CORE-BUCKLING TISSUE DISPENSER AND DISPENSING METHOD

Abstract: A dispenser and dispensing method for flexible web material that is wound into a roll on a readily deformable hollow core (C) has a housing carrying opposed parallel guide tracks (22-24) to guidingly receive roll core supports (E,F) projecting from the roll ends and a spring biased lever (40) pivoted on such housing, the lever (40) applying an axial force to the hollow core (C) at one roll end and being maintained in a roll retaining condition by the presence, in a roll dispensing position, of a hollow roll core that is held against downward displacement from such position. An axial force (FR) is applied against the other end of the hollow core. The lever (40) serves to retain a reserve roll (R) in a reserve roll position remote from the roll dispensing position with the lever (40) being released from such retaining condition when the web material is exhausted and the hollow core (C) is deformed downwardly, assisted by the axial forces (FR) applied to the hollow core ends, to enable removal of this core (C) from the roll dispensing position whereupon such reserve roll (R) moves to the dispensing position.

Description: The invention concerns a method of dispensing flexible web material from rolls according to the introductory part of claim 1. The invention further concerns a dispenser of rolls for flexible web material wound into a roll on a readily deformable hollow core according to the introductory part of claim 5. A corresponding method and dispenser are known from the European patent application EP-A 0 146 793. The features known from this publication ascertain that the empty core sections which made up the intact roll core will always drop out automatically whether or not a reserve roll is present elsewhere within the dispenser. Occasionally the automatically dropped empty core sections cause inconveniences and even can be dangerous when they lie around on the floor. Even when the paper web is glued to one of the core sections at the start of the winding roll, the removal of the core is carried out automatically and, again, at least one core section will fall around and land on the floor. It is the object of this invention to remove the hollow core that is retained against displacement within a roll dispensing position until manually deformed. For fulfilling this object the invention proposes the characterizing parts of claims 1 and 5 respectively. Once the hollow core is exposed by exhausting web material from the first roll then the exposed hollow core is physically deformed downwardly, assisted by the axial forces applied to the upper portions of the ends of the first roll hollow core, thereby enabling removal of this core from the dispensing position. The act of physically deforming and removing the exposed hollow core from the dispensing position thereupon releases the second roll which has been retained in a reserve roll position by reason of the presence of the hollow core at the dispensing position with the reserve roll then moving to the dispensing position. A spring biasing means is mounted on the housing disposed to apply the above mentioned axial force against an upper portion of one end of the hollow core of a roll at the dispensing position. According to a development of the invention a lever is pivotally mounted on the housing having a lower end to detect the presence of a hollow roll core. The upper end of this lever is disposed to obstruct one of the parallel tracks, obstructing it adjacent the upper end of the housing when the presence of the hollow roll core is detected by the lower end. The upper end then acts to retain a reserve roll in the reserve roll position as long as the hollow core of the roll in the roll dispensing position is detected. Further, the lever is spring biased so that the lower end of the lever applies an axial force against an upper portion of the upper end of the hollow core of a roll at the dispensing position. When the lower end of the lever moves inwardly from the dispensing housing side wall on which it is mounted, such event occuring only upon physically deforming the hollow core downwardly assisted by the axial force applied to the upper portion of the hollow core ends and removal of the hollow core from the dispensing position, the lever means shifts such that the reserve roll is released and the parallel tracks guide movement of the reserve roll down to the dispensing position. The invention provides a dispenser for multiple rolls of flexible sheet material wound on readily deformable hollow cores wherein first and second rolls are maintained out of contact within the dispenser by lever means that is released only by physically deforming the hollow core, assisted by axial forces applied to the upper portions of the hollow core ends, thereby enabling removal of the hollow core that is retained against displacement within a roll dispensing position until manually deformed. A prefered embodiment of the invention is now described in detail which is shown on the accompanying drawings. In these drawings figure 1 is a perspective view showing the dispenser housing in accordance with the invention having operating components mounted thereon with the conventional dispenser cover removed. Figure 2 is a sectional view showing a roll entering the upper end of the housing with the parts at the dispensing position in readyness to receive the roll. Figure 3 is a sectional view showing a roll in section in the dispensing position and a reserve roll retained in the reserve roll position. Figure 4 is a sectional view similar to figure 3 showing an empty hollow roll core in the dispensing position indicating the forces operating to effect physically deformed removal of the hollow core. Figure 5 is a sectional view showing a full roll in the dispensing position. Figure 6 is a sectional view showing a modified form of readily deformable hollow core from that illustrated in Figure 4. In describing the dispenser 10 for rolls of wound flexible web material as it is shown on the drawings, and particularly Figure 1, it should be pointed out that to facilitate illustrating structural features of the invention the usual cover that would conventionally be provided has not been shown on the drawings. Reference may be made to Jespersen Patent No. 3,437,388 for an exemplification of how a conventional cover completing the dispenser cabinet may be pivotally mounted in relation to the housing 12 forming the chassis for the working components of the dispenser. With reference to the terminology employed herein, it is to be understood that in referring to rolls of flexible web material wound on readily deformable hollow cores it is intended that the term readily deformable hollow core be construed to include a tubular or cylindrical core made of light weight paperboard such as shown in Figure 6 so as to be readily deformable or of a core construction as shown in section on Figure 3 wherein the core intermediate its ends is scored or otherwise weakened to make it readily deformable. The flexible material in the form of toilet paper is conventionally wound on this readily deformable hollow core together with end caps which may be molded of plastic and inserted into the tubular core to provide the roll core support spindles projecting outwardly from the end of the core within the roll. Referring to Figure 1 on the drawings in describing the dispenser 10, the housing 12 provides a first side wall 14, a second side wall 16 and a back wall 18. It will be understood that in use of dispenser 10 the housing 12 forming the chassis for the working components of the dispenser will be approximately mounted on a wall at the desired location for dispenser use. Thus, the back 18 of housing 12 will be provided with appropriate openings (not shown) to accommodate the fasteners employed in affixing dispenser 10 to the desired wall location. As has been mentioned above, the conventional cover which along with housing 12 completes the dispenser cabinet is not shown. Side walls 14 and 16 are provided with aligned holes 20, these holes serving as pivot points to mount the dispenser cover such as suggested in the dispenser of Jespersen Patent No. 3,437,388. Side wall 14 of housing 12 is provided with an inwardly facing channel 22. Likewise, the opposite side wall 16 is provided with an inwardly facing channel 24. As may be best visualized from Figures 3 and 4, this pair of inwardly facing channels 22 and 24 serves to guidingly receive the spindles which form part of the roll core and serve as the roll core supports where they project from the opposite ends of the rolls when the rolls are loaded into dispenser 10. Preferably the channels 22 and 24 are of different widths to accommodate different diameter spindles forming the roll core supports for the rolls that are loaded into dispenser 10. These different width channels mate with different diameter roll core support spindles to insure the proper unwinding direction and roll orientation in loading the rolls into dispenser 10. However, in the structure of dispenser 10 where the pair of rolls loaded into the dispenser are maintained out of contact with each other in the manner which will be explained, the particular direction of winding or unwinding of the rolls used in the dispenser is not totally critical to dispenser operation. In any event, the feature of different width guide tracks accommodating different diameter roll core supports spindles is known and discussed in the above mentioned Jespersen Patent No. 3,437,388. Each of the guide track channels 22 and 24 in the side walls 14 and 16 of housing 12 is provided at its lower end with a saddle member, this member being numbered 26 at the bottom of channel 22 and 28 at the lower end of channel 24. It may be noted that the bottom of housing 12 is open at 30 such that the roll D retained in the roll dispensing position at the bottom of dispenser 10 projects downwardly through open bottom 30 as shown on Figures 3 and 5 for the web material on roll D to be accessible from dispenser 10 to the intending user. Referring to Figure 3, the make up of roll D may be described as exemplifying the type of rolls of flexible web material contemplated for dispensing in the dispenser 10 of this invention. Thus, roll D has the flexible web material wound on a tubular hollow roll core C. In the form of roll core illustrated on Figures 3 and 4, the core C is rendered readily deformable by having a series of spaced circumferential score lines S formed intermediate the ends of the core. It will be understood that other weakening techniques may be employed to render the core readily deformable once the wound web material initially carried on the core has been exhausted. Another form of readily deformable hollow core C′ is illustrated in Figure 6. In the type of core C′ the core is formed from a light weight material such that the forces applied to the core as described hereinafter to enable easy removal of the hollow core are sufficient to physically deform the core without the necessity for weakening scores S such as shown in the readily deformable core on Figures 3 and 4. In the form of roll core illustrated, the roll core supports for either core C or C′ are provided by an end cap E inserted in the outer end of the tubular hollow core and an end cap F inserted in the tubular hollow core at the opposite end. It will be seen from Figure 3 how the core support spindle of end cap E engages in the saddle member 26 at the bottom of channel 22 and the core support spindle of end cap F engages in the saddle member 28 at the bottom of channel 24 to support roll D in the roll dispensing position within the housing 12 of dispenser 10. As so supported, the toilet paper material on roll D projects down through the open bottom 30 of housing 12. As illustrated on the drawings, the open bottom 30 is defined within the side walls 14 and 16, and back wall 18 of housing 12, these walls extending down beneath saddle members 26 and 28. Generally, with the dispenser cover (not shown) in place, the cover in association with the housing 12 might take the configuration shown in the above discussed Jespersen Patent No. 3,437,388. With such a configuration the toilet paper material on roll D is exposed through the open bottom 30 of dispenser 10. It will be understood that the roll R partially shown on Figures 3 and 4 as it is retained in a reserve roll position within housing 12 would have a similar make up to the make up that is hereinabove described with reference to roll D. The operating control for the dispenser 10 as between the two rolls D and R loaded into the housing 12 is provided by a control lever 40. This lever is pivotally mounted in channel 22 of side wall 14 on pivot pin 42. This pivotal mounting enables pin 42 to simply pass through the sides of channel 22 to effect the desired mounting of control lever 40. Lever 40 has a lower sensing end 44 which serves to sense the presence of a hollow roll core C. As will be explained, this lower end also applies an axial force F L (Figure 4) to the upper portion of the end of the hollow core C. This sensing of a hollow roll core such as that of roll D as shown on Figure 3 occurs when this first roll is retained at the roll dispensing position within housing 12. An upper support end 46 on pivotally mounted lever 40 serves to retain a second roll R in the reserve roll position within housing 12 such as roll R also shown on Figure 3. A leaf spring 48 which may be rivoted at 50 to the outer wall of channel 22 serves to bias control lever 40 toward the position as shown in Figure 2. This biasing force of spring 48 thus urges the sensing end 44 of lever 40 toward the roll dispensing position within housing 12. It consequently urges support end 46 of lever 40 away from the reserve roll position within housing 12 also as shown on Figure 2. More importantly the biasing force of leaf spring 48 applies the force F L to the upper portion of one end of the hollow core C. The upper support end of control lever 40 is formed with a reverse bend in the embodiment shown such as to provide a surface 56 which is inwardly inclined relative to the plane of the first side wall 14 of housing 12. This inclined surface 56 physically engages with the roll core support spindle such as shown in Figures 3 and 4 with reference to roll R retained in the reserve roll position within housing 12 of dispenser 10. As will be apparent from the showing on these figures, the inward inclination of surface 56 on the upper support end 46 of lever 40 tends to utilize the weight of roll R acting down on the spindle resting on inclined surface 56 in a manner tending to urge lever 40 and its upper support end 46 outwardly from blocking track 22. Thus the weight of roll R promotes the action of the lower end 44 of lever 40 in pressing inwardly against the upper portion of the end of core C thereby providing an added biasing force against core C tending to buckle the readily deformable core upon exhaustion of web material. The second side wall 16 of housing 12 is provided with a spring biased latch 60 which may be riveted at 62 to the outer wall of channel 24 for this latch 60 to lie within channel 24. The spring biased latch 60 has its lower end 64 spaced above saddle member 28 at the bottom of channel 24. Thus it is spaced sufficiently above such saddle member that the spindle of end cap F on the hollow core C may freely rest on saddle member 28 beneath the end 64 of latch 60 as shown on Figures 3 and 4. It will be understood that as the spindle of end cap F moves down along the guide track channel 24 this spindle will act to depress latch 60 until it moves beneath the latch end 64. In this position reverse movement along the guide track 24 is blocked by latch 60. This blocking action serves to prevent the right end of roll D (as seen on Figure 3) from being raised up within housing 12 of the dispenser thus preventing pilferage of full or partial toilet paper rolls from the dispenser 10. It will be recognized that the left end of roll D is likewise prevented from being raise back up within channel 22 by the lower sensing end 44 of lever 40 overlying the spindle on end cap E, again as shown in Figures 3 and 4. The second side wall 16 of housing 12 is also provided with a biasing leaf spring 70. This spring may have its upper end suitably riveted at 72 to side wall 16. Spring 70 is positioned adjacent the roll dispensing position within housing 12 to project inwardly and perform two functions. Initially, with a full roll D such as shown in Figure 3 spring 70 applies a frictional resistance to one end of the roll which is retained in the roll dispensing position. This function of the spring 70 acts to retard rotation of roll D or the roll disposed in the dispensing position so that it does not freely revolve or spin as web material, such as toilet paper, is withdrawn from dispenser 10 by the intending user. Importantly, leaf spring 70 applies an axial force against the upper portion of one end of the hollow roll core C, this force being identified F R on Figure 4. Operation of the dispenser 10 as hereinabove described may now be explained. In Figure 1 the dispenser housing 12 is shown in its empty or unloaded condition. The sectional view of Figure 2 shows the initial or first roll D as it is being loaded with its core support spindles (not shown) guidingly engaging with the track channels 22 and 24 as the roll passes down into the dispensing position at the lower end of housing 12. In Figure 3, roll D is shown with its support spindles on the hollow core C resting on the saddle members 26 and 28 of channels 22 and 24, respectively. In this position, roll D has the material thereof exposed through the open bottom 30 of housing 12 for ready access to the intending user. Further in Figure 3, the second or reserve roll R has been loaded into the housing by its spindles being entered into the upper ends of channels 22 and 24, respectively. But, the presence of roll D as it passed down into the dispensing position location has shifted lever 40 such that the upper support end 46 of such lever has been moved into channel 22 to form a stop within channel 22. As shown on Figure 3 the left spindle of roll R has come into engagement with this stop by the spindle resting on the inclined surface 56 of upper support end 46 of lever 40. It will be recognized that the biasing spring 70, as best seen on Figure 1 has been compressed by the downward movement of roll D such that spring 70 is applying frictional resistance to retard free rotation of roll D. Likewise the downward movement of the spindles of roll D into engagement with saddle members 26 and 28 has caused the spindle on end cap F to pass beneath the latch end 64 on spring biased latch 60. Accordingly, with the roll sensing end 44 of lever 40 overlying the left spindle on roll D and the end 64 of spring biased latch 60 overlying the right spindle of roll D, any attempt to raise the roll D is effectively blocked by these two elements overlying the core support spindles on the opposite ends of roll D. The above described condition of rolls D and R as shown on Figure 3 where they are both retained in their respective dispensing and reserve roll positions will continue while utilization of web material from roll D is taking place by the toilet paper web being withdrawn by intending users. Also during the use of web material from roll D the control lever 40, especially under the biasing force of spring 48 will be continuously sensing the hollow roll core C. Thus, the second roll R in the reserve roll position is continuously retained in this position during the sensing of hollow roll core C. As will be seen from Figure 3, the diameter of rolls R and D in relation to the length of lever 40, where such lever extends above its pivot pin 42, is such as to maintain these full rolls R and D out of contact with each other. Thus, with this particular full size roll and length of pivotally mounted lever 40, rolls R and D will be continuously maintained out of contact with each other as web material is being withdrawn from roll D. The sensing of the hollow core C of roll D is thus employed to continue retention of roll R in the reserve roll position with the two rolls out of contact with each other at least when the core of roll D approaches becoming empty so that in this latter stage of exhausting roll D there is no friction between the reserve roll R and roll D. The important concept is that sensing of the intact core of roll D be utilized to continue retention of roll R in the reserve roll position and at least retain the two rolls out of contact with each other during the stage when roll D nears exhaustion of its web material. When the web material is fully withdrawn and roll D becomes exhausted the condition shown on Figure 4 exists. At this time, the reserve roll or second roll R is still retained in the reserve roll position at the upper end of housing 12. However, the lower sensing end of 44 of lever 40 as it presses axially against the upper portion of the end of hollow roll core C urges buckling of the core upon occurrence of exhaustion of web material from hollow core C. The forces acting on the readily deformable hollow core C may best be described by reference to Figure 4 and the reference characters displayed thereon. The full roll D has the spindles of its core end caps E and F supporting the roll wound on hollow core C resting in the saddles 26 and 28, respectively. As shown in Figure 3, when the web material making up roll D becomes exhausted the weight of core C and its end caps E and F is still resting on the saddles 26 and 28 as shown in Figure 4. Thus, there are reaction forces R L and R R acting along the lines of the arrows shown at the left and right where the spindles contact the saddles. At the same time axial forces are being applied to the upper portion of the opposite ends of core C by the lower end 44 of spring biased lever 40 and the leaf spring 70 on the other side of the dispenser cabinet 12. These axial forces are represented by the arrows F L and F R on Figure 4. These axial forces applied from the left and right identified F L and F R in and of themselves tend to buckle the core C downwardly by their being applied to the upper portions of the opposite core ends. This downward buckling of core C is further promoted by the force F L generating a twisting moment about the contact point where the spindle of end cap E engages with saddle member 26 resisted by the reaction force R L . Similarly, the force F R acting against the opposite end of the core C produces a twisting moment about the contact point of the spindle of end cap F resisted by the reaction force R R . These two twisting or turning moments applied at the opposite ends of the hollow core C further promote downward buckling of the readily deformable core C. Thus, when web material is exhausted from core C so that such material is not present to strenghten the readily deformable core, a slight downward assisting pressure W applied manually as depicted on Figure 4 enables easy removal of core C from being held in saddles 26 and 28 at the dispensing position within dispenser 10. Summarized, still referring to Figure 4, the axial forces F L and F R place the upper surface of core C under compression thereby tending to buckle it. Additionally the turning moments between F L and R L , and F R and R R at each end tend to twist the buckled core downwards and out of the dispenser when a minimal force W is applied to the upper surface of core C, thereby making easy removal of the core and its end caps E and F. Thereupon the hollow core C disengages from the track channels 22 and 24 and their saddle members 26 and 28, falling out of the bottom 30 of dispenser housing 12. This frees lever 40, especially under the urging of leaf spring 48, to move to a position as shown in Figure 2. Such movement of the lever 40 shifts the sensing end 44 into the roll dispensing position area and likewise shifts and support end 46 of lever 40 away from the reserve roll position area thereby opening track guide channel 22 such that the spindles of roll R are now freed for this roll to move down into the dispensing position at the bottom of housing 12. This condition for roll R is shown on Figure 5. From this figure it will be noted that the lever 40 has again been shifted by its lower sensing end 44 detecting the hollow core C within roll R. This shifting of lever 40 again moves the upper support end 46 of lever 40 into a position to block track channel 22. Thereafter, in loading a new roll into the dispensing housing 12, by entering its outwardly projecting roll core support spindles into the opposite channels 22 and 24, this new roll can only pass down these channels to a point where one of its spindles encounters the upper support end 46 of lever 40 which is blocking the channel 22. Again this new roll will be held in reserve until such time as the roll located in the roll dispensing position resting on the saddle members 26 and 28 has been exhausted. Upon exhaustion of material from this latter roll, the buckling forces acting on the opposite ends of the readily deformable core C, assisted by a minor downward pressure W, will physically deform the core C for its removal from the track channels and saddle members. While the foregoing is believed to constitute a complete description of a preferred embodiment of the invention, it is to be recognized that various modification, changes, alterations, etc. may well appear to those skilled in the art. Therefore, the invention is not considered to be limited by the specifics of the disclosed embodiment, but rather to be embrasive of all subject matter falling within the terms of the hereinafter appended claims.

Claims: A method of dispensing flexible web material from rolls (D) that are wound on readily deformable hollow cores (C) comprising the steps of: holding a first roll (D) at a roll dispensing position against displacement from said position, utilizing the presence of said hollow core (C) at said dispensing position to retain a second roll (R) of flexible web material at a reserve roll position, applying axial forces to the upper portions of the ends of said hollow core (C), removing said hollow core (C) upon exhaustion of said web material from said first roll (D), releasing said second roll (R) from said reserve roll position for movement to said dispensing position upon said removal of said hollow core (C), characterized by the steps of: circumferentially weakening at least one portion of said hollow core (C) intermediate said core ends and physically deforming said hollow core (C) downwardly assisted by said axial forces and a minor downward pressure by a user. A method according to claim 1, comprising the further steps of retarding rotation of said first roll (D) in said roll dispensing position by one of the axial forces before the complete exhaustion of said web material from said first roll (D). A method according to claim 1 or 2, wherein said holding a first roll (D) and retaining a second roll (R) includes maintaining said first and second rolls (D, R) out of contact with each other. A method according to claim 3, wherein releasing said second roll (R) for movement to said dispensing position includes supporting said second roll (R) for guided movement from said reserve roll position to said roll dispensing position. A dispenser (10) for rolls (D, R) of flexible web material wound into a roll on a readily deformable hollow core (C) comprising an upstanding housing (12) providing opposed parallel track means (22, 24) extending upwardly from a roll dispensing position to an upper reserve roll position within said housing (12) to guidingly receive roll core supports (E, F) projecting from opposite ends of each hollow roll core (C), upwardly facing saddle means (26, 28) closing the lower end of each track means (22, 24) at said roll dispensing position to hold the core supports (E, F) of a dispensing roll (D) against downward displacement from said dispensing position, lever means (40) pivotally mounted on said housing (12) having a lower end (44) disposed to detect the presence of the hollow core (C) of a roll (D) at said roll dispensing position and an upper end (46) disposed to obstruct at least one of said track means (22, 24) adjacent the upper end of said housing (12) when the presence of such hollow core (C) is detected, said upper end (46) acting to retain a reserve roll (R) in said reserve roll position when said lower end (44) detects the hollow core (C) of a roll (D) in said roll dispensing position, spring means (48) biasing said lower end of said lever (40) to apply an axial force against an upper end portion of one end of the hollow core (C) of a roll (D) at said roll dispensing position, said lower end (44) shifting inwardly of said housing (12) when the hollow core (C) is removed whereupon the reserve roll (R) is released and said parallel track means (22, 24) guide movement of the reserve roll (R) to said dispensing position, characterized by: biasing means (70) mounted on said housing (12) disposed to apply an axial force against an upper portion of the other end of the hollow core (10) of a roll (D) at said roll dispensing position and weakening means (S) at at least one portion of said hollow core (C) intermediate said core ends, respectively a light-weight material for the core (C') to provide said readily deformable structure of said hollow core (C) that will only be physically deformed by an external force. A dispenser according to claim 5 wherein said lever means (40) includes a pivot in one of said track means (22, 24), a lever (40) mounted on said pivot, said pivot being disposed intermediate said lower and upper ends (44, 46) of said lever (40), and said biasing means (70) is provided by a spring mounted adjacent the other of said opposed parallel track means (22, 24). A dispenser according to claim 6 wherein said spring (70) is provided by a leaf spring having one end fixedly mounted adjacent said other track means (24) and the other end projecting out to press against the upper portion of one end of the hollow core (C) of a roll (D) at said dispensing position. A dispenser according to claim 5, 6 or 7 wherein said parallel track means (22, 24) are provided by a pair of inwardly facing channels and said saddle means (26, 28) are provided by semi-circular walls closing the lower end of said channels.

Inventors: DELUCA, RAYMOND F., JESPERSEN, PAUL W.
Applicants: GEORGIA-PACIFIC CORPORATION
Application year: 1987
Main classification: A47K10
IPC codes: A47K10