sensors.

FIGS. 69A-69Cshow an example light pipe system for both chute sensors for an example product dispenser. With reference toFIG. 69A, the product dispenser3001may have a first chute3048and a second chute3049, each of which may be designed to direct dispensed product to a user, such as from a corresponding first and second dispensing mechanism.FIG. 69Ashows a second light pipe3046for the second chute3049. The second light pipe3046extends from a second printed circuit board3047(e.g., PCB3111inFIG. 67C). The second light pipe3046may include an emitter light pipe arm3047athat is configured to direct light into the second chute3049. The second light pipe3046may also include a receiver light pipe arm3047bthat is configured to receive reflected light and direct it back to a receiver positioned on the PCB3047. In this regard, with reference toFIGS. 69A and 69B, product that passes through the second chute3049may cause light emitted from the emitter light pipe arm3047ato reflect back into the receiver light pipe arm3047bto indicate the presence of the product in the second chute3049. Thus, the chute sensor may form a reflective IR sensor. As shown inFIG. 69B, the second light pipe3046may be configured to direct light into the second chute3049at a position downstream of a second tear bar mechanism3003. In such embodiments, the chute sensor may be configured to only indicate when product is in the chute and not yet retrieved by a user (e.g., torn off using the tear bar mechanism). This positioning is important because there may be product that remains upstream of the tear bar mechanism even after a successful dispense and tearing occurs.FIG. 69Cshows that a first light pipe3041may be positioned to sense product in the first chute3048downstream of the first tear bar mechanism3004in a similar manner to the second light pipe3046. In some embodiments, the first light pipe3041may extend from a first PCB (e.g., PCB3116inFIG. 67C) and be configured in a similar manner to the second light pipe3046.

Though the above described examples employ light pipes, some example embodiments may employ other structures to reflect and/or direct light, such as mirrors. For example, one or more mirrors could be positioned at various points within the dispenser to redirect light in a desired direction or according to a desired pattern.

Though some example described embodiments contemplate sensing product, the funnel sensors and/or chute sensors may be used to sense other objects, such as a user's hand. In this regard, in some embodiments, if a funnel sensor senses a user's hand, the controller may be configured to initiate automatic or assisted loading operations (such as described herein). In such a situation, a user may be bringing their hand close to the funnel to begin loading or installing the product roll therein. In some embodiments, if a chute sensor senses a user's hand, the controller may be configured to cause operation of the corresponding dispensing mechanism so as to attempt to provide product to the user. In such a situation, the user may be attempting to reach up the chute to grab a small remaining portion of the product, thereby indicating a desire for dispensed product.

Tear Bar Detection Mechanism

Some embodiments of the present invention may include one or more tear bar detection mechanisms (e.g., tear bar detection mechanisms124,129ofFIG. 2) that are each configured to detect when a sheet of the product roll has been torn using the tear bar. For example, each chute may include a tear bar detection mechanism. By utilizing a tear bar detection mechanism, the controller may determine when a sheet has been dispensed and removed. Such information may be useful for various features contemplated by some embodiments of the present invention, including for example determining whether or not the product dispenser or dispensing mechanism is operating properly (e.g., if the dispensing mechanism is jammed), performing hang mode operation of the dispenser (e.g., the dispensing mechanism may operate after a user removes a sheet to cause the next portion of the product roll to “hang” out of the dispenser for subsequent tearing by the next individual), determining the amount of the product roll that has been dispensed (e.g., by counting how many sheets have been dispensed and knowing the programmed length of each dispensed sheet), among other things.

FIGS. 71A-71Fillustrate example tear bar detection mechanisms that can be used by various embodiments of the present invention.

FIG. 71Aillustrates a tear bar3210that pivots about an axis3211. The tear bar3210includes serrated edges3212that are configured to, when a user pulls on a portion of the paper towel hanging from the dispenser, contact and cut the paper towel. As the paper towel is pulled downwardly, the tear bar3210rotates about the axis3211and contacts a micro switch3215which sends a signal to the controller indicating that the sheet has been dispensed.

FIG. 71Billustrates a tear bar3210′ that pivots about an axis3211′. The tear bar3210′ includes serrated edges3212′ that are configured to, when a user pulls on a portion of the paper towel hanging from the dispenser, contact and cut the paper towel. As the paper towel is pulled downwardly, the tear bar3210′ rotates about the axis3211′ to trigger a sensor (e.g., an IR sensor) that emits a light beam between a transmitter3215a′ and a receiver3215b′. In response, a signal is sent to the controller indicating that the sheet has been dispensed.

FIG. 71Cillustrates a tear bar3210″ that pivots about an axis3211″. The tear bar3210″ includes serrated edges3212″ that are configured to, when a user pulls on a portion of the paper towel hanging from the dispenser, contact and cut the paper towel. A magnet3215a″ is affixed or coupled to the tear bar3210″. As the paper towel is pulled downwardly, the tear bar3210″ rotates about the axis3211″ and the magnet3215a″ moves toward a magnet sensor3215b″ (e.g., a Hall Effect sensor). In response to sensing the magnet3215a″, a signal is sent to the controller indicating that the sheet has been dispensed.

FIG. 71Dillustrates a tear bar3210′″ that pivots about an axis3211′″. The tear bar3210′″ includes serrated edges3212′″ that are configured to, when a user pulls on a portion of the paper towel hanging from the dispenser, contact and cut the paper towel. As the paper towel is pulled downwardly, the tear bar3210′″ rotates about the axis3211′″ and establishes electrical conductivity with an electrical contact3215b′″ (e.g., electricity is passed to the electrical contact3215b″ through the tear bar3210′″ by a wire connection3215a′″. In response, a signal is sent from the electrical contact3215b″ to the controller indicating that the sheet has been dispensed.

FIG. 71Eillustrates a tear bar3210″″ that pivots about an axis3211″″. The tear bar3210″″ includes serrated edges3212″″ that are configured to, when a user pulls on a portion of the paper towel hanging from the dispenser, contact and cut the paper towel. A strain gauge sensor3215″″ is affixed or coupled to the tear bar3210″″. As the paper towel is pulled downwardly, the tear bar3210″″ rotates about the axis3211″″ and the strain gauge sensor3215″″ is pulled (e.g., along arrow S). In response, the strain gauge sends a signal to the controller indicating that the sheet has been dispensed.

FIG. 71Fillustrates a tear bar3210′″″ that pivots about an axis3211′″″. The tear bar3210′″″ includes serrated edges3212′″″ that are configured to, when a user pulls on a portion of the paper towel hanging from the dispenser, contact and cut the paper towel. As the paper towel is pulled downwardly, the tear bar3210′″″ rotates about the axis3211′″″ and emits one or more vibrations or vibration pattern(s). An accelerometer3215′″″ is positioned in a suitable location to sense vibrations, for example the accelerometer3215′″″ is positioned on a nearby printed circuit board3216′″″. In particular, actuation of the tear bar3210′″″ may emit a recognizable and specific vibration pattern that can be recognized by the accelerometer3215′″″ as dispensing of a sheet of the paper towel. In response, a signal is sent to the controller indicating that the sheet has been dispensed.

Additional example tear bar mechanisms and the various features that can be used due to information gathered by the tear bar mechanism can be found in U.S. application Ser. No. 12/437,921, entitled “Sheet Product Dispenser With Sensor For Sheet Separation”, which is assigned to the assignee of the present application and incorporated by reference herein in its entirety.

While some of the above described example embodiments utilize a movable tear bar to determine a tear event, some embodiments of the present invention may utilize other sensors, such as one or more chute sensors (e.g., the chute sensor examples described herein) to detect tearing and/or removal of a dispensed sheet. In such example embodiments, the tear bar may be stationary and/or the paper may be pre-perforated. In a further example, another type of sensor, such as an accelerometer, may be used to sense the occurrence of a tear event. For example, a stationary tear bar may vibrate upon removal of the paper towel. In such an embodiment, the accelerometer may sense the vibration and determine the occurrence of the tear event.

Motor Operation Sensing, Assigning Sheet Length

Some embodiments of the present invention provide product dispensers that may be configured to sense when a motor for a dispensing mechanism operates. Such information can be used by the controller of the product dispenser for a number of different operations including, for example, ensuring dispensing of a desired sheet length, detecting a jamming scenario, detecting an out of paper or near out of paper scenario, among many others.

In some embodiments, the motor operation sensing information may be utilized by the controller for detecting various scenarios related to the product roll and/or dispensing mechanism, such as some examples described herein. Additionally or alternatively, in some embodiments, knowledge of how many times the motor operates may be utilized with a known time period and/or other information, such as information gathered from other sensors (e.g., a funnel sensor, a chute sensor, a tear bar detection mechanism, a product level sensors, etc.), to determine various scenarios regarding the product roll and/or dispensing mechanism.

In some embodiments, knowing when the motor operates, such as one full rotation of the motor, or alternatively, fractions of a full rotation, may allow the controller to cause the desired sheet length of a dispensed portion of paper towel to be achieved for the dispense. To explain, the number of times a motor rotates is correlated to the number of rotations of the drive roller for the dispensing mechanism, for example by a known gear ratio. The number of rotations of the drive roller is directly correlated to the length of dispensed paper towel, since the size of the drive roller is known. Thus, the controller may be configured to cause the motor to operate and count the number of rotations of the motor. When a certain number of rotations is achieved, then the controller may cease operation of the motor. In this regard, a desired sheet length can be achieved by stopping the motor when the desired sheet length is reached. In some embodiments, the controller may be configured to cause one of at least three different sheet lengths to be dispensed. As described herein in greater detail, the maintainer may set a desired sheet length for dispensing, such as through interaction with a user interface.

Embodiments of the present invention contemplate a number of different ways to sense operation of the motor for the dispensing mechanism. The following describes some example ways in which the product dispenser may be configured to sense operation of the motor of the dispensing mechanism (e.g., each dispensing mechanism).

In some embodiments, with reference toFIGS. 72-75B, the product dispenser (such as through the controller) may be configured to monitor and filter a voltage signal from the motor to detect operation of the motor. For example,FIG. 72shows a graph3300illustrating an example voltage signal return of a motor taken over time. During operation of the motor, shown as a time period3305, the voltage signal can be filtered to enable sensing of commutation spikes/noise as the motor switches poles during operation. Each spike may indicate a full or fractional rotation of the motor, which may correspond to a rotation of the drive roller. In some embodiments, the voltage signal shown inFIG. 72may be weak and difficult to monitor. As such, in some embodiments, the voltage signal may be amplified, such as using the circuit3310shown inFIG. 73, which includes one or more bandpass filters/amplifiers3312. Using the bandpass filters/amplifiers, unwanted low and high frequency noise in the voltage signal can be filtered out, leaving an easily recognizable signal that is amplified. An example of the desired frequency response is shown as3325in the graph3320inFIG. 74.

In some embodiments, the filtered and amplified signal is sent to a comparator, which compares the motor signal to a set reference voltage and outputs a high logic signal when the motor signal is greater than the set reference voltage. This results in a pulse being sent to the controller every time the motor commutates (e.g., switches poles during operation).FIG. 75Ashows a simulation3330of the voltage signal chain in an example embodiment during operation of the motor, where the time period3338shows the effect of commutation ripple on the signal (e.g., see the ripples in the signal), and operation before and after time period3338ignores the effect of commutation ripple (e.g., no ripples in the signal). Notably, the time period shown before and after the time period3338is not representative of signal response and was added to aid in reference of different signals/information that would otherwise be hard to discern within time period3338. The first, top voltage signal3337, which is shown in green, is the motor voltage and is exaggerated to illustrate fluctuations in the voltage. The second signal3332, which is blue, is the signal after the first filter/amplify stage. The third signal3331, which is red, is the signal after the second filter/amplify stage. The fourth, steady signal3334, which is cyan, is the comparator reference voltage. The fifth signal3335, which is purple, is the comparator output which outputs a low (e.g., 0V) signal each time the third signal is less than the comparator, and outputs a high (e.g., 3.3V) signal each time the third signal is greater than the comparator. An example desired signal is the 360 Hz sine wave shown during operation of the motor signal (e.g., during time period3338). In this example, the controller will receive an indication of motor operation (e.g., a count) whenever the signal is greater than the comparator reference voltage. In this regard, the controller may receive a pulse every time the motor switches poles.

FIG. 75Billustrates an example circuit diagram3310′ for an example implementation of the motor operation sensing. In the depicted embodiment, the commutation voltage ripple is picked up directly from the positive lead of the motor, which is connected to positive battery voltage. In the depicted embodiment, the motor may rotate at a maximum of 3500 rpm, which correlates to a commutation frequency of 350 Hz. If the paper bunches or if the batteries deplete, it may slow the motor down. Thus, the filter is built to pick up and amplify the commutation signal throughout the motor's operational range. The signal is amplified and filtered by the operational amplifiers U6A and U6B. Each filter stage is a second order multiple feedback topology, with a Chebyshev response. The first stage is centered at 114 Hz, and the second stage is centered at 352 Hz (seen as the first and second “bumps” in curve3325shown inFIG. 74). Together, these filters center at 200 Hz and amplify the signal with a gain of 10. The −3 dB points are at 40 Hz and 1000 Hz. The final stage of the sensing circuit is a comparator that compares the amplified motor signal to a set reference voltage. When the motor signal is greater than the reference, the comparator sends a logic high to the controller. Thus, a digital pulse train is sent to the controller to make the counting easy to implement.

In some embodiments, other methods for sensing operation of the motor may be utilized. For example, the controller may monitor the battery voltage to sense operation of the motor. Additional information regarding example embodiments that utilize battery voltage to sense motor operation can be found in U.S. application Ser. No. 14/750,333, entitled “Methods, Systems, and Apparatus for Monitoring a Dispensing State of a Dispensing System”, which is assigned to the assignee of the present application and incorporated by reference herein in its entirety.

Some embodiments of the present invention contemplate other types of sensors for sensing motor operation.FIGS. 76A-76Cillustrate example motor operation sensing systems that can be used by various embodiments of the present invention.

FIG. 76Aillustrates an example motor operation sensing system that includes a drive roller3350connected to a cam plate3355. The depicted embodiment includes a cam plate3355with a perimeter profile that includes an engagement surface such that as the drive roller3350rotates (e.g., around arrow MD), the cam plate3355rotates and interacts with a micro-switch3360at its pole to indicate a rotation of the drive roller. In response, the micro-switch3360sends a signal to the controller indicating that the motor has commutated and/or the drive roller has rotated.

FIG. 76Billustrates another example motor operation sensing system that includes a drive roller3350′ connected to a perforated plate3355′. As the drive roller3350′ rotates, the perforated plate3355′ also rotates. An optical sensor3360′ is positioned to pass light from one end of the optical sensor3360′ to the other end of the optical sensor3360′ and through the perforated plate3355′. In particular, the light is emitted toward one or more holes in the perforated plate3355′. As the perforated plate3355′ rotates, the light will be interrupted at one or more points during the rotation cycle. In such a manner, the rotations of the perforated plate3355′ and drive roller3350′ can be counted. In response, corresponding signals are sent to the controller indicating that the motor has commutated and/or the drive roller has rotated.

FIG. 76Cillustrates another example motor operation sensing system that includes a drive roller3350″ connected to a magnet3355″. As the drive roller3350″ rotates, the magnet3355″ also rotates. A Hall Effect sensor3360″ is positioned proximate the magnet3355″ and configured to sense when the magnet3355″ completes a rotation cycle. In response, a signal is sent to the controller indicating that the motor has commutated and/or the drive roller has rotated.

Product Level Gauges, Dispense from Smaller Product Roll

As noted herein, some embodiments of the present invention provide a product dispenser that is configured to dispense from one of two product rolls. In particular, in some embodiments, with two separate dispensing mechanisms, either dispensing mechanism can be used to dispense from either product roll. A goal of some embodiments of the present invention is to provide the best opportunity to avoid a completely empty scenario (e.g., where both product rolls are empty and the dispenser cannot meet user demand). In order to attempt to avoid such a scenario, some embodiments of the present invention seek to always dispense product from the smaller of the two installed product rolls. In such a situation, the smaller (first) product roll will be depleted first, leaving the larger (second) product roll as a back up to dispense while the originally smaller (first) product roll is depleted. Further, since the now depleted (first) product roll can be replaced without the need to replace the currently dispensing other (second) product roll, there is the largest time opportunity for the maintainer to replace the now depleted (first) product roll and avoid a completely empty scenario. Further, such a configuration may help ensure that all of the paper within the dispenser is used up in a timely manner. For example, such a configuration may avoid a single roll sitting in the dispenser as a “permanent” back up roll, with the maintainer always (or often) replacing and dispensing from the other roll.

Along these lines, in some embodiments, the product dispenser (such as through the controller) may be configured to identify which of the first product roll and the second product roll is the smaller roll (i.e., more product has been used from the roll), and then cause dispensing to occur from the smaller roll until it is depleted. After that, the product dispenser may be further configured to dispense from the remaining roll (which was the larger roll).

In some embodiments, the dispenser may use a product level (e.g., fuel) gauge for aiding in identification of the smaller product roll. The following examples provide various product level sensors that may be utilized to aid in identification of the size of the product roll, such as how much product is remaining on the product roll.

In some embodiments, the product dispenser may include one or more pivoting product level arms for each product roll. The pivoting product level arm may be rotatably connected to the dispenser housing at one end. At the other end, the product level may contact the outer circumference of the product roll. As the product roll size decreases (as product is dispensed), the product level arm will rotate toward the center of the product roll. This angular change can be sensed and used (e.g., by the controller) to determine the remaining amount of product on the product roll.FIGS. 77 and 78each illustrate example product level arms3405,3415that abut the outer circumference of the product roll3407,3417at one end and pivot about point3406,3416on the dispenser3400,3410at the other end. Each figure shows three different positions of the product level arm3405,3415as the product roll is depleted. InFIG. 77, the product level arm3405abuts the product roll3407using a roller3402. InFIG. 78, the product level arm3415directly contacts the product roll3417using surface3414. Notably, the product level arms3405,3415ofFIGS. 77 and 78are also used for web management such as described herein. Further, the product level arm3405ofFIG. 77includes guide rollers3409that aid in web management, such as described herein.

Other example embodiments of suitable product level sensors for the product dispenser are product level sensors using a pivoting arm or a linear displacement sensor such as the examples described in U.S. application Ser. No. 15/247,019, entitled “Sheet Product Dispenser with Product Level Gauge System”, which published as U.S. Publication No. 2017/0057775 on Mar. 2, 2017, and which is assigned to the assignee of the present application and which is hereby incorporated by reference in its entirety.

In some embodiments, while having two product rolls, only one product level sensor may be used to determine which dispensing mechanism to utilize (such as to dispense from the smaller of the two product rolls). In this regard, other sensors can be utilized to determine when dispensing occurs and track the amount of product remaining on the product roll without the product level sensor. For example, for the product roll not being directly monitored by a product level sensor, the amount of product remaining can still be determined using a known starting amount of product and subtracting therefrom the number of dispenses times the sheet length of each dispense. The product level sensor could be utilized to determine the amount of product remaining on the other product roll—thereby enabling determination of which product roll has less product remaining. In similar regard, the tracking and amount remaining estimation could be performed for both product rolls, meaning that no product level sensor was necessary. Further information regarding various ways to estimate an amount of product remaining in a dual product roll dispenser can be found in U.S. Publication No. 2017/0057775 referenced above, which is incorporated herein by reference in its entirety.

In some embodiments, other estimation type routines can be performed to achieve a similar effect as if the dispenser was dispensing from the smaller product roll. For example, the product dispenser may be configured to use a product level sensor to determine if one of the product rolls has less than a predetermined amount of product remaining (e.g., less than 75%). In the instance in which the product roll has less than the predetermined amount, the product dispenser may cause dispensing from that product roll. Since a new product roll should not have less than the predetermined amount (e.g., 75%), the product dispenser would likely be dispensing from the smaller of the two product rolls. If the product roll did not have less than the predetermined amount, then the product dispenser may cause dispensing from the other product roll first. Such a system enables use of only one product level sensor. However, in some embodiments, two product level sensors could be used (e.g., one for each product roll) and a similar threshold check could be performed to determine which product roll to dispense from first.

In some embodiments, the product dispenser (such as through the controller) may be configured to compare the various ratios of rotation of the product rolls to corresponding drive rollers to help determine which product roll is smaller and/or an estimated amount of product remaining on at least one product roll. For example, the product dispenser (such as through the controller) may be configured to detect and compare rotation of the first product roll to rotation of the first drive roller (alternatively, the first motor) of the first dispensing mechanism to form a first rotation ratio (e.g., the time period for a rotation cycle of the first product roll over the time period for a rotation cycle of the first drive roller). Likewise, the product dispenser (such as through the controller) may be configured to detect and compare rotation of the second product roll to rotation of the second drive roller (alternatively, the second motor) of the second dispensing mechanism to form a second rotation ratio (e.g., the time period for a rotation cycle of the first product roll over the time period for a rotation cycle of the first drive roller). By comparing, these ratios, the controller can determine which product roll is smaller (e.g., the smaller of the two ratios indicates a smaller product roll—as less time is required to complete a rotation cycle for a smaller product roll). In some embodiments, the controller may determine the time period of a rotation cycle of each product roll and determine which product roll is smaller due to that product roll completing a rotation cycle in less time.

FIG. 79shows another product level sensor embodiment that uses a rotation sensor, such as may be used for comparing the ratio of rotations between the product rolls and corresponding drive rollers. Such an example rotation sensor may be configured to count the rotations of the product roll. The illustrated example embodiment provides a product dispenser3420with a first rotation sensor3425configured to sense rotation of the first product roll3451and a second rotation sensor3435configured to sense rotation of the second product roll3456. Additionally, the product dispenser3420includes a third rotation sensor3445configured to sense rotation of the first drive roller3423of the first dispensing mechanism3421and a fourth rotation sensor3455configured to sense rotation of the second drive roller3428of the second dispensing mechanism3426.

As shown inFIG. 79, the first product roll3451is smaller than the second product roll3456. When the product dispenser3420dispenses from the first product roll3451, the controller may measure the first rotation sensor3425(for rotation of the first product roll3451), and may also measure the third rotation sensor3445(for rotation of the first drive roller3423). Further, when the product dispenser3420dispenses from the second product roll3456, the controller may measure the second rotation sensor3435(for rotation of the second product roll3456), and may also measure the fourth rotation sensor3455(for rotation of the second drive roller3428). Then, for a like number of rotations from the third rotation sensor3445(for the first drive roller3423) and the fourth rotation sensor3455(for the second drive roller3428), the controller may determine whether the first rotation sensor3425(for the first product roll3451) or the second rotation sensor3435(for the second product roll3456) counted more rotations. InFIG. 79, the first rotation sensor3425(for the first product roll3451) will count more rotations than the second rotation sensor3435(for the second product roll3456) because the first product roll3451is smaller than the second product roll3456. In this manner, the product dispenser3420(such as through the controller) may determine that the first product roll3425is smaller, and the product dispenser3420may choose to dispense from the first product roll3451first until it is depleted for benefits (increased use of the reserve roll) that have been described herein. Conversely, if the second rotation sensor3435(for the second product roll3456) counts more rotations than the first rotation sensor3425(for the first product roll3451), the product dispenser3420may determine that the second product roll3456is smaller, and the product dispenser may choose to dispense from the second product roll3456first until it is depleted.

In some embodiments, the rotation sensors may be used to determine the size of a product roll. For example, as the product dispenser dispenses from the first drive roller3423, the product dispenser3420may measure the third rotation sensor3445(for the first drive roller3423) and the first rotation sensor3425(for the first product roll3451). The ratio of rotations is proportional to the diameter of the first product roll3451, and may be used to determine the amount of product remaining on the first product roll3451(e.g., the known diameter of the first drive roller may be used with the ratio of rotations to determine the diameter of the first product roll). Similarly, as the product dispenser3420dispenses from the second drive roller3428, the product dispenser may measure the fourth rotation sensor3455(for the second drive roller3428) and the second rotation sensor3435(for the second product roll3456), and use the ratio of rotations (along with the known diameter of the second drive roller3428) to determine the diameter of the remaining portion of the second product roll3456and, thus, the amount of product remaining on the second product roll3456.

In some embodiments, the ratio of duration of time for a full rotation of the product roll versus the ratio of duration of time for a full rotation of the drive roller can be used to determine the size of the product roll. For example, as the product dispenser dispenses from the first drive roller3423, the product dispenser3420may measure the time it takes to complete a full rotation of the first drive roller3421(e.g., by using the third rotation sensor3445) and the time it takes to complete a full rotation of the first product roll3451(e.g., by using the first rotation sensor3425). Since the diameter of the drive roller is known, the ratio of the time it takes to complete a full rotation of the product roll versus the time it takes to complete a full rotation of the drive roller can be used to determine the diameter of the product roll and, thus, the amount of remaining product on the product roll. The same method can be utilized for determining the amount of product remaining on the second product roll3456using the second rotation sensor3435and the fourth rotation sensor3455.

In some embodiments, the product dispenser may include one or more IR sensors configured to determine the amount of product remaining on a product roll. For example,FIG. 80Ashows an example embodiment of a product dispenser3500with a first IR sensor3525configured to measure the amount of product remaining for the first product roll3551and a second IR sensor3535configured to measure the amount of product remaining for the second product roll3556. The first IR sensor3525is configured to emit an infrared wavelength that reflects off of an external surface3554of the first product roll3451. The reflected infrared wavelength is then sensed by an IR receiver of the first IR sensor3525. Likewise, the second IR sensor3535is configured to emit an infrared wavelength that reflects off of an external surface3559of the second product roll3456. The reflected infrared wavelength is then sensed by an IR receiver of the second IR sensor3535.

In some embodiments with a web management feature (such as a roll partition, divider, etc.), one or more IR sensors may be positioned on the web management feature and directed toward one or more of the product rolls. For example, with reference toFIG. 80B, an example roll partition3540may include a handle3541(e.g., for a user to grasp and cause rotation of the roll partition). The roll partition3540(or the handle thereof) may define a cross beam3543that can be used for logo display and/or reinforcability. Additionally, in some embodiments, with reference toFIG. 80C, one or more IR sensors may be housed within a portion of the roll partition3540, such as the cross beam3543. In the depicted embodiment, the one or more IR sensors may be positioned within an installation space3549. In some embodiments, a single IR sensor may be installed in the installation space3549and include one or more emitter and one or more receiver that are oriented to detect product from a product roll (e.g., along either arrow IRS1or IRS2). In some embodiments, a single IR sensor may include multiple emitters and/or receivers that may be oriented to detect product from both product rolls—such as being oriented toward each arrow IRS1and IRS2). In some embodiments, two separate IR sensors may be utilized to detect product from both product rolls (each IR sensor being oriented toward a corresponding product roll).

In some embodiments, the controller (such as through the first IR sensor3525) may be configured to determine the intensity of the reflected IR compared to the emitted IR. The controller may then be configured to determine the size of the first product roll3551by comparing the first reflected IR to the first emitted IR. Likewise, the same analysis can be performed with respect to the second product roll3556. In this manner, the product dispenser may know the size of each product roll. The product dispenser (such as through the controller) may then determine which product roll is smaller and dispense from that product roll first.

In another embodiment, both IR sensors3225,3535may be configured to emit a known intensity of light and measure the reflected intensities of light. The controller may compare which reflected intensity is weaker (from a roll surface that is further away because the roll is smaller) and thereby determine which roll is smaller.

In another embodiment, a first product roll is larger than a second product roll yet the reflected intensity from the first product roll is weaker than the reflected intensity from a second product roll due to factors such as the IR transmitter and/or receiver for the first product roll being mounted further away from the first product roll holders, or mounted at an angle, or is configured to transmit less IR intensity, or other factors. In such a case, the controller can be configured to determine that the weaker reflected intensity for the first product roll is still large enough to compensate for those factors, and the controller may then determine that the second product roll is smaller and should be dispensed from first.

In another embodiment, the IR sensor emits a light beam and measures the amount of time that it takes for the light to reflect off of a product roll and return to an IR detector. The amount of time that the light travels is directly correlated to the distance from the product roll, since the speed of light is known and constant. In this manner, the controller is able to determine the distance to the product roll surface and, thus, the diameter of the product roll. Alternatively, the product level sensor may emit a sound signal and measure the amount of time that it takes for the sound to reflect off of a product roll surface and return to the product level sensor. The amount of time that the sound travels is directly correlated to distance from the roll, since the speed of sound is very consistent in the typical operating temperatures of the dispenser. In this manner, the controller is able to determine the distance to the product roll surface and, thus, the diameter of the roll.

Along the above lines, some embodiments of the present invention contemplate other types of product level sensors for determining the amount of product remaining on a product roll or determining which product roll is smaller (e.g., has less product remaining).FIGS. 81A-81Billustrate example product level sensors that can be used by various embodiments of the present invention.

FIG. 81Aillustrates an example rotary product level sensor3625that is configured to measure the speed of rotation (RF1) of the product roll3651. This information can be used, for example, in order to determine the size of the product roll or in comparison with rotation of the drive roller for comparison with another product roll (such as described above) to determine which product roll is smaller.FIG. 81Billustrates an example strain measurement product level sensor3625′ that is configured to measure the strain (FF2) of the weight change of the product roll3651′ as it dispenses. This information can be used, for example, to determine the size of the product roll or in comparison with the strain associated with dispensing from another product roll (similar to the ratio comparisons for rotation of the product roll and the drive roller as described above) to determine which product roll is smaller.

In some embodiments, both product rolls may be replaced with full product rolls. In such a scenario, either product roll may be dispensed from. In some such embodiments, the product dispenser may default to dispensing from the first product roll (e.g., the top product roll). Alternatively, the product dispenser may default to dispensing from the second product roll (e.g., the bottom product roll). Likewise, a maintainer may replace a partially depleted product roll, leaving behind two full product rolls. In such a scenario, in some embodiments, the product dispenser may be configured to dispense from the older of the product rolls (e.g., the product roll that has been installed the longest). In other embodiments, the controller is configured to dispense, alternately, from both product rolls for a period of time in order to gather enough information to determine which roll is smaller.

Jam Detection

In some embodiments, the controller of the product dispenser may be configured to determine the occurrence of a jam scenario. This may be accomplished in multiple ways. In an example embodiment, the controller determines how many times the motor has been energized to dispense paper and whether or not paper has been detected by the chute sensor. In this regard, if there is expected to be paper in the chute but the chute sensor does not indicate the presence of paper, then the controller may determine that a jam has occurred (e.g., above the chute sensor). In some embodiments, a product level sensor (such as example product level sensors described herein) and/or funnel sensor may be checked to confirm that there is product available for dispensing (making sure the motor isn't running without product). In some embodiments, the controller monitors the motor and/or drive roller rotations to determine if a jam has occurred. For example, if the controller energizes the motor to dispense product yet the motor does not rotate, then the controller may determine that a jam (or other inoperable condition) has occurred. In some embodiments, the controller monitors the position of the product level arm3415and rotations of a product level roller3402to determine if a jam has occurred. For example, if the position of the product level arm3415indicates that there is product on the roll yet the product level roller3402is not rotating, then the controller may determine that a jam (or other inoperable condition) has occurred. In the event of a jam scenario, the product dispenser (such as through the controller) may be configured to automatically switch dispensing to the other product roll (which would utilize the other dispensing mechanism that is most likely not jammed). Further, the jam scenario could be communicated to the maintainer, such as through a maintainer user interface, the main user interface, or wirelessly (e.g., a text message, email, etc.).

Auto-Switch Product Roll Dispensing, Out of Paper Scenario

As noted herein, some embodiments of the present invention provide a product dispenser that is configured to dispense from one of two product rolls. In particular, in some embodiments, with two separate dispensing mechanisms, either dispensing mechanism can be used to dispense from the associated product roll. In some embodiments, it is desirable to automatically switch dispensing from one dispensing mechanism for one product roll to the other dispensing mechanism for the other product roll without additional steps required by the user. For example, in some embodiments, a user may initiate the dispense (such as by detection from the activation sensor). The product dispenser may determine that the first product roll is empty (or near empty) and automatically dispense from the second product roll. In this manner, there is seamless transition between dispensing of both product rolls and user demand is realized.

In some embodiments, the controller may be configured to use various information, such as from the funnel sensor, motor operation sensor, and/or product level sensor to determine when one product roll is out-of-paper or nearly out-of-paper. For example, in some embodiments, the controller may be configured to determine the occurrence of an out of paper scenario by determining whether or not paper has been detected by the funnel sensor. In some embodiments, the attempted operation of the motor or actuation of the activation sensor can trigger a check of the corresponding funnel sensor to determine if there is an out of paper scenario. In this regard, if there is no paper detected by the funnel sensor, then the product roll is likely empty. In some embodiments, a product level sensor (such as example product level sensors described herein) may be used to determine whether there is any product remaining, for example by determining whether a roller3402is rotating when the associated motor is energized. Further, in some embodiments, a product level sensor can be checked to determine if the product roll is nearly out of paper. When such a determination is made, the controller may automatically switch to dispensing from the other remaining product roll (such as described above). In some embodiments, other indications may cause the controller to switch operation to the other dispensing mechanism and product roll, such as a rotation sensor associated with the motor, drive roller, and/or product roll indicates that the corresponding rotation mechanism is rotating either too quickly or not quickly enough (e.g., depending on the scenario).

User Interface

In some embodiments, the product dispenser may include a user interface (e.g., the user interface114shown inFIG. 2). In some embodiments, the user interface may be configured for interaction with the maintainer (e.g., janitor) and/or consumer (e.g., user receiving the dispensed portion of the product).FIG. 82shows an example user interface7000.

In some embodiments, the cover must be opened in order to access the user interface and/or other portions of the chassis. Alternatively, in some embodiments, at least a portion of the chassis may be accessible to a user/maintainer without opening the cover. In this regard, in some embodiments, the user interface7000(or portions thereof) may be physically accessible, but may be disabled from a user. Further, access could be granted to such features in various ways, such as by opening the cover, entering a code, swiping a badge, etc.

In some embodiments, the user interface may form a part of a chassis that includes, for example, the first and second dispensing mechanism, the first and second chutes, and/or additional components (e.g., the controller, etc.). In some embodiments, the cover may be designed such that the chassis can be replaceable without opening the cover. For example, the chassis could be a “snap-in” module. Such an embodiment may provide for easy maintenance and replacement capabilities.

In some embodiments, the user interface may be configured to enable a maintainer to select one or more options for dispensing the product. For example, with reference toFIG. 82, the user interface7000includes four buttons7010a-dthat can be selected by the maintainer. In this regard, in some embodiments, the maintainer may open the cover to reveal a portion of the user interface7000that enables a maintainer to access and select one or more options. In the depicted embodiment, the maintainer may select (i) whether or not the dispenser should be in on-demand (or command) mode or hang mode using button7010a; (ii) the range of the activation sensor using button7010b(e.g., there are three predetermined range settings to select from); (iii) the desired sheet length for each dispensed portion of the product using button7010c(e.g., there are three predetermined sheet length options); or (iv) the time delay between each dispense using button7010d(e.g., there are three predetermined time delay period options).

In some embodiments, the buttons7010a-dmay be tactile buttons that provide tactile feedback to the maintainer upon selection. In other embodiments, the buttons7010a-dmay be other forms of buttons, including, for example, capacitive sensor based buttons.

In some embodiments, one or more LEDs may be utilized to provide an indication of the option selected. For example, with reference toFIG. 82, the button7010afor selecting whether or not the dispenser should be in hands-free mode or hang mode is surrounded by an annular LED7012. Since the options for selecting which dispenser mode are limited to two (hands-free or hang), the annular LED7012may be one solid light. In some embodiments, other configurations may be implemented. For example, buttons7010b-dare surrounded by annular rings7011a-cthat are each divided into three sections, each corresponding to a different LED (see e.g., LEDs7013a-cfor annular ring7011band button7010c). Depending on the selected option, the corresponding LEDs7013a-ccould be illuminated. For example,FIG. 82Aillustrates a situation where the maintainer has selected a first predetermined sheet length option using button7010c. In this depicted example, only the first LED7013ais illuminated, with the second and third LED7013b-cnot illuminated.FIG. 82Billustrates the situation where the second predetermined sheet length was selected using button7010cand, thus, the first and second LEDs7013a-bare illuminated.FIG. 82Cillustrates the situation where the third predetermined sheet length was selected using button7010cand, thus, the first, second, and third LEDs7013a-care illuminated. The visual indication provided by the sequential illumination of the LEDs7013a-cgives intuitive feedback to the user regarding which option is selected.

Though the above described user interface includes circular buttons and annular LEDs, some embodiments of the present invention contemplate other shapes and placements for the buttons and LEDs.

In some embodiments, the user interface may be configured to enable a user to manually operate the one or more dispensing mechanisms (such as to clear a jam or help in loading a new product roll). With reference toFIG. 82, the user interface7000includes two feed buttons7031,7036, one for each dispensing mechanism. In this regard, the feed buttons are color coded to aid in recognition of which dispensing mechanism will be operated by pushing of the corresponding button. For example, the funnel cover7075of the second dispensing mechanism for the second nip7061has a green-ish color. Likewise, the bottom feed button7031has an indication space with a green-ish color to denote that it will cause operation of the second dispensing mechanism. In this regard, pushing the other feed button7036will cause operation of the first dispensing mechanism.

In some embodiments, such as described herein, the product dispenser (such as through the controller) may be configured to determine the occurrence of a jam situation for each of the dispensing mechanisms. In such a situation, an LED may illuminate in some manner to indicate the jam and the dispensing mechanism in which the jam has occurred. For example, with reference toFIG. 82, the user interface7000includes an LED7032that corresponds to the feed button7031for the second dispensing mechanism and an LED7037that corresponds to the feed button7036for the first dispensing mechanism. In such embodiments, the controller may determine that a jam occurred in the first dispensing mechanism and, in response, cause the LED7037to begin blinking (or other indication) to indicate the jam and the corresponding dispensing mechanism to the user. Moreover, one purpose of the feed button is to enable a user to clear jams by pressing the feed button. Providing a blinking LED on the appropriate feed button leads to intuitive pushing of the feed button to clear the jam.

In some embodiments, the user interface may include a portion designed to provide information to the maintainer and the consumer. For example, the user interface7000ofFIG. 82includes a screen7025. With reference toFIGS. 83A-B, the screen7025may display information to the user (e.g., consumer or maintainer). Such information may be displayed using one or more LEDs and/or back lighting. In the depicted embodiment ofFIG. 83B, the screen7025has caused illumination of a first icon7026that indicates a low battery, a second icon7027that indicates that the dispenser has been activated, and a third icon7028that indicates that a problem has occurred, such as there is a jam, there is a low amount of product remaining, or there is an out of product scenario (e.g., one product roll or both product rolls), though other indications or information may be provided to the user.

In some embodiments, an activation sensor origin7020may be positioned proximate the screen7025and may be shaped or otherwise designed to draw a user's attention to it to indicate the general space in which they should place their hand to cause initiation of a dispense. In some embodiments, the activation sensor origin7020may be shaped and/or designed to enable light from the activation sensor (e.g., IR light) to pass therethrough. Further, in some embodiments, the activation sensor origin7020may be shaped and/or designed to separate the pathway of light for the activation sensor from light used to illuminate one or more indicators (e.g., icons7026,7027,7028).

In some embodiments, the user interface may provide an indication to a user that a task or feature has been properly (or in some cases improperly) completed, such as by providing an animation of lights to indicate the completion of the task. For example, with reference toFIGS. 84A-C, the user interface7000may perform an animation after proper loading of sheet product occurs in one of the dispensing mechanisms. For example, if a maintainer properly feeds the leading edge of a product roll into the second nip7061and through the second dispensing mechanism (e.g., by using the manual feed button or the automatic/assisted loading feature) and that leading edge is detected as being properly loaded (e.g., by a corresponding chute sensor), the user interface7000may perform the animation to communicate a proper loading to the maintainer.

FIGS. 84A-Cillustrate an example animation.FIG. 84Ashows that the animation first comprises illumination of the first annular LED7012surrounding the first button7010aand the three sections of the fourth annular LED7011csurrounding the fourth button7010d.FIG. 84Bshows that the animation continues second with de-illumination of the first annular LED7012surrounding the first button7010aand the three sections of the fourth annular LED7011csurrounding the fourth button7010dalong with illumination of the three sections of the second annular LED7011asurrounding the second button7010band the three sections of the third annular LED7011bsurrounding the third button7010c. Finally,FIG. 84Cshows that the animation continues third with de-illumination of the three sections of the second annular LED7011asurrounding the second button7010band the three sections of the third annular LED7011bsurrounding the third button7010cand illumination of a center icon7027on the screen7025. In this manner, the animation shows lights illuminating in a pattern that moves toward the center of the user interface7000. Such an example animation provides an intuitive sense of completion associated therewith, thereby indicating a complete or proper loading.

While the above description details one example animation, some embodiments of the present invention contemplate other example animations and patterns to provide one or more indications to a maintainer or consumer. Along similar lines, though the above example is directed to indicating a proper loading, some embodiments of the present invention contemplate other tasks for which proper completion or improper completion may be indicated to the maintainer or consumer (e.g., a jamming scenario; an out-of-paper scenario; a successful loading of the product roll into the roll holders, among many others).

Battery Management

In some embodiments, the product dispenser (such as through the controller) may be configured to monitor the battery voltage to determine the amount of battery remaining. In this regard, some embodiments of the present invention seek to provide an indication to the user when the battery life of the current batteries are low. Additionally, some embodiments of the present invention seek to utilize the measured battery voltage being used for other features, such as determining information about the motor or other used components (e.g., to confirm proper operation of the motor, change operational parameters of the motor, such as how long the motor needs to run to achieve an assigned sheet length, etc.).

In some embodiments, in order to determine the remaining life of the one or more batteries, the controller of the product dispenser may be configured to monitor the battery voltage being used. In some embodiments, an analog-to-digital conversion may be performed on the battery voltage. In some embodiments, the controller may be configured to utilize a rolling average algorithm to gather the lowest average battery voltage taken during a dispense cycle (e.g., the time period it takes to complete a full dispense). The controller may be configured to then use the lowest average to determine an amount of battery life remaining, so as to account for the “worst case” scenario (though other averages can be utilized, such as highest average, mean average, median average, etc.). Further, the controller may, based on the amount of battery life remaining, calculate the estimated time remaining before a replacement is needed based on a number of factors, including, for example, an estimated number of dispensers over a time period (e.g., hour, day, year, etc.) and/or an estimated number of energy tasks over a time period. Example energy tasks include running the motor(s), checking the product level sensor(s), measuring the battery, checking one or more sensors, among many others (such as those examples described herein). Such estimates may be based on historical data (such as entered during manufacturing) or, in some cases, may be based on observed data specific to at least the current product dispenser.

In some embodiments, the product dispenser (such as through the controller) may be configured to indicate a low battery to a user and/or maintainer, such as through the user interface or the maintainer user interface. For example, the controller may be configured to cause one or more LEDs to illuminate when the battery life is below a predetermined threshold. Additionally or alternatively, other indications may be provided, such as an estimated time remaining until a replacement is needed. While the above example includes providing an indication using an LED, other ways to provide an indication are contemplated, including, for example, sending a message (e.g., text or email) to the maintainer, providing text on the user interface, etc.

Motor Control, Motor Lock

Some embodiments of the present invention seek to provide more efficient operation of the motor and product dispenser as a whole. In this regard, in some embodiments, the product dispenser (such as through the controller) may be configured to control the motor to reduce bleeding of the product from the roll (e.g., a user manually pulling the product through the rollers of the dispensing mechanism). In some embodiments, to prevent bleeding, the controller may be configured to brake the motor. For example, some embodiments of the present invention may short both sides of the motor together, such as to the battery positive. In some embodiments, the controller may be configured to brake the motor for a certain amount of time after each dispense. Additionally or alternatively, the controller may be configured to brake the motor any time the motor is not running.

Gear Ratio

Some embodiments of the present invention seek to increase the efficiency of operation of the motor, such as to increase battery life and reduce overall energy usage. In this regard, the product dispenser includes a gear ratio for operation of the motor of each dispensing mechanism. The gear ratio is the ratio of the size of the gears that transfer rotation of the motor to the drive roller of the dispensing mechanism. In some embodiments, the product dispenser includes a lowered gear ratio. In some embodiments, the lowered gear ratio results in a faster dispense (e.g., less time to achieve a dispense of the product).

In some embodiments, the overall drivetrain is comprised of a plurality of gears which determine the overall gear ratio. The drivetrain may be comprised of at least two gears, but could be any number of gears more than two. To determine the overall gear ratio of the drivetrain, the output gear pitch diameter (or number of teeth) is divided by the input gear pitch diameter (or number of teeth) for each pair of gears in contact. In some embodiments, the drivetrain uses a compound gear to transfer from one gear set to another gear set. A compound gear has two gears on the same shaft, which therefore rotate at the same rotational speed. In some embodiments, the drivetrain may use one or more intermediate gears to transfer speed and torque from the input gear to the output gear. In such an example, the intermediate gears may function only to switch rotation direction and spacing between the input gear and the output gear. To determine the output rotational speed, the input speed is divided by the gear ratio.

As an example, the following scenario is presented: a motor input gear has 16 teeth followed by meshing with a 40 tooth gear; the 40 tooth gear is a compound gear with 20 teeth on the other gear; the 20 tooth gear then meshes with the output gear that has 50 teeth. For this example, the gear ratio is determined by: (40/16)×(50/20)=6.25:1. If the input speed from the motor is 3600 rpm, then the output rotational speed is 3600 rpm/6.25=576 rpm.

In some embodiments, various factors may be used to optimize the efficiency of the drivetrain. Some example factors include: feed roller diameter (determines speed of paper delivery and required torque), resistance to motion (friction from bearings/bushings, applied friction to the paper delivery system and gear shaft and tooth friction) and the motor performance curve (motor torque, rotational speed, efficiency, etc.).

Static Management

Some embodiments of the present invention seek to reduce the effects of static electricity build-up in the product dispenser. In this regard, static electricity can build-up due to the product (e.g., paper) passing across various surfaces within the product dispenser. In some embodiments, the product dispenser may include one or more static electricity paths that provide a pathway from a metal surface within the product dispenser to “ground”. In such embodiments, for example, the product dispenser may include a pathway (e.g., a wire) that passes from the product dispenser into an external structure, such as the wall where the product dispenser is mounted. In some embodiments, every metal surface within the product dispenser may include a pathway that is grounded. Additional information regarding static electricity management and corresponding pathways to ground can be found in U.S. Pat. No. 6,871,815, entitled “Static Build Up Control in Electronic Dispensing Systems”, filed Sep. 27, 2011; U.S. Pat. No. 7,017,856, entitled “Static Build-Up Control in Dispensing System”, filed Mar. 23, 2004; U.S. Pat. No. 7,182,289, entitled “Static Build-Up Control in Dispensing System”, filed Feb. 3, 2005; and U.S. Pat. No. 7,387,274, entitled “Static Build-Up Control in Dispensing System”, filed Jan. 10, 2006; each of which is assigned to the Assignee of the present invention and is incorporated by reference herein in its entirety.

In some embodiments, the product dispenser may include a configurable lock for controlling access to the inside of the product dispenser. For example, with reference toFIG. 85A, the product dispenser may be configured to enable a user to open the cover8012, such as through a lock feature8090located on the top8016of the product dispenser housing8014. As shown in the depicted embodiment, a user8017may use a key8095to open the cover8012by inserting the key8095in the lock feature8090. In such a situation, the lock feature8090is in the locked configuration.

In some circumstances, the product dispenser may be mounted on a wall and the lock feature8090may be difficult to reach and/or see for a user (e.g., the user may have to reach up above their head and over the top8016of the dispenser housing8014to reach the lock feature8090). In such a situation, it may be difficult for a user (e.g., maintainer) to align the key8095with the lock feature8090to open the cover8012. In this regard, with reference toFIGS. 85B-C, in some embodiments, the lock feature8090may define one or more sloped surfaces8091that lead a key8095(such as through leading the example key's two legs8096a-b) into one or more proper holes8092a-b. The sloped surfaces8091may form a “vortex” that help guide the key8095(e.g., through gravity and/or a pressure force causing the key to run down the slope of the surface) into the proper alignment to enable easy opening of the cover8012. In the depicted embodiment, the legs8096a-bof the key8095may fit within the corresponding holes8092a-bof the lock feature8090and contact a latch8082. By pushing further down on the latch8082, one or more openings8083may be released from corresponding engagement structures of the cover8012to release and open the cover8012. While the above described example includes a key with two legs, any shape key or number of legs may be used by various embodiments in forming a key/lock interaction that encourages the key into proper alignment to enable easy opening of the cover.

In some embodiments, the lock feature8090may be configurable to enable installation of a permanent button8070. This changes the lock feature8090into an unlocked configuration (although the latch8072may still be engaged to keep the cover closed). For example, with reference toFIGS. 85D-E, a user (e.g., maintainer) may install a button8070into the lock feature8090such that a user only need push down on the button8070to open the cover8012. In this regard, the button8070may define two legs8071a-bthat each include an outward projection8072. The legs8071a-bmay be designed to flex inwardly as a tapered section of the outward projection8072passes into the holes8092a-bof the lock feature8090. Once past the holes8092a-bof the lock feature8090, the legs8071a-bwill extend outwardly and the outward projection8072will hold the button8070in the lock feature8090. Further, the legs8071a-bwill extend into the dispenser housing toward the latch8082. By pushing down on the button8070, the legs8071a-bwill engage the latch8082to release and open the cover8012(e.g., in a similar manner to that shown inFIG. 85Cwith the legs8096a-bof the key8095).

In some embodiments, the button8070may be removable to reset the lock feature8090to the locked configuration. For example, with reference toFIG. 85F, the key8095may be used from inside the product dispenser to push the button8070out of engagement with the lock feature8090. In the depicted embodiment, the legs of the key8095have passed through corresponding holes8084in the latch8082to contact and remove the legs of the button8070from engagement with the lock feature8090.

In some embodiments, the button8070may be used to replace the lock feature8090. For example, with reference toFIG. 85E, the lock feature8090may be removed (e.g., in a similar manner to that shown inFIG. 85Fwith the legs8096a-bof the key8095), and the button8070may be inserted in the remaining space. In some such embodiments, the button8070may have a bottom surface that engages the latch8082when pushed by the user. Additionally, in some embodiments, the bottom surface of the button8070may have a cylindrical contour to allow the button to rest in a predominantly parallel manner to the dispenser housing8014.

Example System Architecture

A schematic representation of components of an example product dispenser system100according to various embodiments described herein is shown inFIG. 2. It should be appreciated that the illustration inFIG. 2is for purposes of description and that the relative size and placement of the respective components may differ. The product dispenser system100, which includes a product dispenser105(e.g., a sheet product dispenser), includes components and systems that are utilized in various embodiments described herein.

The product dispenser105may include many different components and/or systems (such as shown inFIG. 2), including, for example, a controller110, a roll partition140, a first dispensing mechanism121, a second dispensing mechanism126, a first funnel sensor141, a second funnel sensor146, a first chute sensor142, a second chute sensor147, a first tear bar mechanism124, a second tear bar mechanism129, a memory112, a communication interface113, one or more user interfaces114, a power system116, an activation sensor120, one or more product sensors (e.g., product level sensors)118, and other system(s)/sensor(s)115. Though shown inFIG. 2as being a component of the product dispenser105, such components are not required to be part of the product dispenser105according to various embodiments herein. For example, product dispensers of various embodiments described herein may include different components, but still function according to the desired embodiment. For example, some embodiments only include one product roll (as opposed to the two shown inFIG. 2) and, thus, the components may only include one dispensing mechanism, one chute sensor, one funnel sensor, and one tear bar mechanism. Similarly, some embodiments may employ a transfer mechanism (as known in the art) to enable transfer between product rolls for dispensing from a single dispensing mechanism. Along these lines, the depicted embodiment ofFIG. 2is provided for explanatory purposes and is not meant to be limiting.

As will be described in more detail herein, the controller110provides logic and control functionality used during operation of the product dispenser105. Alternatively, the functionality of the controller110may be distributed to several controllers that each provides more limited functionality to discrete portions of the operation of product dispenser105.

The product dispenser105may be configured to hold two full product rolls. For example, the depicted product dispenser105houses a first product roll151, such as may be received by a first set of roll holders that are attached to a base of the product dispenser105. Additionally, the product dispenser105houses a second product roll156, such as may be received by a second set of roll holders. In the depicted embodiment, the second product roll156is received within roll holders that are attached to a roll partition140.

The roll partition140may be designed, in some embodiments, to hold a product roll (e.g., product roll156). Additionally, the roll partition140may be movably (e.g., pivotably) attached to the base and/or cover of the product dispenser105, thereby enabling movement of the roll partition between a closed position and an open position. In some embodiments, the roll partition140may be configured to help separate or manage the web paths of the first product roll151and the second product roll156.

The activation sensor120may be configured to sense/receive user input (such as a user's hand or portion thereof) indicating a desire to cause the product dispenser105to dispense a portion of product (e.g., a portion of sheet from the first or second product roll). The activation sensor120may be any type of sensor or feature capable of receiving user input to begin dispensing, including for example, a capacitive sensor, a light sensor, an IR sensor, a mechanical lever or button, etc. The activation sensor120may be in communication with the controller110such that the controller110can determine when to cause dispensing of the product.

The first and second dispensing mechanism121,126may each be configured to cause dispensing of a portion of the product, such as a portion (or length) of the roll of product (e.g., the first or second product roll). Depending on the configuration, the dispensing mechanisms121,126may each comprise a motor (e.g., first motor122or second motor127, respectively) that drives one or more drive rollers (e.g., first roller(s)123or second roller(s)128, respectively). In each dispensing mechanism, a portion of the product roll may be sandwiched (e.g., in frictional contact) between the drive roller and one or more pinch rollers such that operation/rotation of the drive roller causes dispensing of a portion of the product roll. The first and second dispensing mechanism motors122,127may be in communication with the controller110such that the controller110may control operation of the motors122,127.

The first and second funnel sensors141,146may each be positioned within or relative to the funnels for the corresponding first and second dispensing mechanisms121,126and configured to sense the presence (or absence) of product within the corresponding funnels. For example, the first funnel sensor141may be positioned to sense for product within the funnel leading into the first dispensing mechanism121. In some embodiments, the first and second funnel sensors141,146may be configured to utilize IR sensing capabilities to sense the presence of the product in the funnel. In some embodiments, however, other types of sensors may be utilized (e.g., capacitive sensors, light sensors, mechanical sensors, etc.). The first and second funnel sensors141,146may be in communication with the controller110such that the controller110may determine when product is present or absent within each funnel.

The first and second chute sensors142,147may each be positioned within or relative to the chutes for the corresponding first and second dispensing mechanisms121,126and configured to sense the presence (or absence) of product within the corresponding chutes. For example, the first chute sensor142may be positioned to sense for product within the chute extending from the first dispensing mechanism121(e.g., where the product is dispensed). In some embodiments, the first and second chute sensors142,147may be configured to utilize IR sensing capabilities to sense the presence of the product in the chute(s). In some embodiments, however, other types of sensors may be utilized (e.g., capacitive sensors, light sensors, mechanical sensors, etc.). The first and second chute sensors142,147may be in communication with the controller110such that the controller110may determine when product is present or absent within each chute.

The first and second tear mechanisms124,129may each be configured to enable tearing of the dispensed portion of the product roll. In this regard, the first and second tear mechanisms124,129may each comprise a tear bar or other feature that can enable a user to provide a force to tear off the portion of the product roll. For example, the first and second tear mechanisms124,129may include a serrated edge that cuts into the sheet when the user pulls the dispensed product. The separated portion of the product from the product roll may then be used and discarded as necessary by the user. Alternatively, the first and second tear mechanisms124,129may be configured to perform a tear or partial tear prior to interaction with the user such that the user simply pulls on the pre-torn portion of the product roll to complete dispensing of the portion of the product. In some embodiments, the first and second tear mechanisms124,129may be configured to detect the occurrence of tearing of the product. For example, the serrated edge of a blade of the first and second tear mechanisms124,129may be configured to sense and/or move in response to tearing occurring. In some embodiments, other types of tear mechanisms that can sense tearing of the product can be utilized. In this regard, the first and second tear mechanisms124,129may be in communication with the controller110such that the controller110may determine when product is torn (such as during a dispense).

The product sensor(s)118(e.g., product level sensor(s)) is configured to sense product data (e.g., from the first and/or second product roll). In some embodiments, the product data may correspond to dispensing from at least one of the first product roll or the second product roll (e.g., how much product is being dispensed, when product is being dispensed, which product roll is dispensing occurring from, etc.). Additionally or alternatively, the product data may correspond to an amount of product remaining for at least one of the first product roll or the second product roll (e.g., a remaining size of the product roll, an amount of the product roll remaining, etc.). The product sensor118may be in communication with the controller110such that the controller110may receive the product data and perform one or more determinations regarding the product data (e.g., if one or more of the product rolls are substantially depleted, which product roll is dispensing, if there is leftover product in an exit chute, if there is a product jam, among others). Depending on the configuration of the product dispenser105and/or the desired information/product data, one or more product sensors118may be configured to sense data from the first product roll151, the second product roll156, and/or other components of the product dispenser105(e.g., the first and second tear mechanisms124,129, the first and second dispensing mechanisms121,126, etc.).

The controller110is a suitable electronic device capable of executing dispenser functionality via hardware and/or software control, with the preferred embodiment accepting data and instructions, executing the instructions to process the data, and presenting the results. Controller110may accept instructions through the user interface114, or through other means such as but not limited to the activation sensor120, other sensors, voice activation means, manually-operable selection and control means, radiated wavelength and electronic or electrical transfer. Therefore, the controller110can be, but is not limited to, a microprocessor, microcomputer, a minicomputer, an optical computer, a board computer, a complex instruction set computer, an ASIC (application specific integrated circuit), a reduced instruction set computer, an analog computer, a digital computer, a molecular computer, a quantum computer, a cellular computer, a solid-state computer, a single-board computer, a buffered computer, a computer network, a desktop computer, a laptop computer, a personal digital assistant (PDA) or a hybrid of any of the foregoing.

The controller110may be operably coupled with one or more components of the product dispenser105. Such operable coupling may include, but is not limited to, solid-core wiring, twisted pair wiring, coaxial cable, fiber optic cable, mechanical, wireless, radio, and infrared. Controller110may be configured to provide one or more operating signals to these components and to receive data from these components. Such communication can occur using a well-known computer communications protocol such as Inter-Integrated Circuit (I2C), Serial Peripheral Interface (SPI), System Management Bus (SMBus), Transmission Control Protocol/Internet Protocol (TCP/IP), RS-232, ModBus, or any other communications protocol suitable for the purposes disclosed herein.

The controller110may include one or more processors coupled to a memory device112. Controller110may optionally be connected to one or more input/output (I/O) controllers or data interface devices (not shown). The memory112may be any form of memory such as an EPROM (Erasable Programmable Read Only Memory) chip, a flash memory chip, a disk drive, or the like. As such, the memory112may store various data, protocols, instructions, computer program code, operational parameters, etc. In this regard, controller110may include operation control methods embodied in application code. These methods are embodied in computer instructions written to be executed by one or more processors, typically in the form of software. The software can be encoded in any language, including, but not limited to, machine language, assembly language, VHDL (Verilog Hardware Description Language), VHSIC HDL (Very High Speed IC Hardware Description Language), Fortran (formula translation), C, C++, Visual C++, Java, ALGOL (algorithmic language), BASIC (beginners all-purpose symbolic instruction code), visual BASIC, ActiveX, HTML (HyperText Markup Language), and any combination or derivative of at least one of the foregoing. Additionally, an operator can use an existing software application such as a spreadsheet or database and correlate various cells with the variables enumerated in the algorithms. Furthermore, the software can be independent of other software or dependent upon other software, such as in the form of integrated software.

In this regard, in some embodiments, the controller110may be configured to execute computer program code instructions to perform aspects of various embodiments of the present invention described herein. For example, the controller110may be configured to determine an instance in which one of the product rolls is substantially depleted. In such a regard, in some embodiments, the controller110may be configured to switch between operation of the first and second dispensing mechanisms121,126to ensure constant ability to dispense product—such as described in various example embodiments herein.

The user interface114may be configured to provide information and/or indications to a user. In some embodiments, the user interface114may comprise one or more light emitting diodes (LEDs) to indicate such information (e.g., low battery, dispensing is occurring, low product amount, transfer complete, etc.). In some embodiments, the user interface114may include a screen to display such information. In some embodiments, the user interface114may include an interface on the exterior of the product dispenser105such as for an end consumer. Additionally or alternatively, the user interface114(including a second user interface) may be configured to provide information or indications to a maintainer (e.g., maintenance personnel), such as internally of the cover of the product dispenser105.

In some embodiments, the user interface114may be configured to receive user input such as through a keypad, touchscreen, buttons, or other input device. The user interface114may be in communication with the controller110such that the controller110can operate the user interface114and/or receive instructions or information from the user interface114. In some embodiments, the user interface114may include an interface on the exterior of the product dispenser105such as for an end consumer. Additionally or alternatively, the user interface114(including a second user interface) may be internal of the cover of the product dispenser105, such as for a maintainer (e.g., maintenance personnel).

The communication interface113may be configured to enable connection to external systems (e.g., an external network102). In this manner, the controller110may retrieve data and/or instructions from or transmit data and/or instructions to a remote, external server via the external network102in addition to or as an alternative to the memory112.

In an example embodiment, the electrical energy (e.g., power116) for operating the product dispenser105may be provided by a battery, which may be comprised of one or more batteries arranged in series or in parallel to provide the desired energy. For example, the battery may comprise four 1.5-volt “D” cell batteries. Additionally or alternatively, the power116may be supplied by an external power source, such as an alternating current (“AC”) power source or a solar power source, or any other alternative power source as may be appropriate for an application. The AC power source may be any conventional power source, such as a 120V, 60 Hz wall outlets for example.

The other sensor(s)/system(s)115may be any other type of sensors or systems that are usable in various embodiments of the present invention. Some example additional sensors or systems include a position sensor, a time sensor, a cover opening or closing sensor, among many others.

As indicated herein, some embodiments of the present invention may be utilized with other types of product dispensers (such as mechanical product dispensers). Additional information regarding non-automated (mechanical) product dispensers, including components and functionality thereof, can be found in U.S. Pat. Nos. 7,270,292 and 5,441,189, both of which are assigned to the owner of the present invention and incorporated by reference in their entireties.

Embodiments of the present invention provide methods, apparatuses and computer program products for controlling and operating product dispensers according to various embodiments described herein. Various examples of the operations performed in accordance with embodiments of the present invention will now be provided with reference toFIGS. 86-90.

FIG. 86illustrates a flowchart according to an example method for controlling operation of a product dispenser to provide for automatic or assisted feeding according to an example embodiment4000. The operations illustrated in and described with respect toFIG. 86may, for example, be performed by, with the assistance of, and/or under the control of one or more of the controller110, memory112, communication interface113, user interface114, product sensor118, first or second dispensing mechanism121/126, first or second funnel sensor141/146, first or second chute sensor142/147, first or second tear mechanism124/129, activation sensor120, and/or other sensor(s)/system(s)115of the product dispenser105.

Operation4002may comprise receiving an indication from a funnel sensor that a leading edge of a product is proximate the dispensing nip of a dispensing mechanism. The controller110, memory112, communication interface113, and/or first or second funnel sensor141/146may, for example, provide means for performing operation4002. Operation4004may comprise causing operation of the motor for the drive roller of the dispensing nip. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4004. Operation4006may comprise receiving an indication from a chute sensor that a leading edge of a product is within the chute. The controller110, memory112, communication interface113, and/or first or second chute sensor142/147may, for example, provide means for performing operation4006. Operation4008may comprise causing operation of the motor to cease to end the automatic or assisted feeding operation to load the product roll into the dispensing mechanism. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4008.

FIG. 87illustrates a flowchart according to an example method for controlling operation of a product dispenser to provide for dispensing product according to a desired sheet length according to an example embodiment4100. The operations illustrated in and described with respect toFIG. 87may, for example, be performed by, with the assistance of, and/or under the control of one or more of the controller110, memory112, communication interface113, user interface114, product sensor118, first or second dispensing mechanism121/126, first or second funnel sensor141/146, first or second chute sensor142/147, first or second tear mechanism124/129, activation sensor120, and/or other sensor(s)/system(s)115of the product dispenser105.

Operation4102may comprise receiving a request to dispense the product. The controller110, memory112, communication interface113, and/or activation sensor120may, for example, provide means for performing operation4102. Operation4104may comprise causing operation of the motor to rotate the drive roller to begin a dispense. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4104. Operation4106may comprise counting motor rotations during operation. The controller110, memory112, communication interface113, and/or other sensor(s)/system(s)115may, for example, provide means for performing operation4106. Operation4108may comprise causing operation of the motor to cease when a certain number of motor rotations have occurred to dispense a desired sheet length of the product. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4108.

FIG. 88illustrates a flowchart according to an example method for controlling operation of a product dispenser to provide for dispensing product from the smaller product roll according to an example embodiment4200. The operations illustrated in and described with respect toFIG. 88may, for example, be performed by, with the assistance of, and/or under the control of one or more of the controller110, memory112, communication interface113, user interface114, product sensor118, first or second dispensing mechanism121/126, first or second funnel sensor141/146, first or second chute sensor142/147, first or second tear mechanism124/129, activation sensor120, and/or other sensor(s)/system(s)115of the product dispenser105.

Operation4202may comprise receiving a request to dispense the product. The controller110, memory112, communication interface113, and/or activation sensor120may, for example, provide means for performing operation4202. Operation4204may comprise determining an amount of fuel (e.g., product) remaining for a first product roll. The controller110, memory112, communication interface113, and/or product sensor118may, for example, provide means for performing operation4204. Operation4206may comprise determining an amount of fuel remaining for a second product roll. The controller110, memory112, communication interface113, and/or product sensor118may, for example, provide means for performing operation4206. Operation4208may comprise causing dispensing to occur from the product roll with the lesser amount of fuel remaining. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4208.

FIG. 89illustrates a flowchart according to an example method for controlling operation of a product dispenser to provide for dispensing product from the smaller product roll according to an example embodiment4300. The operations illustrated in and described with respect toFIG. 89may, for example, be performed by, with the assistance of, and/or under the control of one or more of the controller110, memory112, communication interface113, user interface114, product sensor118, first or second dispensing mechanism121/126, first or second funnel sensor141/146, first or second chute sensor142/147, first or second tear mechanism124/129, activation sensor120, and/or other sensor(s)/system(s)115of the product dispenser105.

Operation4302may comprise determining a time period for a rotation cycle of a first product roll. The controller110, memory112, communication interface113, product sensor118and/or other sensor(s)/system(s)115may, for example, provide means for performing operation4302. Operation4304may comprise determining a time period for a rotation cycle of a drive roller associated with the first product roll. The controller110, memory112, communication interface113, product sensor118and/or other sensor(s)/system(s)115may, for example, provide means for performing operation4304. Operation4306may comprise determining a time period for a rotation cycle of a second product roll. The controller110, memory112, communication interface113, product sensor118and/or other sensor(s)/system(s)115may, for example, provide means for performing operation4306. Operation4308may comprise determining a time period for a rotation cycle of a drive roller associated with the second product roll. The controller110, memory112, communication interface113, product sensor118and/or other sensor(s)/system(s)115may, for example, provide means for performing operation4308. Operation4310may comprise comparing a first ratio of the rotation cycle time period for the first product roll over the rotation cycle time period for the drive roller associated with the first product roll with a second ratio of the rotation cycle time period for the second product roll over the rotation cycle time period for the drive roller associated with the second product roll. The controller110, memory112, and/or communication interface113may, for example, provide means for performing operation4310.

Operation4312may comprise receiving a request to dispense the product. The controller110, memory112, communication interface113, and/or activation sensor120may, for example, provide means for performing operation4312. Operation4314may comprise causing dispensing to occur from the product roll associated with the smaller ratio. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4314.

FIG. 90illustrates a flowchart according to an example method for controlling operation of a product dispenser to provide for dispensing product from the next product roll according to an example embodiment4400. The operations illustrated in and described with respect toFIG. 90may, for example, be performed by, with the assistance of, and/or under the control of one or more of the controller110, memory112, communication interface113, user interface114, product sensor118, first or second dispensing mechanism121/126, first or second funnel sensor141/146, first or second chute sensor142/147, first or second tear mechanism124/129, activation sensor120, and/or other sensor(s)/system(s)115of the product dispenser105.

Operation4402may comprise receiving a request to dispense the product. The controller110, memory112, communication interface113, and/or activation sensor120may, for example, provide means for performing operation4402. Operation4404may comprise receiving an indication from a first funnel sensor associated with a first product roll that no product is present within the funnel. The controller110, memory112, communication interface113, and/or first or second funnel sensor141/146may, for example, provide means for performing operation4404. Operation4406may comprise causing dispensing to occur from a second product roll in response to receiving the indication. The controller110, memory112, communication interface113, and/or first or second dispensing mechanism121/126may, for example, provide means for performing operation4406.

FIGS. 86-90illustrate flowcharts of a system, method, and computer program product according to various example embodiments described herein. It will be understood that each block of the flowcharts, and combinations of blocks in the flowcharts, may be implemented by various means, such as hardware and/or a computer program product comprising one or more computer-readable mediums having computer readable program instructions stored thereon. For example, one or more of the procedures described herein may be embodied by computer program instructions of a computer program product. In this regard, the computer program product(s) which embody the procedures described herein may be stored by, for example, the memory112and executed by, for example, the controller110. As will be appreciated, any such computer program product may be loaded onto a computer or other programmable apparatus, such that the computer program product including the instructions which execute on the computer or other programmable apparatus creates means for implementing the functions specified in the flowcharts block(s). Further, the computer program product may comprise one or more non-transitory computer-readable mediums on which the computer program instructions may be stored such that the one or more computer-readable memories can direct a computer or other programmable device to cause a series of operations to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus implement the functions specified in the flowcharts block(s).

Associated systems and methods for manufacturing example product dispensers described herein are also contemplated by some embodiments of the present invention.

CONCLUSION