Abstract:
A sheet material dispenser for dispensing portions of sheet material to which a liquid composition has been applied includes a feed mechanism for holding and advancing the sheet material, and a drive mechanism which displaces a carriage along a path of motion. An applicator assembly, deployed on the carriage, includes at least one container containing a composition to be applied to the sheet material and at least one applicator for directing a quantity of the composition towards a surface of the sheet material. In preferred cases, each container and a corresponding applicator are combined as an interchangeable prefilled dispensing container to facilitate user replacement. A controller actuates the applicator assembly to apply a quantity of the composition to the surface of the sheet material while the drive mechanism carries the applicator assembly along the path of motion.

Description:
FIELD AND BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to a disposable sheet material dispenser, and in particular, the manner in which a composition is applied to a sheet material. 
         [0002]    There is a growing demand and consumers expectations for more environment friendly products, and products containing fewer synthetic ingredients. This applies especially when dealing with infants, babies and people who need medical treatment. 
         [0003]    Wet tissues or “wipes” are widely used. In order for the material of the wipes to remain stable during a long period of soaking in liquid, the material is typically a non-woven cloth with a high proportion of synthetic non-biodegradable ingredients. The liquid also typically contains significant amounts of preservatives to prevent contamination by microorganisms. Notwithstanding the presence of such preservatives, the use of an open package of wet tissues for a long period may still result in contamination of the tissues from human touch or other exposure to sources of bacteria etc. 
         [0004]    There is still a need to provide a flexible efficient and hygienic method to supply a wet tissue at need with the wetting operation being performed at the time of delivery with a choice between different liquids and adjustable moisture in the tissue. 
         [0005]    U.S. Pat. No. 6,457,434 B1 addresses some of the aforementioned shortcomings by providing a user with a sheet material dispenser in which the cleaning agent is stored in closed containers protected from external contamination until needed. When the user activates the device, it applies a chosen agent to a sheet material, and then dispenses it to the user. The aforementioned dispenser provides the user with additional options in which he is able to select a particular cleaning agent or agents, and to vary the quantity applied to the sheet material. However, this device requires maintenance activities inconvenient for an average user. The user periodically needs to refill the spent cleaning agent containers. This process involves navigating through an array of tubes to locate the empty container, removing the appropriate lid with its attached tube, refilling the appropriate container, re-fastening the lid and its attached tube assembly, and bleeding out the air remaining in the tubes. The containers of the device disclosed cannot be hermetically sealed, and any change between different compositions to be applied is complicated by the need to thoroughly clean out the container prior to refilling. 
         [0006]    Other patents of possible relevance to the present invention include U.S. Pat. No. 4,598,664, U.S. Pat. No. 3,980,203, U.S. Pat. No. 3,979,781, EP 0680721, DE 3922159, DE 3409905, DE 3109205, WO 8804150, U.S. Pat. No. 3,995,582, U.S. Pat. No. 3,837,595, GB 1333465, U.S. Pat. No. 5,265,509, U.S. Pat. No. 5,044,556, U.S. Pat. No. 3,804,061, U.S. Pat. No. 3,776,773, GB 2045722, WO 9304622, DE 3101474 and CH 653874. 
         [0007]    There is therefore a need for a dispenser that applies a composition to a sheet material immediately prior to its use while simplifying the maintenance activities required. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention is a sheet material dispenser for dispensing portions of sheet material to which a composition has been applied. 
         [0009]    According to the teachings of the present invention there is provided, a sheet material dispenser for dispensing portions of sheet material to which a composition has been applied, the dispenser comprising: (a) a feed mechanism for holding and advancing the sheet material, (b) a drive mechanism including a carriage, the drive mechanism being configured to displace the carriage along a path of motion; (c) an applicator assembly deployed on the carriage so as to be carried along the path of motion, the applicator assembly including at least one container containing a composition to be applied to the sheet material and at least one applicator for directing a quantity of the composition towards a surface of the sheet material; and (d) a controller associated with the feed mechanism, the drive mechanism and the applicator assembly, the controller being configured to actuate the applicator assembly to apply a quantity of the composition to the surface of the sheet material while the drive mechanism carries the applicator assembly along the path of motion. 
         [0010]    According to a further feature of the present invention, the container and at least part of the applicator are implemented together as an interchangeable prefilled dispensing container. 
         [0011]    According to a further feature of the present invention, the applicator assembly includes a plurality of the containers and a plurality of the applicators, a first of the containers containing a first composition selectively dispensed by a first of the applicators, and a second of the containers containing a second composition different from the first composition selectively dispensed by a second of the applicators, and wherein the controller includes an electronic selection mechanism for selectively actuating the applicator to apply a desired selection of the first and second compositions. 
         [0012]    According to a further feature of the present invention, the controller is configured to selectively vary a quantity of the composition applied to the sheet material by the applicator. 
         [0013]    According to a further feature of the present invention, there is also provided a cutting mechanism selectively actuated by the controller and deployed to sever a portion of the sheet material. 
         [0014]    According to a further feature of the present invention, the container is implemented as a pressurized container, and wherein the applicator includes a spray nozzle and an actuator to actuate the spray nozzle so as to direct the composition onto the sheet material. 
         [0015]    According to a further feature of the present invention, the pressurized container and the spray nozzle are implemented as an interchangeable prefilled dispensing container. 
         [0016]    According to a further feature of the present invention, the carriage includes engagement features for releasably mechanically engaging the interchangeable prefilled dispensing container, and wherein the engagement features and the interchangeable prefilled dispensing container are shaped to maintain a predetermined alignment of the spray nozzle relative to the carriage. 
         [0017]    According to a further feature of the present invention, the container is implemented as a non-pressurized container, and wherein the applicator includes a pump mechanism and an actuator for actuating the pump mechanism so as to direct the composition from the container towards the sheet material. 
         [0018]    According to a further feature of the present invention, the pressurized container and the pump mechanism are implemented as an interchangeable prefilled dispensing container. 
         [0019]    According to a further feature of the present invention, the interchangeable prefilled dispensing container further includes a spray nozzle, and wherein the carriage includes engagement features for releasably mechanically engaging the interchangeable prefilled dispensing container, and wherein the engagement features and the interchangeable prefilled dispensing container are shaped to maintain a predetermined alignment of the spray nozzle relative to the carriage. 
         [0020]    According to a further feature of the present invention, the controller is configured to selectively vary a speed of motion of the carriage, thereby varying a quantity of the composition applied to the sheet material by the applicator. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    The invention is herein described, by way of example only, with reference to the accompanying drawings, wherein: 
           [0022]      FIG. 1  is an isometric view of a sheet material dispenser, constructed and operative according to the teachings of the present invention, the dispenser being shown with a side panel removed and a front panel open to reveal the internal mechanism. 
           [0023]      FIG. 2  is an isometric view similar to  FIG. 1  with additional components removed to review the primary features of a loading system. 
           [0024]      FIG. 3  is an isometric view similar to  FIG. 1  showing selectively the primary components of an applicator system. 
           [0025]      FIG. 4  is an isometric view of a cutter system from the dispenser of Figure 
           [0026]      FIG. 5  is a side view of a preferred embodiment from the dispenser of  FIG. 1  showing the main components of an applicator mechanism employed for a non-pressurized container. 
           [0027]      FIG. 6  is a general circuit diagram for the dispenser of  FIG. 1  showing the primary electrical components. 
           [0028]      FIG. 7  is a basic drawing of the control panel for the dispenser of  FIG. 1  showing several controls and a system status display. 
           [0029]      FIG. 8  is a side view of an alternative embodiment from the dispenser of  FIG. 1  showing an applicator mechanism employed for a pressurized container. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0030]    The present invention is a device that applies a chosen composition to a sheet material and then dispenses the sheet material to the user. Preferred implementations of the dispenser provide the user with options to apply single or multiple compositions and to regulate the quantity applied. 
         [0031]    The principles and operation of the dispenser according to the present invention may be better understood with reference to the drawings and the accompanying description. In general terms, the device of the present invention includes a feed mechanism ( FIG. 2 ) which advances the sheet into a predefined location and holds it firmly in place. A drive mechanism ( FIG. 3 ) moves a carriage holding different types of compositions along the sheet width. Simultaneously an applicator deployed on the carriage applies the composition to the sheet surface. After the applicator completes the application, the feed mechanism ( FIG. 2 ) feeds the sheet and its contents through a dispensing opening and a cutter mechanism ( FIG. 4 ) severs the sheet. 
         [0032]    Referring now to the features of the present invention in more detail, a first preferred embodiment of the drive mechanism includes a motor and gear assembly  12  coupled to a carriage  40  ( FIGS. 3 &amp; 8 ), an encoder and a timing belt  37 , and a carriage guide  39  for defining a direction of motion for the carriage. One or more additional guide rail may support the carriage as it moves along its path of motion. A flange  24  extends from the reverse side of the carriage  40 , and connects to a bearing arrangement seated in the carriage guide  39 . The motor and gear assembly  12  coupled to the bearing arrangement, powers carriage movement along the guide  39 . 
         [0033]    Although the preferred implementation illustrated herein employs a motor and drive belt as a particularly simple and cost-effective option to move the carriage, it will be appreciated that a range of different linear actuators may be used for this purpose. Examples of suitable linear drives suitable for displacing the carriage include, but are not limited to, linear electric motors, jackscrews and ball screws. 
         [0034]    Most preferably, each composition container and at least part of the corresponding applicator are implemented together as an interchangeable prefilled dispensing container  14 . Specifically, the interchangeable prefilled dispensing container  14  preferably includes all components coming in direct contact with the corresponding liquid composition and is preferably supplied as a pre-filled disposable unit generally similar to a common spray-can or pump-action spray (according to the different embodiments to be discussed below). This greatly simplifies the replenishment of the applied compositions to a simple removal of the empty prefilled dispensing container and insertion of a new prefilled dispensing container, and avoids soiling of the inside of the device and other complications of the prior art devices. Dispensing containers  14  are preferably factory filled and are “non-refillable” in the sense that they cannot be readily refilled by the consumer. 
         [0035]    The carriage  40  carries each interchangeable prefilled dispensing container  14  mounted between two protruding container clamp elements  41 , typically formed from or lined with resilient material and spaced to match the container diameter. When the interchangeable prefilled dispensing container  14  ( FIGS. 3 &amp; 8 ) is inserted between the clamp elements, the resilient clamp elements  41  flex slightly holding the container firmly in place ( FIGS. 3 ,  5  &amp;  8 ). Most preferably, interchangeable prefilled dispensing container  14  and container clamp elements  41  are shaped, for example with flat sides, to maintain a predetermined alignment of the spray nozzle relative to the carriage, thereby ensuring application of the applied composition in the correct direction onto the sheet material. 
         [0036]    A first preferred embodiment of the applicator mechanism, illustrated in  FIG. 8 , employs pre-pressurized containers with spray nozzles, preferably integrated into a replaceable prefilled dispensing container  14  for each composition. Each dispensing container includes a pressurized container  32  and a spray nozzle  31  configured to be actuated by pressure on a release button  38 . The spray of each composition is selectively actuated by a corresponding solenoid  33  mounted on the flange of carriage which selectively pulls downwards on lever arm  34 , thereby applying force to actuate release button  38 . An electronic control (discussed further below) is connected to solenoids  33  via flexible wires (not shown) and coordinates the drive and applicator mechanisms. 
         [0037]    Upon dispenser activation, the drive mechanism moves the carriage to one end of the guide where the electronic controller synchronizes the carriage position with the applicator to ensure the applicator starts and stops application of the composition while the corresponding applicator is opposite the sheet material. As the drive mechanism brings the carriage and its contents to the appropriate location, the controller activates the solenoid  33  responsible for releasing a chosen composition. That solenoid exerts a downward force on lever arm  34  which pivots and applies a force on the release button  38  to actuate spray nozzle  31 . The composition is then sprayed onto the sheet material as the carriage continues to traverse the sheet width. 
         [0038]    An alternative embodiment of the carriage and applicator mechanism is illustrated in  FIG. 5 . In this case, the applicator is based upon a pump mechanism, typically operated by relative motion of the container and a lid portion. The pump mechanism preferably feeds to a spray nozzle, similar to the previously mentioned embodiment. 
         [0039]    In this case, the applicator assembly includes a separate, non-pressurized container for every composition type  27 . Each container  27  is mounted so as to be vertically displaceable relative to a cover  26 , thereby actuating a pump mechanism deployed therebetween. Here again, the container, cover and included pump mechanism are preferably implemented as an interchangeable prefilled dispensing container  14 . A pivot lever  25  is actuated by a solenoid  23  to displace container  27  upwards. Depending upon the force generated by the actuator and the volume displaced by each stroke of the pump mechanism, a single pump stroke actuated gradually over the course of the carriage motion may be sufficient to apply the desired quantity of a composition to the sheet material. Alternatively, the up-down pumping motion may be repeated during motion of the carriage in order to provide continuous, or near continuous, coverage of the sheet material. 
         [0040]    Although illustrated herein with a solenoid  23  actuating dispensing through action of a pivot lever  25 , it will be noted that various alternative types of actuator and/or mechanical linkages may be used. By way of non-limiting example, a motor may be employed to operate a ball screw to actuate the pumping displacement, either directly or via a pivot arm. 
         [0041]    Upon dispenser activation, an electronic controller moves the carriage to one end of guide  39  (visible in  FIG. 3 ) to synchronize the carriage position with the applicator to ensure the composition is applied as the carriage traverses the sheet width and stops when it reaches the sheet end. As the carriage begins to traverse the sheet the controller activates the appropriate solenoid  23  (see  FIG. 5 ) responsible for the chosen composition, creating a downward force on a pivot lever  25 . The lever  25  in turn applies an upward force to the underside of a non-pressurized container  27 . The container base  27  then slides upward, thus displacing the composition through the nozzle  26  onto the sheet as the carriage traverses the sheet width. 
         [0042]    According to one option, an electronic controller configured to modulate the solenoid pulse rate and/or pulse duration implements a user selected option to vary the composition application during a single applicator pass. An alternate embodiment includes an electronic controller ( FIG. 6 ) configured to vary the drive mechanism motor speed  12 . 
         [0043]    Turning now to further features of the user interface and control system,  FIGS. 1 and 3  illustrate a preferred implementation of a user control panel, and  FIG. 6  illustrates a corresponding preferred implementation of an electronic controller. For basic operation, the control panel of  FIG. 3  includes three primary actuator buttons  7  for dispensing a portion of sheet material treated with a corresponding one of the available compositions. One or more secondary button  19  allows selection of an “extra fluid” option, applying more than the standard quantity of the selected composition. The increased quantity may be implemented, depending upon the applicator embodiment used, by modifying operation of the applicator, by slowing down the rate of carriage movement, or by applying the selected composition during one or more additional scanning motion of the carriage. For example, a “normal” quantity may be delivered during a single sweep across the sheet material while the extra fluid option is implemented by application of fluid during both sweeps of a bi-directional (to and fro) motion. Various additional functions are preferably provided via a small operation panel, designated  10  in  FIG. 1  and shown in more detail in  FIG. 7 . These options typically include settings for the default quantities and “extra fluid” quantities for each of the composition types. Additionally, or alternatively, the operation panel may allow definition of more complex options such as combinations of different compositions applied to the sheet material in selected proportions. These more complex options may then be actuated directly from the control and display panel, or may be associated with one of the “pre-set” buttons. 
         [0044]    Turning briefly to  FIG. 6 , this illustrates the main inputs and outputs of an electronic controller according to one preferred implementation of the present invention. In this case, in addition to the power supply, the controller receives inputs from the operation panel, from the primary and secondary buttons, and from an encoder and microswitches indicative of various operative parameters (e.g., carriage position, cover open/closed, sheet material correctly/incorrectly positioned). Outputs from the controller typically include control signals to relays powering motors for the feed mechanism, carriage drive mechanism and the cutter mechanism, as well as the solenoids for actuating dispensing of each composition. Additional outputs typically include user interface outputs to various control lights, audio alarms and/or the display panel for indicating various system operation states or programming information to the user. 
         [0045]    Parenthetically, although the present invention is illustrated herein in the context of an example showing three containers for selective application of three different compositions, it will be appreciated that the invention may also be employed to advantage with more or fewer compositions. Thus, in various applications, an implementation with only a single interchangeable prefilled dispensing container  14 , providing selectively a single applied composition (and optionally dry sheet material) may be sufficient. 
         [0046]    Turning now to the remaining features of the device of the present invention, the sheet material feed mechanism preferably includes a sheet material roll support  2   a  ( FIGS. 1 &amp; 2 ) which sits within U-shaped brackets  3  formed on the inside surfaces of the sides of the housing. A roll  2  which serves as the source of the sheet material for the device preferably rotates freely on roll support  2   a . A motor and gear  9  drives sets of pinch rollers  4  and  5  via a timing belt  20 , and its movement is monitored by an encoder  43 . Pinch roller sets  4 ,  5  are preferably manually actuated by depression of a manual feed button  42  to facilitate loading of the sheet material between the pinch rollers. The user inserts the free end of the roll of sheet material between set of pinch rollers  4  and activates the manual feed by depressing button  42  ( FIG. 1 ) until the sheet material passes down through pinch roller set  5 . The feed mechanism then holds the sheet material in place for application of compositions and advances the sheet material as required during operation of the device. Alternatively, one of each pair of pinch rollers may be mounted on the cover  11  so as to facilitate positioning of the roll of sheet material when the device is open and so that the sheet material is gripped when the cover is closed. 
         [0047]    A preferred implementation of a cutter system is shown in  FIG. 4 . The cutter system includes a circular blade  37 , a blade carriage  38 , a motor and gear assembly  15  for displacing the blade carriage and spinning the blade, an encoder and timing belt  36 , and cutter guide  44 . After the composition applicator ( FIGS. 5 &amp; 8 ) has completed the applications, the electronic controller ( FIG. 6 ) activates the sheet feed mechanism ( FIG. 2 ), which advances the sheet together with its applied composition into a final dispensing position. The controller ( FIG. 6 ) than activates the cutter motor  15  which moves a spinning blade along the cutter guide  44  traversing the sheet, and severs the sheet from its roll. 
         [0048]    A user periodically is required to replace spent composition container. He opens the machine cover  11 , removes the empty dispensing container  14  from within the container clamp elements  41 , inserts a full replacement prefilled dispensing container  14  in its place and closes the machine cover. In a preferred embodiment in which the controller keeps track of estimated liquid usage and provides warning of near-empty containers, the user also resets the liquid volume estimate for the corresponding composition via operation panel  10 . This replacement procedure is clearly significantly more convenient, cleaner and faster than the procedure required of the prior reference, U.S. Pat. No. 6,457,434 B1, discussed above. 
         [0049]    Manual feed button  42  ( FIG. 1 ) may be employed to dispense a portion of dry sheet material, such as for wiping up a spill. 
         [0050]    The power supply and control system include a 220V/110V transformer ( FIG. 6 ), and a control card  21  including a microprocessor for coordinating motor, and actuator functions. The card typically receives input signals from 6 position switches, three push switches, three “Additional Liquid” push switches  19 , three motor encoders, and several liquid and sheet material counters. 
         [0051]    The operation panel  10  ( FIG. 7 ) preferably includes an on/off button, and indicators for the system mode, remaining liquid, remaining sheet material, and malfunctions. 
         [0052]    It will be noted that the present invention may be applied to a wide range of applications including, but not limited to, medical applications, cosmetic applications, and healthcare or childcare applications. In the medical field, a dispenser with antiseptic liquid and cleaning liquid may be used to advantage in each medical treatment room such as patient room, surgery room and first aid in a hospital, or in a public healthcare center. The dispenser may also be used to advantage for dispensing medications which are applied by spreading or smearing onto the skin. 
         [0053]    Examples of compositions considered particularly useful for medical applications include, but are not limited to:
       1. Antiseptic liquids for body and hands.   2. Cleaning lotion for hands   3. Alcohol or other skin disinfectant.   4. Anti-inflammatory medicines, especially for large body area.   5. Medications for treatment of psoriasis and other skin conditions, particularly for application to large skin areas.       
 
         [0059]    Examples of compositions considered particularly useful for cosmetic applications include, but are not limited to:
       1. Mineral compositions for skin treatment.   2. Facial lotion for cleaning or moisturizing.   3. All-over body cleanser with or without fragrance.   4. All kinds of after shave lotion or moisturizing lotion.   5. Make-up remover.       
 
         [0065]    Examples of compositions considered particularly useful for healthcare or babycare applications include, but are not limited to:
       1. All-over body cleanser with or without fragrance.   2. Tissues moistened with mineral water and vitamins such as vitamin E for infants and for facial care.   3. All kinds of protecting solutions for infants with or without mineral oil.   4. Alcohol or other skin disinfectant for cleaning.       
 
         [0070]    The on demand customized dispenser is ideally for restaurants and luxury hotel use especially with all over body cleaner with fragrance or fragrance-free. 
         [0071]    It will be noted that the present invention may be implemented with a wide range of sheet materials including, but not limited to, wood-pulp-based tissue paper of single or multiple ply, synthetic tissue and various non-woven fabrics. Most preferably, tissue paper is used. 
         [0072]    It will be appreciated that the above descriptions are intended only to serve as examples, and that many other embodiments are possible within the scope of the present invention as defined in the appended claims.