Abstract:
A towel dispenser includes a housing for receiving toweling. The housing includes a main body; a loading door that is configured to rotate relative to the main body between a closed position and an open position; and a guide system that includes a first roller attached to the main body and a second roller attached to the loading door. The towel dispenser may include a motor for driving dispensing of the toweling from the housing and an associated sensor. The towel dispenser can be mounted to an underside of a cabinet. In an aspect, the loading door includes a curved body and a lip that generally extends in parallel to a top surface of the housing away from the curved body.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a U.S. continuation patent application of, and claims priority under 35 U.S.C. §120 to, U.S. nonprovisional patent application Ser. No. 11/854,193, filed Sep. 12, 2007 now U.S. Pat. No. 7,887,005, which nonprovisional patent application published as U.S. patent application publication no. 2009/0065628, which patent application and patent application publication, and any patent issuing therefrom, are incorporated by reference herein. 
    
    
     COPYRIGHT STATEMENT 
     All of the material in this patent document is subject to copyright protection under the copyright laws of the United States and other countries. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in official governmental records but, otherwise, all other copyright rights whatsoever are reserved. 
     BACKGROUND 
     This invention relates generally to towel dispensers and more particularly to “hands free” towel dispensers. 
     Towel dispensers are well known and generally include a housing configured to receive a roll of toweling, a guide system that defines a path for the toweling, and a motor for moving the toweling along the path to the exterior of the housing. The guide system can include rollers or fixed guides and typically includes a driven roller connected to the motor. A switch or sensor for detecting motion or proximity of an object is provided to initiate the operation of the motor. For example, in a known dispenser, a controller is electrically connected to the sensor and is configured to activate the motor when the sensor generates a signal that indicates the presence of a hand. Conventional towel dispensers are configured to dispense towels from continuous rolls of non-perforated toweling and include a device for cutting the toweling to dispense individual towels. The length of the individual towels provided by the dispenser is determined by the amount of time that the motor is operated or by measuring the individual towel as it is dispensed. 
     Conventional toweling dispensers operate as follows. A roll of toweling is placed within the housing and threaded through the guide system. A user causes a towel to be dispensed by placing a hand or other object near the sensor. Alternatively, the dispensing of toweling can be initiated by pressing a button or switch that is configured to activate the motor. Dispensing of the toweling can be stopped when the hand is removed or when a predetermined length of toweling has been dispensed. 
     One problem associated with conventional toweling dispensers is that they are not configured to accommodate typical pre-perforated toweling such as that used typical households. Another problem with conventional dispensers is that they can be difficult to load and thread the toweling along the path defined by the guide system. 
     BRIEF SUMMARY OF THE INVENTION 
     Accordingly, there is a need to provide a towel dispenser for automatically dispensing an individual towel wherein the length is determined by a pre-made perforation such as those formed in consumer paper towels. 
     There is a further need to provide a towel dispenser in which toweling can be relatively easily loaded. 
     Therefore there is provided a towel dispenser that includes a housing for containing toweling. The toweling includes a first towel and a second towel that are connected together and separable at a perforation formed between the first and second towel. The housing is configured to define a path P for the toweling. A motor and a perforation sensor are provided for dispensing the toweling and are electrically connected together. The perforation sensor is configured to generate a signal indicative of the presence of the perforation and the motor is configured to deactivate in response to the signal. 
     According to another embodiment of the present invention, the motor and a controller are positioned within the housing. The controller is electrically connected to both the motor and the perforation sensor and is configured to activate and deactivate the motor after the perforation sensor generates the signal indicative of a perforation. 
     According to another embodiment of the present invention, the controller is configured to deactivate the motor a predetermined period of time after receiving the signal. 
     According to another embodiment of the present invention, the predetermined period of time is sufficient for the perforation to exit the housing. 
     According to another embodiment of the present invention, the predetermined period of time is sufficient for the perforation to be aligned with a separation device. 
     According to another embodiment of the present invention, the housing includes a separation device when the motor is deactivated. 
     According to another embodiment of the present invention, the separation device is an edge positioned near the path P. 
     According to another embodiment of the present invention, there is provided a drive roller and a sensor roller, each having outer surfaces that define a portion of path P. 
     According to another embodiment of the present invention, the perforation is expanded opened when the perforation is in proximity to the sensor. 
     According to another embodiment of the present invention, the drive roller is configured to operate such that it has a first surface speed and the sensor roller is configured to operate such that it has a second surface speed. 
     According to another embodiment of the present invention, the first surface speed of the drive roller is greater than the second surface speed of the sensor roller such that the toweling is in tension between the drive roller and the sensor roller. According to another embodiment of the present invention, the sensor roller is generally cylindrical and defines a first diameter at each of a first end and a second end and a second diameter between the first end and the second end, wherein the second diameter is greater than the first diameter. 
     According to another embodiment of the present invention, the second diameter is defined by a ridge formed between the first and second end of the sensor roller. 
     According to another embodiment of the present invention, the housing includes a guide system that defines path P and includes a first set of guiding members positioned on a first side of the toweling and a second set of guiding members positioned on a second side of the toweling. 
     According to another embodiment of the present invention, the housing includes a main body and a loading door pivotally attached to the main body and movable between a closed first position and an open second position, the second set of guiding members being attached to the loading door. 
     According to another aspect of the present invention, there is provided a method of dispensing towels from a dispenser. A housing is provided for containing toweling. The toweling includes a first towel and a second towel that are connected together and separable at a perforation formed between the first and second towel, the housing being configured to define a path P for the toweling. A motor and a sensor for sensing the perforation are electrically connected together. The sensor is configured to generate a signal indicative of the presence of the perforation and the motor is configured to deactivate accordingly. The motor is activated to propel the toweling along path P. The motor is deactivated after the sensor generates a signal indicating the presence of the perforation. 
     According to another embodiment of the present invention, a controller is provided that is electrically connected to the motor and to the sensor, and the controller is configured to deactivate the motor a predetermined period of time after the signal is generated by the sensor. 
     According to another embodiment of the present invention, the perforation is opened when the perforation is near the sensor. 
     According to another embodiment of the present invention, a drive roller and a sensor roller are configured to be driven by the motor, wherein the toweling contacts drive roller in path P after it contacts the sensor roller in path P. The drive roller and the sensor roller are operated such that the drive roller has a faster surface speed than the sensor roller such that tension is applied to the toweling between the drive roller and the sensor roller. 
     According to another embodiment of the present invention, the motor is operated until the perforation has traveled along path P past the drive roller. 
     According to another embodiment of the present invention, there is provided a method for loading a towel dispenser. A housing for receiving toweling is provided, wherein the toweling includes a first towel and a second towel that are connected together and separable along a perforation formed between the first and second towel. A movable loading door is attached to the housing and has an open first position wherein toweling can be loaded into the housing and a closed second position. The housing also includes a guide system configured to define a path P for the toweling and the guide system includes a first set of guiding members attached to the housing and a second set of guiding members attached to the loading door such that the guide system defines path P when the loading door is in the first position. The loading door is moved to the open second position. Toweling is placed within the housing. A length of toweling is extended from the housing over the loading door. The loading door is moved to the closed first position such that toweling extends along path P. 
     According to another embodiment of the present invention, a motor and a controller are positioned within the housing for dispensing the toweling are provided. A sensor for sensing the perforation is also provided wherein the sensor is configured to generate a signal indicative of the presence of the perforation and the controller is configured to receive the signal and to deactivate the motor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter that is regarded as the invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which: 
         FIG. 1  is a perspective view of a towel dispenser according to one embodiment of the present invention showing the dispenser in a typical application; 
         FIG. 2  is a perspective view of the towel dispenser shown in  FIG. 1 ; 
         FIG. 3  is a side cut-away schematic view of a portion of the dispenser shown in  FIG. 1  showing a first toweling path; 
         FIG. 4  is a side cut-away schematic view of a portion of the towel dispenser shown in  FIG. 1  showing a second toweling path; 
         FIG. 5  is a perspective schematic view of a portion of the dispenser in an open position for receiving a roll of toweling; and 
         FIG. 6  is a partial perspective schematic view of a portion of the dispenser during operation of one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views,  FIG. 1  shows a towel dispenser  10  according to one embodiment of the present invention. The dispenser  10  is for automatically dispensing conventional pre-perforated paper towels such that they can be separated at a perforation  16 . Therefore the dispenser  10  can be mounted where consumer paper towels are typically made available such as under a household cabinet  18  and above a counter  19  as shown in  FIG. 1 . 
     Referring now to  FIGS. 2 and 3 , dispenser  10  includes a housing  20  that includes a main body  22  and a loading door  24 . The main body  22  includes side walls  26  and a front wall  28 . The main body  22  defines a cavity  32  that is dimensioned to receive toweling  12 . In this regard, tabs  34  are positioned within cavity  32  on opposite sides of cavity  32  for supporting the toweling  12 . In the illustrated embodiment, the cavity  32  is dimensioned to receive the toweling  12  in the form of a roll  14  of standard consumer paper toweling but it should be appreciated that the toweling  12  could be accordion folded or the like. A perforation  16  (as shown in  FIG. 6 ) is formed within the toweling  12  of roll  14 . The perforation  16  is dimensioned to define an edge of an individual towel and to assist separation of individual towels from the roll  14 . Roll  14  will typically contain many perforations  16 . It should be appreciated that, alternatively, the toweling  12  could be accordion folded or otherwise provided. One edge of front wall  28  defines a separation device  36  for further assisting the separation of individual towels from roll  14 . 
     As used herein, the term “toweling” refers to any sheet or web material that is suitable for wiping or drying. By way of example and not limitation, toweling  12  can be formed of paper, a synthetic material (such as a polymeric film), woven textile, or a non-woven textile material. As used herein, the term “perforation” refers to the point of separation between individual sheets within the toweling  12  and can be defined by a score, a opening or row of openings formed in toweling  12  such that an individual towel can be separated from the toweling  12 . 
     The loading door  24  is pivotally attached to the main body  22  and movable between a closed first position and an open second position. When in the closed first position, the door  24  covers an opening  38  that is formed in the main body  22 . When in the open second position, the door  24  provides for access to the cavity  32  through the opening  38 . Position indicating sensors (not shown) are provided for generating a signal indicative of the position of the door  24 . The door  24  includes a curved body  42 , a lip  44 , and two bracket walls  46  that are disposed generally perpendicularly to the lip  44  and at opposite sides thereof. As can be seen in  FIG. 1 , when the door  24  is in the closed first position, lip  44  of door  24  and the front wall  28  define a gap  45 . 
     Referring now to  FIG. 5 , a guide system  50  is positioned within the housing  20  and includes a plurality of guiding members. The guide system  50  defines a path P as shown in  FIGS. 3 and 4 . The path P can contact the guide bar  53  as shown in  FIG. 3  or can bypass the guide bar  53  as shown in  FIG. 4 . The guide system  50  is configured such that when the roll  14  of toweling  12  is positioned within the cavity  32 , toweling  12  extends along path P through the gap  45 . 
     A first set of guiding members are attached to the main body  22  and include a drive roller  52  and a guide bar  53 . The drive roller  52  extends between side walls  26  and is positioned between cavity  32  and front wall  28 . Guide bar  53  also extends between side walls  26  and is positioned between the drive roller  52  and the cavity  32 . A second set of guiding members includes a rotatable sensor roller  54  and rotatable a pinch roller  58  that each extend between the two bracket walls  46  and are movable with the door  24 . 
     Continuing to refer to  FIG. 5 , the sensor roller  54  is generally cylindrical and is connectable to a motor  62  via a transmission and that includes a gear  66  that is attached to the sensor roller  54 . In the illustrated embodiment, the sensor roller  54  is configured to be driven such that it has a slower surface speed that the drive roller  52 . In this manner, tension is created in toweling  12  between the sensor roller  54  and the drive roller  52  such that the perforation  16  can be expanded. Alternatively, the sensor roller  54  is not attached to the motor  62  but is configured to be rotated by contact with the toweling  12 . 
     In the illustrated embodiment, the sensor roller  54  has a centrally formed circumferential ridge  55  disposed between two end sections  56 . The end sections  56  have a first diameter and the ridge  55  has an second diameter. The second diameter of the ridge  55  is greater than the first diameter and is for expanding the perforation  16  as it passes over the sensor roller  54 . Alternatively, the sensor roller  54  could have a consistent diameter across its full length and could be straight or bowed for expansion of the perforation  16 . 
     As can be seen in  FIG. 5 , the sensor roller  54  is positioned generally parallel to the pinch roller  58 . The pinch roller  58  is generally cylindrical and of uniform diameter and includes a plurality of sub-rollers  59 . The pinch roller  58  is also connectable to motor  62  via the transmission. 
     Referring now to  FIGS. 3 and 4 , the motor  62  is mounted on one of the side walls  26  and is configured to be powered by a battery  68 . The motor  62  is mechanically connected to the drive roller  52  by the transmission. In the illustrated embodiment, the transmission includes a plurality of gears. As used herein, the term “gears” refers to a device having a toothed surface that is configured to interlock with another toothed surface. Alternatively the transmission could include a belt and pulley, wheels, or other such power transmitting structure. 
     Referring now to  FIG. 3 , a perforation sensor  80  is included in the housing  20  and is configured to generate a signal indicative of the presence of a perforation  16  in the toweling  12 , i.e., a perforation signal. In the illustrated embodiment, the perforation sensor  80  is a photo-electronic device and includes a light source  82  positioned on one side of path P and a photo-conductive receiver  84  positioned on an opposite side of path P and is operable to detect light from the light source  82 . The sensor  80  is configured to generate a signal when it receives light from the light source  82 . In this regard, light from the light source  82  is normally blocked by the toweling  12  between the light source  82  and the receiver  84 . However, if a perforation  16  is positioned between the light source  82  and the receiver  84 , then the light passes through the perforation  16  to the receiver  84  and the sensor  80  generates the perforation signal. In the illustrated embodiment, the light from the light source  82  is directed at a relatively small portion relative to the width of the toweling  12 . In other embodiments the light source  82  and the receiver  84  can be configured such that the light source  82  emits light that is directed to more of the toweling  12 , up to the full width of the toweling  12 . 
     Alternatively, the light source  82  and the receiver  84  could be positioned on the same side of the path P and a reflector (not shown) positioned on the opposite side of the path P. It should also be appreciated that the sensor  80  can be based on other known technologies such as the following: The sensor  80  can be capacitive and use a capacitive coupled sensor. The sensor  80  can be based on mechanical detection and detect a perforation  16  through movement of a micro-switch that mechanically changes states when a perforation  16  moves past the sensor  80 . The sensor  80  can be based on the hall effect and be configured to sense a marker on the toweling  12  such as a metal flag. The sensor  80  could be configured to detect a perforation  16  based on a change in radio frequency. 
     A proximity sensor  92  is mounted on main body  22  as shown in  FIGS. 2 and 3 . The proximity sensor  92  is configured to generate a signal that is indicative of the presence of a hand or other object. An alternative on switch  94  is positioned on the housing  20  and is operable to close an electrical circuit. An emergency off switch  96  is positioned on the housing  20  and is operable to close an electrical circuit. 
     A controller  98  is mounted within the housing  20 , as shown in  FIG. 3 , and is electrically connected to the perforation sensor  80 , the motor  62 , the battery  68 , the emergency off switch  96 , the proximity sensor  92 , the position indicating sensors of the loading door  24 , and the on switch  94 . The controller  98  is configured to activate the motor  62 , based on a signal from the proximity sensor  92  or the off switch  96  and to deactivate the motor  62  after the perforation signal is generated by perforation sensor  80 . In the illustrated embodiment, the controller  98  is configured to deactivate the motor  62  a predetermined time after the perforation signal is generated such that the perforation  16  is positioned near the separation device  36 . The controller  98  is also configured to activate the motor  62  when the on switch  94  is closed and to deactivate the motor  62  when the emergency off switch  96  is closed. 
     The present invention can be better understood with respect to the operation of the dispenser  10  as follows. Prior to dispensing towels, the roll  14  is placed within the housing  20  and a length of the toweling  12  extending from roll  14  is threaded along path P so that the toweling  12  extends from roll  14  through gap  45 . Dispensing of a towel is initiated by moving an object such as a person&#39;s hand such that it is detected by the proximity sensor  92 . The controller  98  activates the motor  62  in response to a signal generated by the proximity sensor  92  and toweling  12  is dispensed through gap  45 . When a perforation  16  is detected by the perforation sensor  80 , it generates the perforation signal that is then received by the controller  98 . The controller  98  deactivates the motor  62  after the perforation  16  has passed through the gap  45 . In this regard, the perforation  16  is positioned outside of the housing  20  and a towel can easily be removed by tearing the toweling  12  at the perforation  16  either free from separation device  36  or by engaging separation device  36  with the toweling at the perforation  16 . 
     Referring now to the detection of perforation  16  by the perforation sensor  80 , as can be seen in  FIG. 6 , each opening of the perforation  16  has a first diameter D prior to reaching the sensor roller  54 . In the illustrated embodiment, each opening of the perforation  16  is expanded to have a second diameter D 2  between the sensor roller  54  and the drive roller  52 . Each opening of the perforation  16  is further expanded to have a third diameter D 3  if the opening passes over or near ridge  55  of the sensor roller  54 . The third diameter D 3  is greater than the second diameter D 2  which is greater than the first diameter D 1 . Alternatively, the sensor roller  54  and the drive roller  52  are not configured to expand the openings of the perforation  16  prior to detection of the perforation  16  by the perforation sensor  80 . In this alternative, perforation sensor  80  is configured to detect the perforation  16  when the opening  38  has the first diameter D 1 . 
     The present invention also provides a method for loading the towel dispenser  10 . The loading door  24  is moved to its open second position such that opening  38  is accessible and the sensor roller  54  and the pinch roller  58  are moved clear of path P. The roll  14  is inserted into the housing  20  through the opening  38  and positioned on tabs  34 . A length of toweling  12  is extended from the roll  14  across the loading door  24  such that it extends over the sensor roller  54  and the pinch roller  58 . The loading door  24  is moved to the closed first position such that the sensor roller  54  and the pinch roller  58  are moved up into position to define path P. In this manner, the toweling  12  that was extended over the sensor roller  54  and the pinch roller  58  is threaded along path P. The pinch roller  58  traps the toweling  12  against the drive roller  52 . In one embodiment, upon closing of the loading door  24 , the controller  98  activates the motor  62  to dispense an individual towel as described above. 
     In an alternative embodiment of the present invention, there is provided a user interface (not shown) which is configured to provide for selection of a quantity of perforations to be detected before the motor  62  is deactivated. In this manner, the user can select the number of paper towels to be dispensed during one dispensing cycle. The number selected can be displayed on display  99  as can the number of towels actually dispensed per cycle. 
     The foregoing has described a towel dispenser  10  capable of dispensing toweling  12  until a perforation  16  within the toweling  12  is detected. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation.