Abstract:
An automatic product dispenser determines if the roll loaded into the dispenser is approved for use with the dispenser. The core of a roll receives a plug that engages a hub within the dispenser. The plug has a feature that alters an electromagnetic field created proximate the hub. The alteration of the electromagnetic field may then be used to determine if the plug, and thus the roll, is usable with the dispenser.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a national stage application under 35 U.S.C. §371 of International Application Ser. No. PCT/US2010/032061. 
     BACKGROUND OF THE INVENTION 
     The present invention is generally directed to product dispensers and, more particularly, to a dispenser having a lockout feature that prevents the dispensing of product from a non-approved source. 
     Automatic towel and similar product dispensers have been developed to reduce the waste generally associated with manual dispensers. Automatic dispensers typically include a motor driven drive roller that advances web material, such as hand towel material, from a web material roll. Early automatic dispensers required a user to depress a feed button to activate the drive roller. More recently, automatic dispensers have incorporated proximity sensor technology to allow hands-free or otherwise contact-free activation of the drive roller. 
     Conventional automatic dispensers advance web material from the web material roll according to predetermined settings that result in the same amount of web material being dispensed regardless of the particular characteristics of the web material to be dispensed. For example, a conventional automatic towel dispenser will advance a fixed amount of web material from a web material roll independent of the absorbency of the web material. As a result, it is possible for too much or too little web material to be dispensed; both of which can lead to waste. When too much web material is dispensed, the excess cannot be retrieved and reused and therefore creates waste. When too little web material is dispensed, a user will often retrigger the dispenser to dispense additional web material possibly resulting in additional waste. 
     Accordingly, a number of “smart” dispensers have been developed that are able to obtain information about certain characteristics of a web material roll, or the web material wrapped therearound, and adjust the dispensing settings accordingly. One such dispenser is described in U.S. Pat. Pub. No. 2005/0171634. This publication describes a dispenser having a reader or scanner that communicates with an RFID “smart” chip or tag embedded in the core of a roll. The smart chip includes information relating to the type of product to be dispensed. For a roll of hand towel material, that information may include absorbency, basis weight, and manufacturer. The scanner reads this information from the smart chip and communicates that information to a processor that adjusts performance settings accordingly. For example, the feed length may be adjusted based on the information contained in the smart chip. Additionally, the processor may disable the automatic drive or feed components if an unapproved or unrecognized roll is loaded into the dispenser. The automatic drive components may also be disabled if no information is gathered from the smart chip, which may occur when a roll absent a smart chip is loaded into the dispenser. This “lockout” feature is intended to reduce jamming of the dispenser, damage to the dispenser, and/or unsatisfactory dispensing of web material that may result from use of an unapproved or an unrecognized roll. 
     In addition to significantly adding to the cost of each roll and the dispenser itself by virtue of the necessary reader(s) and circuitry, such smart chips or RFID tags are only effective if the web material of the roll matches the information encoded in the smart tag. If there is a mismatch between the web material and the encoded information, the performance settings of the dispenser will not be tailored to the specifics of the web material to be dispensed. Further, the lockout feature is designed to prevent the use of unauthorized or unrecognized rolls with the automatic dispenser. If there is an inconsistency between the encoded information and the actual web material to be dispensed, the lockout feature may not function properly. 
     Another “smart” dispenser, which is described in U.S. Pat. No. 7,040,566, uses a bar code-embedded roll and a bar code reader to determine if the roll is from an authorized source before the dispenser is activated to dispense material from the roll. The bar code reader is described as a phototransistor reflective object sensor that reads the bar code associated with a roll loaded into the dispenser and transmits a code signal to a controller that compares the code signal to a set of approved codes maintained in a computer readable database. If the code associated with the code signal does not match an approved code, the dispenser is automatically locked out form dispensing material from the loaded roll. 
     While such a smart dispenser is believed to be effective in preventing unauthorized rolls from being loaded into a dispenser, the cost and the collective size of the components can result in a significant increase in the overall cost, complexity, and size of the dispenser. For example, such a lockout system requires not only the aforementioned bar code reader/sensor and microcontroller but also an analog to digital converter for digitizing the analog output of the reader. 
     The above-described systems can also often be circumvented by removing the bar code or RFID tag and placing them on the core of a new roll or merely in appropriate proximity to the reader. The dispenser can then be loaded with an unapproved or unrecognized roll and be caused to operate as if an approved or recognized roll has been loaded. As a result, the waste management, performance and supply control advantages provided by the smart chips or RFID tags may not be realized. 
     BRIEF DESCRIPTION OF THE INVENTION 
     The present inventors have found that the advantages provided by smart chips, bar code readers, or RFID tags can be realized while avoiding the pitfalls and costs associated therewith. More particularly, the present invention is directed to an automatic web material dispenser that determines if the roll loaded into the dispenser is approved for use with the dispenser. In one embodiment of the present invention, in order to achieve this result, it compares a baseline system frequency to the frequency after the roll has been loaded into the dispenser and determines if changed frequency is within a predetermined range. If so, then the roll is approved for use with the dispenser and the dispenser is activated. In one embodiment, a plug having a metallic feature is loaded into, and adhesively bonded to an open end of a roll of web material. Bonding the plug to the roll is intended to discourage removal of the plug from the roll and inserting the plug into an otherwise plug-less roll of web material. It is also contemplated that the plug could be press-fit into the open end of the roll and in a manner that would discourage removal of the plug from the roll, i.e., results in damage to the plug and/or roll if the plug was removed. When the appropriate modified frequency is recognized, the system can be set to adjust for various particulars of the web material to be dispensed, such as brand name, type, size, and the like, that can be used to automatically tailor the performance settings of the dispenser. 
     It is therefore one object of the present invention to provide an automatic product dispenser having a lockout feature that cannot be easily circumvented. 
     It is a further object of the invention to provide a roll having a recognition device or material that cannot be transferred to other rolls. 
     Therefore, in accordance with one aspect of the present invention, an apparatus for dispensing product from a roll is disclosed. The apparatus includes a drive roller adapted to advance product from a roll. The roll to be loaded into the dispenser includes a frequency changing device or material that may be indicative of the product carried by the roll or merely the source or provider of the roll. The apparatus further includes a controller associated with the drive roller and adapted to determine the frequency resulting from the presence of the frequency changing device or material of the roll, compare the system base frequency to the changed frequency and then, if the changed frequency matches a predetermined frequency, falls within a predetermined range, or is changed a predetermined amount or percentage, permit the drive roller to advance the product from the roll. If the changed frequency does not match the predetermined frequency, shift or range, then the drive motor will not be actuated, thereby preventing the dispensing system from operating to advance product from the roll. 
     In accordance with another aspect, the present invention includes a method of regulating product dispensing from a dispenser. The method includes determining if a roll includes a frequency shifting device or material that fits the predetermined profile. If it does, then the dispensing particulars of the roll can be known and/or set. 
     According to another aspect, the present invention includes a plug for insertion into an open end of a roll of web material for use with an automatic dispensing device. The plug has a metallic feature operative as a frequency shifting device for identifying a brand or source of the roll associated therewith. 
     Other objects, features, and advantages of the invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and the invention includes all such modifications. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout. 
       In the drawings: 
         FIG. 1  is an isometric view of an automatic towel dispenser; 
         FIG. 2  is a front elevation view of the automatic towel dispenser of  FIG. 1  with the front cover removed; 
         FIG. 3  is an isometric view of a roll carrier assembly for use with the automatic towel dispenser of  FIGS. 1-2 ; 
         FIG. 4  is front elevation view of the roll carrier assembly shown in  FIG. 3 ; 
         FIG. 5  is a section view of a portion of the roll carrier assembly shown in  FIGS. 3 and 4 ; 
         FIG. 6  is section view of a hub assembly according to another embodiment of the invention; 
         FIG. 7  is an exploded view of that shown in  FIG. 6 ; 
         FIG. 8  is an isometric view of a plug according to another embodiment of the invention and used to connect a roll web material to the hub assembly of  FIGS. 6 and 7 ; 
         FIG. 9  is a section view of the plug of  FIG. 8 ; 
         FIG. 9A  shows placement of a conductive ring at various positions within the plug of  FIG. 8 ; 
         FIG. 10  is a section view of a plug according to another embodiment of the invention; 
         FIG. 11  is a top plan view of the plug of  FIG. 10 ; 
         FIG. 12  is a schematic view of a control circuit associated with the product discriminating assembly; and 
         FIG. 13  is a perspective view of paper towel core according to another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will be described with respect to an automatic towel dispenser for dispensing web material, but it is recognized that the invention is applicable to automatic dispensers adapted to automatically dispense other types of products, including other paper and non-paper products. Additionally, the invention is applicable with touch-based and touchless automatic dispensers, such as those commercially available from The Colman Group, Inc. of Elkhorn, Wis. 
     As will be explained in greater detail further below, the present invention is generally directed to a dispenser, such as a paper towel dispenser, that includes circuitry for generating an electromagnetic field generally around a roll mount. When an authorized roll is mounted onto the roll mount, the roll will cause a change in the frequency of the electromagnetic field. More particularly, the circuitry includes a frequency generator (oscillator) and a coil for creating the electromagnetic field and the roll includes a uniquely constructed closed loop. Thus, when the roll is loaded into the dispenser, the frequency generator will generate a new waveform having a changed frequency reflective of the mutual inductance between the coil and the closed loop. The new waveform, or one or more characteristics thereof, are the result of the properties of the closed loop. The new waveform, or some form thereof, may then be analyzed to determine if the roll loaded into the dispenser is authorized for use with the dispenser. If so, the dispenser will dispense material from the roll. If not, the dispenser will be locked out and will not operate thereby preventing unintended or impermissible use of the dispenser. 
     An exemplary paper towel dispenser is shown in  FIG. 1 . Automatic towel dispenser  10  includes a back cover  12  designed to be wall-mounted and a front cover  14  coupled to the back cover  12  by a hinge  16 . Paper towel or web material is fed from a web material roll (not shown) contained within the automatic towel dispenser  10  through dispensing slot  18  by a drive assembly  20 , shown in  FIG. 2 . The clamshell design of the automatic towel dispenser  10  allows a roll to be loaded into the automatic towel dispenser  10  by unlocking the front cover  14  from the back cover  12  in a known manner and then rotating the front cover  14  downwardly about hinge  16 . 
     As shown in  FIG. 2 , drive assembly  20  is mounted to the back cover  12  and includes a PC board and motor contained within housing  22  and operatively associated, in a known manner, with a drive roller assembly  24 . The drive roller assembly  24  is designed to grab and forcibly advance web material from a roll of web material (not shown) through dispensing slot  18 . The drive roller assembly  24  may be of conventional design, such as that described in U.S. Pat. No. 7,168,653, the disclosure of which is incorporated herein by reference. As will be described in greater detail below, the motor may be controlled by a processor adapted to smartly control operation of the motor and drive roller assembly, including, when appropriate, disablement of the motor so as to lock out its functionality when an unapproved roll is loaded into the automatic towel dispenser  10 . 
     In one embodiment of the present invention, a continuous sheet of web material is advanced from a roll (not shown) that is preferably mounted on a carrier assembly  26  of the type that includes a pair of roll support plates  28 ,  30  that carry a guide wire  32 , as shown further in  FIGS. 3-4 . Each support plate  28 ,  30  has an inwardly facing hub  34 ,  36 , respectively, that is designed to extend partially through the hollow core of the roll. The hubs  34 ,  36  have a generally circular cross-section to match that of a plug that is inserted into the hollow core of the roll. As will be described more fully below, the plug provides two generally functions. It is used to mount the roll in the dispenser, and more particularly to hub  34 , and includes a metallic member that modifies the waveform emitted by a coil contained in hub  34 . As further shown in  FIG. 2 , a wire  38  extends from the hub  34  to an oscillator within housing  22 . As will be explained, the oscillator and a coil create an electromagnetic field generally about the hub  34 . 
     Referring to  FIG. 5 , the hub  34  provides a housing for a bobbin  40  around which a coil (wire winding)  44  may be wrapped. When the coil  44  is energized, an electromagnetic field is generated. As noted above, the hub  34  is received by one end of the hollow core  46  of the roll. The core  46  has an inner surface  48  and an outer surface  50 . The outer surface  50  is impregnated or otherwise carries a continuous ring of conductive material  52 . Alternately, the conductive material  52  could be placed on the inner surface  48 , or both the inner and outer surfaces  48 ,  50 , or impregnated in the core material. In the illustrated embodiment, the conductive material  52  is arranged in the form of a ring that envelopes a portion of the outer surface  50  of the core  46 . The conductive ring of material  52  (or alternatively, a closed circuit (not shown) or other type of closed loop) is designed to modify the base system frequency as it interacts with the electromagnetic field of the coil. For example, the conductive material  52  for a given core may include one or more of copper, gold, nickel and silver. The width, thickness, purity, type and location of the conductive material can affect the degree of frequency shift or change. In one embodiment, the amount of frequency changing device or material can be used to identify the brand of the roll. 
     In one embodiment, the closed loop  52  is formed as a ring of conductive material around a portion of a roll core  46 . It is recognized, however, that in alternate embodiments, the closed loop  52  may be arranged in other patterns to uniquely identify the roll. For example, multiple rings of conductive material  52  could be used. In one embodiment, one type of conductive material  52  is used, but it is recognized that mixtures of various types of conductive material  52  could be used. Regardless of the contents of the conductive material  52  and how it is placed on the roll, the resulting frequency can uniquely identify the brand, source, or some other defining characteristic of the roll so that a determination can be made as to whether the roll may be used with the automatic towel dispenser  10 . The resulting frequency may also identify the type of material, the size of the roll, and other parameters that may be useful in establishing operating parameters for the automatic towel dispenser  10 . 
       FIGS. 6 and 7  show a hub assembly  54  according to another embodiment of the invention. Hub assembly  54  includes a support plate  56  to which a bobbin  58  is affixed in a known manner. A coil winding  60  is mounted to the bobbin  58 , and a cover  62  having an opening  64  fits over the bobbin  58  and thus coil  60 . An end cap  66  snaps into or is otherwise retained by the bobbin  58 . The end cap  66  fits within the hollow core of the roll. In one embodiment, the shape of the end cap  66  and the core of the roll are matched such that rolls having cores with non-complementary shapes cannot be used with the dispenser. 
     In another embodiment of the invention, a conductive member is loaded into a plug that is used to mount a roll of web material to the hub. As shown in  FIG. 8 , plug  68  is similar in outward appearance to the end cap  66  shown in  FIGS. 6 and 7 . More particularly, the plug  68  has a generally cylindrical shaped stem  70  and a rounded cap  72  preferably integrally formed with the stem  70 . In one embodiment, the stem  70  is shaped to be complimentary with the opening formed in the bobbin  58 . In this embodiment, the complimentary engagement surfaces of the stem  70  and the bobbin  58  prevent the stem from being loaded improperly into the bobbin or used with an unmatched bobbin. An annular ridge  74  is formed with the cap  72  and provides a seat for the roll of web material when the roll is loaded onto the plug  68 . Spaced from the ridge  74  are a set of radial edges  76  that are used to “grip” the core of the roll. 
     As shown in  FIG. 9 , the stem  70  and the cap  72  are formed as a single unitary structure so that an annular recess  78  is provided between the inner surface  80  of the cap  72  and the outer surface  82  of the stem  70 . This construction allows the plug  68  to be inserted into the opening in the bobbin  58  in a manner that seats the stem  70  within the core of the coil winding  60 . In the embodiments of the invention described above, conductive material was incorporated into the roll of web material, such as a conductive ring formed with the roll core. In this alternate embodiment, the plug  68  contains conductive material that interacts with the electromagnetic field generated by the coil  44  to provide a “handshaking” between the dispenser and the roll of web material. While inclusion of the conductive material in the plug  68  may take many forms, such as embedded pieces of conductive material randomly displaced throughout the stem and/or cap, in one embodiment, a metallic ring  84  is loaded into the stem  70 . In a low cost version of the present invention, the metallic ring  84  is a simple metal washer. In a preferred embodiment, the metallic ring  84  is insert molded with the stem  70  and cap  72 . As shown in  FIG. 9A , for example, the metallic ring  84  can be molded, or otherwise positioned, at one of multiple positions within the stem  70  to define the inductive signature of the plug. It will be appreciated that in addition to position, the type of metal and the mass of the metal will impact how the ring  84  interacts with the electromagnetic field generated by the coil  44 . In this regard, it is understood that the position of the ring  84 , its size, and its material composition may be selected to provide a unique signature or marker for the plug  68  and thus the roll associated with the plug  68 . It will also be appreciated that a plug may have more than one conductive insert, e.g., metallic ring, to define its inductive signature. Further, it will be appreciated that the conductive element may take a different shape or form than that illustrated herein. For example, the stem may include recesses that are loaded with conductive rods or pins to define the inductive signature for the plug. 
     In the embodiment shown in  FIG. 9 , the metallic ring  84  is insert molded with the plug  68  and thus is encased within the plug  68 . Integrally forming the ring  84  with the plug  68  locks the “identity” of the plug and prevents the ring  84  from being removed from the plug without destroying the plug itself. Preferably, the plug and the bobbin (or some other element of the hub assembly) are color coded so that the plug and hub assembly are matched to one another. 
     Another embodiment of the invention is shown in  FIGS. 10 and 11 . Plug  112  has a stem  114  and a head  116 . The stem  114  has a generally hollow interior defined by an annular surface  118 . The interior surface  118  is stepped that allows a keyed plastic insert  120  encasing a conductive element (not shown) to be drop-set at different depths within the stem  114 . In a preferred embodiment, four different sets of keyways  122 ,  124 ,  126 ,  128  are formed along the interior surface  118  of the stem  114  and radially spaced from one another to define four different depths at which the plastic insert  120  may be positioned. Each set of keyways preferably includes three keyways to match the three keys  130  formed along an outer radial edge of the plastic insert  120 . In one embodiment, the plastic insert  120  is sonic welded or otherwise fixed in place after the plastic insert  120  is set to the desired depth so that the position of the insert  120  cannot be altered. For example, the insert  120  could be snap-fit into place within the stem  114 . 
     As referenced above, and illustrated in  FIG. 9A , the position of the plastic insert  120  could be changed to modify the effect the metallic member contained within the insert  120  has on the electromagnetic field emitted by the coil. For example, in combination with the conductive properties of the conductive member, each depth setting could be used to tailor certain operating parameters of the drive roller assembly, such as advancement length. This would allow the advancement length to be set for a given roll by changing the position of the insert within the stem of the plug. In yet a further embodiment, the plastic insert and the bobbin (or exposed article of the hub assembly) are color coded. Color coding these components provides a visual reminder to an installer that the insert  120  for the plug must correspond to the color of the bobbin to ensure proper operation when the plug, and roll, are loaded. 
     Additionally, it will be appreciated that the plug could be secured or coupled to the roll in a number of ways. For example, the plug could be adhesively bonded to an open end of a roll of web material. Bonding the plug to the roll is intended to discourage removal of the plug from the roll and inserting the plug into an otherwise plug-less roll of web material. In a similar manner, the plug could be press-fit into the open end of the roll and in a manner that would discourage removal of the plug from the roll, i.e., results in damage to the plug and/or roll if the plug was removed. 
     As shown in  FIG. 12 , the system of the present invention includes a control logic circuit  132  which includes an oscillator  134  which together with coil  44  generates an electromagnetic field proximate the coil  44  and thus a roll positioned over the hub  34 . The oscillator  134  and the coil  44  generate the electromagnetic field at a predetermined frequency which establishes a base system frequency. When a roll having an inductive element, e.g., a ring of conductive material or a plug having a conductive element, associated therewith is brought into proximity of coil  44 , preferably by mounting the roll on the hub  34 , the mutual inductance between the coil  44  and the inductive element will cause the oscillator to generate a waveform of a different frequency than that of the base system frequency. The output of the oscillator, i.e., waveform, is input to a frequency sampler  136  (e.g., an op-amp, logic gate, comparator, etc.) which effectively determines the frequency of the new waveform generated by the oscillator. The frequency, in effect, is representative of the mutual inductance generated by placement of the roll onto the hub or insertion of the plug into the bobbin. A microprocessor  138  analyzes the output of the comparator and, more particularly, compares the frequency, or some characteristic value thereof, to a reference value  140 . The reference value corresponds to a value indicative of an authorized roll. In this regard, the microprocessor  138  includes, or access memory, containing one or more reference values representative of various authorized roll types, brands, etc. 
     It will be appreciated that the aforementioned comparison can take many forms. For example, the comparison can be done by measuring the percent of change of the mutual inductance relative to the system frequency, i.e., output of the oscillator before the roll is placed on or proximate the hub. If the comparison yields a match against the reference, the control logic circuit energizes the system enabling the drive motor to drive the drive roller and dispense web material, as indicated by block  142 . If there is no match, the system is not energized and no material can be dispensed, as represented by block  144 . The automatic towel dispenser  10  may include an indicator LED, for example that is illuminated when the lockout feature is activated. 
     If an unauthorized roll core or plug is loaded on the carrier assembly, the measured frequency or other value will not match the reference frequency or value thus indicating that an unauthorized roll or plug has been loaded on the carrier. It is recognized that the web material dispenser  10  may be adapted to drive multiple types of rolls. Thus, in one preferred embodiment, the automatic dispenser includes a database that is loaded with multiple reference frequencies or values. It is further contemplated that suitable diagnostic tools may be used to provide in-field updates to the database. 
     A number of embodiments are contemplated for providing the closed loop on or in association with the roll of web material in order to provide a means to cause a frequency change in accordance with the present invention. In a first embodiment, a roll core is coated or impregnated with at least one ring of conductive material. The core can be coated on the inside, on the outside or have the conductive material impregnated somewhere between the inside and outside of the core. In a second embodiment, an insert is provided which can be removed or permanently placed inside the core. The insert can be in the form of a plastic or paperboard plug that includes a ring of conductive material or other closed loop. In a third embodiment a label in the form of a ring impregnated with conductive material can be affixed to the side of the roll of web material. In a fourth embodiment, the web material itself can be coated or impregnated with conductive material to form a ring giving the appearance of, for example, a colored stripe used to indicate the end of a roll of register tape. In the fifth embodiment, a removable paper or other band coated or impregnated with a conductive material that encircles the roll of web material at the time of mounting of the web material in the dispenser could be used. In such case, the band would be removed prior to threading the dispenser for feeding the dispenser, but after the activation of the dispenser had occurred. In this embodiment, upon activation, the dispenser would preferably be set up to dispense an amount of a paper commensurate with that on the roll, prior to reactivation. 
     In yet a further embodiment, and with reference to  FIG. 13 , a web material roll  146  has a core  148  that is partially treated with conductive material, such as ring  150 . Glue or similar adhesive  152  is then used to secure the tail  154  of web material to the exterior surface of the core  148 . The adhesive  154  is applied so as to overlay the ring  150  of conductive material. This allows the conductive ring  150  to be damaged when the tail  154  of web towel material is pulled from the core  148 . Thus, the frequency altering effect of the core will no longer result in match with the reference frequency or value. This prevents the core from being re-loaded with web material not designed to be dispensed by the dispenser. In one preferred embodiment, the ring  150  includes conductive material that is applied as paint to the outer surface of the core  148 . Alternately, the conductive material could be sprayed, rolled, or stamped on the core. Also, electro-static techniques could be used to apply the conductive material. In yet another example, the core could be dipped in conductive paint or other fluid or even impregnated in the adhesive used to attach to roll tail. 
     Additionally, while the invention has been described with respect to a web material dispenser that advances a continuous sheet of paper towel from a roll, it is contemplated that the present invention may be used with web dispensers that dispense other types of paper products, such as toilet paper, and tissue papers. Coreless rolls and dispensers without support hubs may be used with the present invention. Further, the present invention may be used with non-paper dispensers. 
     Many changes and modifications could be made to the invention without departing from the spirit thereof. The scope of these changes will become apparent from the appended claims.