Abstract:
A dispenser is used for dispensing flexible material from a coil. The dispenser includes a frame, a coil carriage mounted to the frame and a brake/payout assembly mounted to the frame. The frame defines an axis of rotation about which the coil carriage rotates. The coil is securable within the coil carriage for rotation with the carriage. The brake/payout assembly is operably mounted to the frame and is moveable toward and away from the coil carriage. The brake/payout assembly is biased toward the coil carriage for engagement with the carriage. The brake/payout assembly engages the coil carriage to slow rotation of the carriage and includes a nip region through which the flexible material traverses during payout.

Description:
CROSS-REFERENCE TO RELATED APPLICATION DATA 
       [0001]    This application claims the benefit of priority of Provisional U.S. patent application Ser. No. 61/260,620, filed Nov. 12, 2009, the disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention pertains to a strap dispenser. More particularly, the present invention pertains to a dispenser for flexible material, such as plastic or metal strap, with an improved brake/payout assembly and an improved retention guard for easy coil loading. 
         [0003]    Coil dispensers are used as a source or supply of coil material for many operations. Such coils are often supported on carts for ease of transportation and handling. 
         [0004]    Issues have arisen with cart type dispensers in so far as braking and off-center pulling of strap from the coil, also referred to as strap pull down. Issues also arise with loading coils onto dispensers due the weight of the coils, and with inconsistent and not well controlled strap payout. 
         [0005]    It has also been found that coils that are out of round, typically as a result of crushed cores, can also be problematic in that they may not properly sit in the dispenser and as such may not properly pay out strap. 
         [0006]    Accordingly, there exists a need for a cart type coil dispenser that has an improved strap brake/payout assembly. Preferably, such a dispenser has an improved retention guard and easy coil loading. More preferably still, such a dispenser controls strap payout, and minimizes or prevents coil pull down. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    A dispenser is configured for dispensing flexible material such as plastic or metal strap from a coil having a core or a core-less coil. The coil may be wound onto a peripheral wall of the core. 
         [0008]    The dispenser includes a frame that defines and axis of rotation and a coil carriage mounted to the frame for rotation about the axis of rotation. The coil is securable within the coil carriage for rotation on the frame with the carriage. 
         [0009]    The dispenser includes a brake/payout assembly operably mounted to the frame and moveable toward and away from the coil carriage. In a present embodiment, the brake/payout assembly is pivotally mounted to the frame and is biased toward the coil carriage for engagement therewith. 
         [0010]    The brake/payout assembly engages the coil carriage to slow rotation of the carriage. The brake/payout assembly includes a nip region through which the strap traverses during payout to control payout of the strap. 
         [0011]    In a current embodiment the coil carriage includes a front guard, a rear guard and coil retaining elements to secure the coil between the guards. In one embodiment, the carriage includes three coil retaining elements and one of the coil retaining elements is adjustably mounted to the carriage. 
         [0012]    The brake/payout assembly is configured to engage one or both of the front and rear guards. In a present embodiment, the brake/payout assembly includes a contact roller that is configured to contact the front and/or rear guard to slow rotation of the coil carriage. 
         [0013]    The brake/payout assembly can include a feed roller biasedly mounted toward the contact roller. The rollers define the nip region therebetween. The strap is configured for receipt in the nip region as it is paid out from the coil. 
         [0014]    The contact roller can include one or more contact pads on a periphery thereof for contact with the front and/or rear guards. The contact and feed rollers can be formed from a low friction material. 
         [0015]    A present dispenser is formed as a cart with wheels for ease of movement, transport and positioning of coils. 
         [0016]    These and other features and advantages of the present invention will be apparent from the following detailed description, in conjunction with the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0017]    The benefits and advantages of the present invention will become more readily apparent to those of ordinary skill in the relevant art after reviewing the following detailed description and accompanying drawings, wherein: 
           [0018]      FIG. 1  is a rear perspective view, partially exploded, of a strap dispenser embodying the principles of the present invention; 
           [0019]      FIG. 2  is a front perspective view of the dispenser shown without the front guard and with a coil being positioned on the dispenser; 
           [0020]      FIG. 3  is a front perspective view of the dispenser, again shown without the front guard, but with the coil positioned on the dispenser; 
           [0021]      FIG. 4  is a front view of the strap dispenser; 
           [0022]      FIG. 5  is perspective view of the brake/payout guide assembly; and 
           [0023]      FIG. 6  is a partially exploded view of the brake/payout guide assembly of  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment with the understanding that the present disclosure is to be considered an exemplification of the invention and is not intended to limit the invention to the specific embodiment illustrated. 
         [0025]    It should be further understood that the title of this section of this specification, namely, “Detailed Description Of The Invention”, relates to a requirement of the United States Patent Office, and does not imply, nor should be inferred to limit the subject matter disclosed herein. 
         [0026]    Referring now to the figures there is shown a cart type strap dispenser  10  with improved brake/payout assembly and easy coil loading embodying the principles of the present invention. The dispenser  10  is formed as a rolling cart and includes a frame  14 , having a back  16 , a top  18  including a handle  20 , and a bottom or base  22 . The frame  14  can be formed from tubular elements, as shown, to improve strength and endurance and to reduce overall costs. The bottom  22 , back  16  and handle  20  are formed from vertical uprights  24  and one or more cross-pieces  26 . The upper portion  28  of the cart  10  can be removable for shipping and storage. A pair of braces  30  extend between the uprights  24  of the back  16 . An axle or stub  32  (the rear part of which is shown) extends outwardly or forwardly from the braces  30 . 
         [0027]    To facilitate moving the coil C and cart  10 , the cart  10  is configured with wheels  34 . A basket or bin  36  can be disposed at about the handle  20 . The base  22 , opposite of the wheels  34  can be formed as a tubular member, optionally with a rubber or other non-slip (high friction) surface  38 . 
         [0028]    A coil carriage  40  is mounted to the cart  10 . In a present embodiment, the carriage  40  is mounted on the axle  32  that extends outward from the braces  30 . The carriage  40  includes a rear guard  42 , a front guard  44  and a spindle  46  on which the front  44  and rear  42  guards are positioned. As can be seen in the figures, the coil C is sandwiched between the guards  42 ,  44 . 
         [0029]    The spindle  46  is configured to ride on the axle  32 —as such the spindle  46  can be hollow to allow the spindle  46  to slide onto the axle  32 . The entire carriage  40  is thus configured to rotate about the axle  32 , on the cart  10 . 
         [0030]    Each the rear  42  and the front  44  guards are formed by spoke members  48  and a ring member  50  at about the ends of the spoke members  48 . The coil C is sandwiched between the guards  42 ,  44  when in position on the dispenser  10 . As will be discussed below, this is important to prevent strap pull-down. In a present embodiment, there are three spoke members  48   a - c  positioned at 120 degrees from one another. It will, however be appreciated that other numbers of spoke members (e.g., four, five or the like) can be used to support the ring member  50 , and that carriages  40  with such other numbers of spoke members  48  are within the scope and spirit of the present invention. 
         [0031]    Coil posts  52  are positioned on two of the rear guard spoke members,  48   a,b,  extending outwardly, or toward the front guard  44 . The posts  52  are configured for receiving the coil C—that is, the coil C (actually, the core R of the coil C) rests on the posts  52 . A clamp member  54 , such as the illustrated cammed clamp, is configured to move up to and against the core R, to lock the core R (and thus the coil C) between the posts  52  and the clamp  54  on the carriage  40 . The clamp  54  is fitted into a slotted opening  56  in the spoke  48   c  to allow the clamp  54  to move inward and outward so that it can be snugged up against the core R. 
         [0032]    The present arrangement, which uses two posts  52  and a clamp  54  at 120 degrees from one another is configured to allow for the use of a coil C (core R) that may be out of round, for example, a crushed core, in the dispenser  10 . Conventional dispensers do not function well with such out-of-round coils, and as such some other means to use the strap must be devised. The present configuration, on the other hand, allows for using such out-of-round coils, and prevents the coil C from moving or shifting between the posts  52  and clamp  54 , and maintains the coil C centered, as the carriage  40  rotates in the dispenser  10 . 
         [0033]    The dispenser  10  includes a brake/payout guide assembly  58 . The assembly  58  is mounted to the frame  14  along, for example, one of the back vertical posts  24 . The assembly  58  is pivotally, biasedly mounted to the dispenser  10  (by a post  57  and spring  59 ) to urge the assembly  58  into contact with the coil C and/or the coil carriage  40 . In a present dispenser  10 , the brake/payout assembly  58  contacts the carriage  40  at one or both of the front  44  and rear  42  guards to provide a braking function. It will, however, be appreciated that the assembly  58  can be configured to contact the coil C instead of or in addition to the guards  42 ,  44 . 
         [0034]    The assembly  58  includes a bracket  60  having a contact roller  62  and a feed roller  64 . The feed roller  64  is biased (by one or more springs  66 ) toward the contact roller  62 . In use, strap S is dispensed from the top T of the coil C (a top payout) and is threaded into a payout control portion or nip region  68  between the contact  62  and feed  64  rollers. This prevents uncontrolled payout of the strap S by absorbing any inertia generated by the “pulled” strap at the pinch region  68  between the rollers  62 ,  64 . 
         [0035]    The contact roller  62  is mounted to the bracket  60  by an axle  70 . A bearing set  72  (presently a needle bearing set) is disposed in the center opening  74  in the roller  62  to allow the contact roller  62  to freely roll about the axle  70 . A one-way clutch  76  is positioned at about one end of the roller  62  (as it is mounted to the bracket  60 ), to allow for forward rotation of the roller  62  and to prevent rearward rotation. The one-way clutch  76  can take the form of a one-way bearing, as indicated at  78 . The roller  62  can be mounted to the bracket  60  with washers  80  and a spring washer  82  (see  FIG. 6 ) on the axle  70  to maintain the roller  62  centered and in tension in the bracket  60 . This configuration also facilitates slowing the roller  62 , and urges the roller against bracket wall  73  to prevent strap from inadvertently slipping between the roller  62  and the wall  73 . 
         [0036]    The contact roller  62  includes friction-surface contact pads  82 . In a present configuration, there are two pads,  82   a,b , one each positioned to contact the front  44  and rear  42  guards when the dispenser  10  is loaded with a narrowest (3 inch) coil C. When the dispenser  10  is loaded with a widest (e.g., 6 or 8 inch) coil C, the rear contact pad  82   a  contacts the rear guard  42 , but the front contact pad  82   b  does not contact the front guard  44 . 
         [0037]    The feed roller  64  is maintained in contact with the contact roller  62 . The feed roller  64  is mounted to the bracket  60  by an axle  84  that is positioned in an oversized opening  86 —that is, the opening  86  is sufficiently larger than the axle  84  so that the feed roller  64  can move toward and away from the contact roller  62 . 
         [0038]    The one or more springs  66  are positioned to urge the feed roller  64  into contact with the contact roller  624 . In a present embodiment, the springs  66  are positioned between a spring block  90  and the axle  84  to urge the feed roller  64  (by applying a force on the axle  84 ) toward (and into engagement with) the contact roller  62 . 
         [0039]    In a present embodiment, both the contact  62  and feed  64  rollers are formed from a low friction material such as a low friction plastic, to allow the strap S to be freely pulled from the coil C, but in a controlled manner. It will be appreciated that one or both of the rollers  62 ,  64  can be formed from other materials, such as various metals and the like and retain the desired low friction characteristics. 
         [0040]    Use of the dispenser  10  is straight-forward. Strap S is fed from the top T of the coil C into the nip region  68  between the contact  62  and feed  64  rollers and is fed to the downstream equipment (e.g., a packaging or strapping machine, not shown). Strap S is fed from the below the rollers  62 ,  64 , upward into the nip  68 , and over the feed roller  64 . As strap S is pulled from the coil C (see directional arrow at  92  in  FIG. 4 ), it is pinched to prevent generating slack between the coil C and the brake/payout assembly  58 . The spring  59  force exerted by the brake/payout assembly  58  on the guards  42 ,  44  (or the coil C) is sufficient to brake continued rotation of the coil C. 
         [0041]    It will be understood that pull down, or pulling the strap S downward along the side of the coil C (rather than from the top T of the coil C), is a problem situation that must be prevented. Otherwise, the strap S can get caught on the spindle  46  and cause strap feed problems. 
         [0042]    The present dispenser  10  prevents such undesirable pull down occurrences by the engagement of the guards  42 ,  44  with the sides of the coil C, at the core R. Specifically, the front and rear guard spoke members  48  maintain the coil strap along the periphery P of the coil (at the top T). As such, if the strap S slips from the periphery P, toward the spindle  46 , the position of the spoke members  48  engaging the core R prevents the strap S from slipping down any further than the location at which the spoke members  48  contact or engage the core R. And, as the coil C continues to rotate, the strap S is pulled from between the coil C and the spoke members  48  and is realigned to the top T or periphery P of the coil C as the spoke member  48  approaches the twelve o′clock position. In this manner, strap pull down is prevented and the strap S is maintained at the coil periphery P. 
         [0043]    Another feature of the present dispenser  10  is an optional quick-release center hub nut or hub lock  94 . One such hub nut  94 , which is illustrated in  FIG. 1 , can be configured so that it slides along the spindle  46  and begins to thread at the point at which the nut  94  is tightened onto the spindle  46 , abutting the front guard  44 . This reduces the time needed to loosen the nut  94 , remove the front guard  44 , replace a strap coil C and replace the guard  44  and nut  94 . The nut  94  can be configured as a wing-type nut, a knurled knob or any other manually operable element. Such quick-release fasteners (e.g., quick release nuts), as well as other securing elements, traditionally threading or otherwise, will be recognized by those skilled in the art, and are within the scope and spirit of the present invention. 
         [0044]    The present dispenser  10  has a number of advantages over those presently known. First, the dispenser  10  is loaded (with a coil C) in the upright or standing position. This eliminates the need to lay the dispenser  10  on its side to load a coil C and then stand the dispenser  10  upright for use. In that coils C can weigh in excess of 100 pounds this makes loading and use easier than known dispensers. In addition, as set forth above, the unique design of the front  44  and rear  42  guards (and the spoke members  48 ) prevents undesirable pull down, and provides an auto-fed realignment of strap S from the coil C during pay out from the dispenser  10 . In addition, the quick release hub  94 , easy-to-handle front guard  44  and coil support posts  52  and coil lock (clamp  54 ) facilitate ready coil C replacement. The carriage  40  design and brake/payout assembly  58  configuration make strap pay out consistent and paced. 
         [0045]    In addition, it will be appreciated that the dispenser  10  has a low center of gravity which reduces the opportunity for tipping or general instability in use. It will also be appreciated that the dispenser  10  design allows for using the dispenser  10  with a wide variety of strap S sizes (widths) and types. As set forth above, the brake/payout guide assembly  58  is a single width and is usable with any width coil C that can be used on the dispenser  10 . Thus, unlike known dispensers which require adjusting the width of the brake or guide assembly for each coil width, the present dispenser  10  is more quickly loaded and set up for use with a universal brake/payout guide assembly  58 . 
         [0046]    All patents referred to herein, if any, are hereby incorporated herein by reference, whether or not specifically done so within the text of this disclosure. 
         [0047]    In the present disclosure, the words “a” or “an” are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. 
         [0048]    From the foregoing it will be observed that numerous modifications and variations can be effectuated without departing from the true spirit and scope of the novel concepts of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated is intended or should be inferred. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.