Abstract:
A wound film dispenser with exterior retainer and method of assembling same are disclosed. The wound film dispenser includes a base to which a lid is hingedly attached via a fold. The interior end walls of the base include false walls which are biased into the base. The false walls include aperture through which the ends of the roll extend to at least partially receive the ends of the roll of wound film material. In so doing, the retainers are provided exterior to the roll of film. The false walls may be biased into the base using braces pushing the top edge of the false wall away from the end walls.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This is a divisional patent application of U.S. patent application Ser. No. 09/993,309 filed on Nov. 6, 2001, now U.S. Pat. No. 6,935,501, issued on Aug. 30, 2005, which is a continuation-in-part of U.S. patent application Ser. No. 09/711,017, filed on Nov. 13, 2000, now U.S. Pat. No. 6,564,942, issued on May 20, 2003. 

   FIELD OF THE INVENTION 
   The invention generally relates to dispensers and, more particularly, relates to dispensers for use in conjunction with wound films such as plastic wrap, aluminum foil, wax paper, and the like. 
   BACKGROUND OF THE INVENTION 
   Cartons for the storage and dispersal of rolls of wound flexible film are well-known. Such cartons are typically manufactured from paperboard material and are folded into a configuration conventionally referred to as a trunk-lid box wherein a base or box of the carton forms an enclosure for the roll with an open top, and the lid is folded relative to the trunk at a natural hinge to thereby allow the lid to close the trunk. 
   A number of criteria need to be considered when manufacturing such a carton. One concern is the ease with which the material can be drawn from the roll. This criteria is a function of a number of variables including the type of material wound onto the roll, the manner in which the roll is positioned or placed within the carton, and the angle at which the material must be pulled from the carton. For example, if the material is highly adhesive in nature, it may tend to adhere to itself thereby requiring a relatively high level of force to pull the material from the roll. Depending upon the degree of tack of the film, and the angle at which the material is pulled from the carton, the roll itself may tend to be pulled completely out of the carton, creating a source of frustration for the user. Morever, once the roll is pulled from the carton, the risk of contamination of the film is increased. 
   Mechanisms have therefore been devised which perform a retention feature within the carton. In other words, the roll itself may be physically held within the carton such that upon a user pulling on the film, the roll is held against the force created by the user, while still enabling the roll to rotate and thereby dispense film. For example, U.S. Pat. No. 4,998,656, assigned to the present assignee, discloses a roll restraining dispensing carton wherein the opposite ends of the carton include collars for retaining the roll within the carton. The collars include apertures which circumnavigate the ends of the roll to thereby physically hold the roll within the carton, and also provide a bearing surface around which the roll may rotate. 
   While such cartons have proven to be successful, it would be advantageous to continue to improve roll retention and dispensing capabilities. Moreover, since such cartons are typically manufactured and loaded with rolls of wound film in an automated process, it would be advantageous to improve the ease with which the carton is manufactured as well. 
   SUMMARY OF THE INVENTION 
   In accordance with one aspect of the invention, a wound film dispenser is provided which comprises a base, a lid, and retention walls. The base includes bottom, left, right, front, and back walls, and an open top defining an interior channel. The lid is hingedly attached to the base. The retention walls are mounted in the first and second ends of the base and each include an aperture adapted to receive an end of the roll of wound film. The retention walls are each non-parallel to the end walls. 
   In accordance with another aspect of the invention, a wound film dispenser is provided which comprises a base, a cover hinged to the base, a roll of wound film within the base, and means for retaining the roll within the base. The means includes false walls biased into the base. 
   In accordance with another aspect of the invention, a method of assembling a wound film dispenser is provided comprising the steps of folding a section of die-cut material into a tube, inserting a roll of wound film into the tube, folding false walls into the tube, and folding at least one flap against each of the false walls. The tube includes first and second open ends, a top surface, a bottom surface, a front surface, and a back surface. The false walls include apertures receiving ends of the wall, as well as braces engaging the flaps and biasing the false walls into the tube. 
   These and other aspects and features of the invention will become more apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric view of a wound film dispenser constructed in accordance with the teachings of the invention, with a roll of wound film held therein; 
       FIG. 2  is an isometric view of the wound film dispenser of  FIG. 1 , but without a roll of wound film disposed therein; 
       FIG. 3  is a longitudinal sectional view of the film dispenser of  FIG. 1  taken along line  3 — 3  of  FIG. 1  with the roll of film shown in partially cut-away form; 
       FIG. 4  is an enlarged cut-away top view of the dispenser of  FIG. 1 ; 
       FIG. 5  is a plan view of a die-cut blank prior to folding according to the teachings of the invention; 
       FIG. 6  is a flow chart depicting a sample sequence of steps which may be employed to construct a wound film dispenser constructed in accordance with the teachings of the invention; 
       FIG. 7  is an isometric view of an alternative roll film dispenser constructed in accordance with the teachings of the invention and shown with a roll of wound film disposed therein; 
       FIG. 8  is a longitudinal sectional view of the dispenser of  FIG. 8  taken along line  8 — 8  of  FIG. 7 , with the roll of film shown in partially cut-away form; 
       FIG. 9  is an enlarged cut-away top view of the dispenser of  FIG. 8 ; and 
       FIG. 10  is a plan view of a die-cut blank prior to folding according to the teachings of the invention. 
   

   While the invention is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined by the appended claims. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring now to the drawings, and with specific reference to  FIG. 1 , a film dispenser constructed in accordance with the teachings of the invention is generally depicted by reference numeral  20 . As shown therein, the film dispenser  20  includes a base  22  to which a lid  24  is naturally hinged at a fold  26 . The base  22  defines an interior channel  28  in which a roll  30  of wound web material  32  is positioned. In the preferred embodiment, the base  22  and lid  24  are manufactured from an integral piece of material such as paperboard, chipboard, cardboard, corrugated board, micro-fluted board, or the like, and is folded and joined in a series of consecutive steps as will be described in further detail herein to form the film dispenser  20 . In one preferred embodiment, the material may be provided in the form of twenty-four point single ply chipboard, but other materials, including chipboard having a lesser point count, are certainly possible. 
   With reference now to  FIGS. 2–5 , the carton  20  is depicted both with and without a roll  30  provided therein. The base  22  includes a bottom wall  34 , a front wall  36 , a back wall  38  and first and second ends  40 ,  42 . The lid  24  includes a top wall  44 , a front wall  46 , and first and second ends  48 ,  50 . The roll  30  includes a core  52  ( FIG. 3 ) around which is wound the web of film  32 . Film  32  may be, but is not limited to plastic wrap, aluminum foil, wax paper and the like. A cutter bar  43  may be provided anywhere on dispenser  20  for severing wrap  32 , such as on bottom wall  34 , or preferably on an inside surface of the lid front wall  46 . 
   As shown in  FIGS. 3 and 4 , each of the ends  40 ,  42  of the base  22  includes a retainer  56  adapted to retain the roll  30  within the dispenser  20 . More specifically, the retainers  56  at least partially surround first and second ends  58 ,  60  of the core  52  to physically hold the roll  30  in the dispenser  20 . The retainers  56  do so with, among other things, reduced material requirements as compared to prior dispensers. 
   In one embodiment, the retainer  56  may be provided in the form of a false wall  62  angled into the interior channel  28 .  FIG. 3  indicates that the false wall  62  is biased into the interior channel  28  at an angle ∝ relative to the ends  40 ,  42 , but it is to be understood that alternative embodiments may angle the false wall  62  differently, or from different surfaces within the dispenser  20  including, but not limited to, the back wall  38 . 
   In the depicted embodiment, the false wall  62  extends from a base section  63  ( FIG. 5 ) hinged to the bottom wall  34  of the base  22  and is angularly biased inwardly by a brace  64 . The brace  64  extends from a back edge  66  of the false wall  62 . The brace  64  is substantially wedge-shaped including a top edge  68 , a tapered side edge  70  and a straight edge  72 . While the brace  64  is indicated to be proximate the back wall  38 , it is to be understood that in alternative embodiments, the brace  64  could be provided, for example, proximate the front wall  36  as well. The brace  64  is preferably not adhered to the back wall  38 , but rather relies on the outward bias afforded by the roll  30 , forcing the straight edge  72  into engagement with the first and second ends  40 ,  42  of the base  22 . Given the angle of the tapered edge  66 , the false wall  62  is angled in an identical fashion. In alternative embodiments, the brace  64  and/or false wall  62  may be adhered into an angled position. 
   As shown best in  FIGS. 4 and 5 , the false wall  62  further includes an aperture  76 . In the depicted embodiment, the aperture  76  is substantially semi-circular in shape and is adapted to receive the first and second ends  58 ,  60  of the core  52 . As shown in  FIG. 3 , the apertures  76  do not receive the entire ends  58  and  60  of the core  52 , but rather only partially receive the core  52  therethrough. Alternatively, if the false walls  62  and/or dispenser  20  are enlarged, and the core  52  lengthened, the ends  58 ,  60  may be entirely received within the false walls  62 . 
     FIG. 4  further depicts the multiple end flaps of the dispenser  20  completing the end walls  40 ,  42 . With regard to the base  22 , a major flap  80  extends from each end of the back wall  38 , while a minor flap  82  extends from each end of the front wall  36 . It is to be understood that the major and minor flaps  80 ,  82  may be attached to opposite walls, may be provided in opposite dimension, or may be provided in similar dimension. Similarly, with respect to the lid  24 , a major flap  84  extends from each end of the top wall  44 , while a minor flap  86  extends from each end of the front wall  46 . 
   Completing the sections of the dispenser  20 , it will be noted that a tear strip  88  is attached along a score line  90  to an outer edge  92  of the lid front wall  46 . As will be discussed in further detail herein, during assembly the dispenser  20  is formed by folding a blank  94  ( FIG. 5 ) into a tube and securing the tear strip  88  to the trunk front wall  36 . Adhesive may be applied to plurality of scored areas  96  to not only secure the dispenser  20 , but facilitate removal of the tear strip  88  when desired without defacing the remainder of the dispenser  20 . 
   In assembling wound film dispensers according to the teachings of the invention, a number of steps may be employed. One exemplary set of steps is depicted in  FIG. 6  in flow chart format. As shown therein, a first step  98  may be to die-cut the blank  94  as depicted in  FIG. 5 . A second step  100  may be to fold the blank  94  into a tube having first and second open ends, meaning that the false wall  62 , and the end flaps  80 ,  82 ,  84  and  86  are not folded inwardly and secured. The roll  30  is then inserted into the tube as indicated by a step  102 . The roll  30  is preferably inserted in an automated fashion by, for example, sliding the roll along a bottom wall  34  a set distance, or until a proximity sensor, or other form of position sensor, is triggered. 
   Once the roll  30  is inserted, the assembly of the end walls  40 ,  42  is commenced by folding the brace  64  normal to the false wall  62  and folding the false wall  62  into the tube, as indicated by a step  104 . In so doing, the ends  58 ,  60  of the core  52  are captured, thereby retaining the roll  30  within the dispenser  20 . The minor flap  82  is then folded inwardly, as indicated in a step  106 , to be adjacent the false wall  62 . The minor flap  82  may be adhered to the false wall  62  once folded. The base  22  is completed upon folding of the major flap  80 , as indicated in a step  108 . The major flap  80  is adhered parallel to the minor flap  82  creating the ends  40 ,  42 . As illustrated in  FIGS. 2 and 3 , when the dispenser  20  is assembled, the brace  64  engages the ends  40 ,  42 , biasing the false walls  62  angularly inward. 
   The dispenser  20  is completed upon folding of minor flap  86  and major flap  84  of the lid  24 , as indicated in a step  110 . More specifically, as shown best in  FIG. 2 , the minor flap  86  is folded normal to the lid top wall  44 , and major flap  84  is then folded parallel thereto and adhered into position. In so doing, the dispenser  20  is completed, substantially enclosing the roll  30  and protecting the roll  30  from contamination. Even after opening, i.e., removal of the tear strip  88 , the lid  24  provides closed ends cooperating with the closed ends of the base  22  to substantially enclose the roll  30 . 
   Referring now to  FIGS. 7–10 , an alternative embodiment of a wound film dispenser constructed in accordance with the teachings of the invention is depicted. Wherein like elements are employed, like reference numerals are used. One difference with respect to the alternative embodiment of  FIGS. 6 and 7  is provided in the form of the brace. As depicted therein, the brace  97  of the alternative embodiment extends from a top edge  98  of the aperture  76 . The brace  97  is substantially polygonal in shape including a front edge  100 , back edge  102 , and first and second side edge  104 ,  106 . The brace  64  is folded away from the false wall  62  so as to allow the front edge  100  to directly engage the ends  40 ,  42 . 
   It is to be understood, that in still further embodiments, the brace  97  can be differently positioned. For example, the brace  97  may extend from one of the sides of the aperture  76 . Moreover, the brace may extend inwardly from the minor flap  82  so as to push the false wall  62  inwardly. 
   From the foregoing, one of ordinary skill in the art will recognize that the teachings of the present invention can be employed to construct a wound film dispenser for wraps and the like, having improved manufacturability and dispensing capability, with reduced material requirements as well.