EARPLUG DISPENSER SYSTEM

Abstract: An apparatus is described which can receive a large number of earplugs from a box and dispense one or two of them at a time to a worker. The apparatus includes a wheel (22) which is rotatable on a frame (12) and which has holes (24) that move in a circular path and that can each receive a single earplug (16). As each hole moves over a dispense passage (18), the earplug in the hole can fall out, and be dispensed. A barrier (42, Fig. 4) lying above the wheel, prevents an earplug from falling into a hole that lies at the passage. The barrier covers only one side (52) of the path (32) of the holes, to allow a deformed earplug to move along the other, uncovered side (54) of the path. The wheel has a narrow slot (80) extending from each hole to the periphery, so a tool can be projected through a frame opening (84) and through the slot to dislodge an earplug stuck in a wheel hole. The wheel has an upward projection (102) with inclined guideways (104) that each guide an earplug into a wheel hole.

Description: EARPLUG DISPENSER SYSTEM BACKGROUND OF THE INVENTION: Workers in industrial plants may take a pair of disposable earplugs at a time from a box. If a worker picks up more than two earplugs, he may simply throw the additional ones away. Furthermore, if a worker has dirty hands, he may leave dirt on other earplugs and other workers will not want to use them. Another approach is to place each pair of earplugs in a separate plastic bag, but this adds cost and inconvenience. A dispenser which enabled "loose" earplugs to be used, with minimal wastage, would be of considerable value. SUMMARY OF THE INVENTION In accordance with one embodiment of the present invention, an earplug dispenser is provided which includes a wheel rotatable on a frame and having holes that each can hold a single earplug. As the wheel turns, and earplugs drop into the holes, each earplug is carried to a dispense location at which drops each earplug out of the hole. A barrier lies above an approach to the dispense location. The barrier can lie above only one side of the hole path, to allow a deformed earplug to pass along the unobstructed other side without being cut. The wheel preferably has narrow slots, each extending radially from its periphery to each hole. If an earplug is jammed in a hole, a person inserts a tool through an opening in the frame and through a slot to dislodge the jammed earplug. The earplug has a central upward projection with inclined guideways that each guides an earplug into a wheel hole. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is an isometric view of an earplug dispenser of the present invention. Fig. 2 is a sectional front view of the earplug of Fig. 1 , without the mounting brackets. Fig.3 is an exploded isometric view of the dispensing mechanism of the dispenser of Fig. 1. Fig. 4 is a view taken on the line 4 - 4 of Fig. 2. Fig. 5 is a sectional view taken on line 5 - 5 of Fig. 4, showing how the barrier rejects an extra earplug from a wheel hole. Fig. 6 is a sectional view taken on line 6 - 6 of Fig. 4, showing how the barrier accommodates a trapped earplug. DESCRIPTION OF THE PREFERRED EMBODIMENTS Fig. 1 illustrates an earplug dispenser 10 which includes a frame 12 that forms a bin 14 which holds earplugs 16. The earplugs are dispensed one at a time through a dispense passage 18, and through a funnel tube 20. A worker grasps the bottom 21 of the funnel tube with his hand to turn the funnel tube and catch a falling earplug. The tube 20 is fixed to a rotatabie wheel 22 that lies within the frame. The wheel has holes 24 that are each large enough to hold a single earplug. As the wheel turns, an earplug in a hole passes to a dispense location which lies over the dispense passage 18. The earplug drops out of the hole into the waiting hand of the worker. The frame 12 and tube 20 are constructed of transparent material to allow viewing of the dispensing mechanism. As shown in Fig. 3, the wheel 22 is rotatably mounted on the frame about an axis 30. The wheel holes 24 are equally spaced from the axis of rotation, and move in a circular path 32 as the wheel turns. The holes are of cylindrical shape, and the path 32 has the width W of the holes. A stationary retainer 34, which is part of the frame, lies adjacent to the lower surface 36 of the wheel to prevent earplugs from falling out of the wheel before they reach the dispense location 37. The retainer lies under the entire circular path of the . holes, except for a cutout 38 where it forms part of the dispense passage 18. A stationary barrier 42, which is also part of the frame, lies immediately above the upwardly-facing top surface 44 of the wheel, to sweep away any second earplug that lies partially in one of the holes above a first earplug that lies fully in the hole. The barrier also blocks the space above the dispense passage 18, to prevent a second earplug from falling into one of the holes as an earplug falls out of the hole at the dispense location 37 which lies above the dispense passage. Fig.5 shows how the leading edge 46 of the barrier 42 can sweep away a second earplug 16B which initially lies partially in a hole 24 above a first earplug 16A. It is assumed that the wheel 22 is moving in the direction of arrow 50. The earplug may be of the type described in U.S. Patent 4,774,938, wherein the earplug is of a soft foam material that is easily deformed but slowly returns to its original configuration. As shown in Fig. 4, the barrier 42 lies above a portion of a first side 52 of the hole path 32, while leaving at least a portion of the space immediately above the second side 54 of the hole path unobstructed. It is possible for a second earplug 16B (Fig. 5) to lie with its lower part 56 trapped in a wheel hole so it is forced to move along the hole path as the wheel turns. In that case, the upper part 58 of that earplug can be accommodated along the second side 54 of the path. Without the uncovered second path side, such a trapped earplug might be squeezed between corners 60, 62 of the wheel hole and of the barrier, and be cut or jam the dispenser. Fig. 6 shows the second earplug 16B with its lower end in the hole, and its middle only temporarily deformed and moving along the second side 54 of the path. The barrier has a recess 63 in its lower surface, except at its ends. The recess walls lie above the top of the wheel by more than 5 percent of the wheel hole height, to minimize deformation of a trapped earplug. The ends 64, 66 (Fig. 4) of the barrier are smoothly tapered at an angle A of between 30° and 60°. The middle edge 74 of the barrier is shown extending along the centeriine of the path. The moderate taper angle causes a trapped earplug to be deflected to the second side 54 of the path (or beyond), rather than be stopped at the barrier end and possibly be cut. The wheel has a plurality of largely radially extending slots 80, each extending from the periphery 82 of the wheel to one of the holes 24. Each slot is narrower than the width, or diameter, of the hole (as seen in a plan view), and narrower than an earplug to prevent an earplug from passing through the slot. The slot, at its narrowest, is preferably less than half the width of a wheel hole. If an earplug should become jammed in a hole, a person can project a tool, such as a key or screwdriver blade, through an opening 84 in the frame and through a slot 80, to move the earplug. The wheel 22 (Fig. 3) includes an upward projection 102 lying radially within the path of the wheel holes. The projection forms a plurality of inclined guideways 104 that are each positioned to guide an earplug in downwardly inclined motion Into a corresponding one of the wheel holes 24. This aids in filling each hole with an earplug, by helping to align the earplug so the axis 106 (Fig. 6) of the earplug tends to align with the vertical axis 108 of the hole. The bin 14 (Fig. 1) holds a removable box 110 that holds earplugs. The box is inserted into the frame top 112. A release device 124 of the box lies in a frame slot. The release device can be pulled out to release bottom box flaps so they can pivot down, so the earplugs can fall out into the bin 14. The dispenser 10 has a pair of flanges 130 to enable the frame to be mounted on a wall. The dispenser can be motor powered, with a motor turning the wheel until the two earplugs have dropped along the dispense passage to a holding station. Such a dispenser would include a sensor that detects the fall of two earplugs to then de-energize the motor, and another sensor which detects the removal of the two earplugs at the holding station to again energize the motor. Thus, the invention provides an earplug dispenser which facilitates the dispensing of earplugs. The dispenser includes a movable earplug-holding device which can be in the form of a belt or chain, but which is preferably a rotatable wheel having a plurality of holes that are each capable of holding a single earplug. The holes move in a circular hole path as the wheel turns, to bring each hole over a dispense passage of the dispenser frame, where an earplug drops out of a hole. A barrier of the frame lying above the wheel, preferably covers only one side of the hole path, and preferably has tapered ends. The wheel has radial slots leading to the holes to facilitate removal of a jammed earplug. The wheel has an upward projection forming inclined guideways that guide earplugs into the holes.

Claims: IN THE CLAIMS: 1. An earplug dispenser which includes a frame that forms a dispense passage, and an earplug-holding device that is movable on said frame and that has a plurality of holes that move in a hole path past a location above said dispense passage where earplugs can fall out of said holes into said passage, characterized by: a barrier which prevents an earplug from falling into one of said holes at said dispense location, said barrier lying above at least a portion of one side of said hole path while leaving at least a portion of the other side of the hole path unobstructed. 2. The earplug dispenser described in claim 1 wherein: said barrier has an end which extends, as seen in a plan view, at an angle A of no more than 60° to said path. 3. The earplug dispenser described in claim 1 wherein: said earplug holding device comprises a wheel having an axis and a periphery and being rotatably mounted on said frame, said wheel having a plurality of slots each extending from said wheel periphery to one of said wheel holes and having a narrowest width less than that of one of said holes as seen in a plan view, to prevent an earplug from falling out; said frame having an opening lying along the path of said slots as said wheel turns, which enables a person to project a tool through said opening and through one of said slots to dislodge an earplug from one of said wheel holes. 4. The earplug dispenser described in claim 1 wherein: said earplug-holding device has an upward projection lying beside said holes, said projection forming a plurality of inclined guideways each positioned to guide an earplug into a corresponding one of said holes. 5. The earplug dispenser described in claim 1 wherein: said barrier has a recess in its lower surface so its lower surface at said recess lies a distance above said earplug-holding device. 6. An earplug dispenser which includes a frame that forms a dispense passage, a wheel rotatably mounted about an axis on said frame and having a plurality of holes that move in a circular path past a dispense location above said dispense passage where earplugs can fall out of said holes into said passage, characterized by: said wheel has a periphery and has a plurality of slots each extending radially from said wheel periphery to one of said holes, to facilitate removal of earplugs lying in said holes, each of said slots having a narrowest width that is less than the width of one of said holes as seen in a view taken along said axis. 7. The earplug dispenser described in claim 6 wherein: said frame has an opening which lies at about the same height as said wheel and which can pass a tool from outside said frame into one of said wheel slots to dislodge a trapped earplug. 8. The earplug dispenser described in claim 6 including: a barrier which lies immediately above said wheel holes to block downward movement of an earplug into a hole lying at said dispense location, said barrier having an end lying along said hole path, with said end extending smoothly at an angle A of between about 30° and 60° to said path. 9. The earplug dispenser described in claim 6 wherein: said wheel includes a largely conical upward projection lying radially within the path of said holes, said projection forming a plurality of inclined grooves each positioned to guide an earplug into a corresponding one of said holes. 10. A method for dispensing one at a time, easily deformable earplugs of a predetermined earplug size, which includes rotatably mounting a wheel about an axis in a frame, where said wheel has a plurality of wheel holes lying on a imaginary circle centered on said axis, so said wheel holes move along a circular path as said wheel rotates, with each of said wheel holes being large enough to hold only a single complete one of said earplugs, and with said path having radially inner and outer sides, establishing a multiplicity of said earplugs above said wheel, establishing a barrier immediately above a part of said path to prevent earplugs from dropping through said barrier into wheel holes lying at said part of said path, while allowing earplugs to fall into said wheel holes at other locations along said path, establishing a retainer under said path except at said part of said path to leave a dispense passage thereat, and rotating said wheel while allowing earplugs to fall into said wheel holes at locations away from said barrier, and allowing one earplug at a time that lies in one of said wheel holes to fall out through said dispense passage, characterized by: said step of establishing a barrier includes establishing a barrier above at least a portion of one of said sides of said path part but not above all of the other side, to allow part of an earplug trapped in a wheel hole to move above said other side of said path. 11. The method described in claim 10 including: constructing said wheel with a periphery and with a plurality of slots each extending radially between said periphery and one of said slots, and constructing said frame with an opening that is largely in line with said wheel periphery; loosening an earplug that is struck in one of said holes by projecting a tool through said frame opening and through one of said slots into said one of said holes. 12. The method described in claim 10 including: forming said wheel with a largely conical projection within said imaginary circle, and with a plurality of inclined guideways each leading to one of said wheel holes; and allowing each of a plurality of earplugs to move along one of said guideways into one of said wheel holes.

Inventors: LEIGHT HOWARD S, LEIGHT, HOWARD, S.
Applicants: LEIGHT HOWARD S, LEIGHT, HOWARD, S.
Application year: 1993
Main classification: G07F11
IPC codes: A47F1, A61F15, G07F11