Patent Publication Number: US-7222816-B2

Title: Guide roller with flanges for a dispenser

Description:
BACKGROUND 
   Institutions and businesses using dispensers of rolled sheet material products in commercial settings depend upon the dispenser to reliably dispense sheet material until the sheet material is depleted. One desirable type of dispenser in such a setting is a “hands free” dispenser. Such a dispenser permits a user to grasp a tail of a sheet material extending from an exit port in the dispenser and to withdraw the sheet of material for use. In this manner, a user is not required to touch the dispenser. When the sheet material in such a dispenser becomes bunched up and jammed within the dispenser, the dispensing mechanism is unable to adequately dispense sheet material to a user, and dispensing failure occurs. Although some dispensers have a rotational device to allow users to dispense such bunched or jammed sheet material, the dispenser must be touched by the user to activate the rotational devise and obtain a sheet of material. This action defeats the purpose of the “hands-free” dispenser, where a user may keep his/her hands free of contamination by avoiding touching a dispenser. 
   It would be desirable to have an apparatus which prevented bunching, jamming and/or dispensing failure of rolled sheet material in a “hands-free”-type dispenser. Such a device would desirably be simple, but it would also be effective in guiding the sheet material from a roll in an even, aligned and measured manner into and through the dispensing mechanism. Further, such an apparatus would desirably prevent the sheet material from moving transversely from one side to the other within a dispenser housing. Such an apparatus would allow sheet material from a new, full roll of sheet material product as well as from a partially or nearly depleted roll of sheet material product to be dispensed reliably from the dispenser without bunching, jamming and/or dispensing failure. 
   DEFINITIONS 
   As used herein, the term “exit port” or “dispensing port” is the opening in a housing of a dispenser for the passage of sheet material out of the dispenser. 
   As used herein, the term “sheet material” means a material that is thin in comparison to its length and breadth. Generally speaking, sheet materials should exhibit a relatively flat planar configuration and be flexible to permit folding, rolling, stacking, and the like. Exemplary sheet materials include, but are not limited to, paper tissue, paper towels, label rolls, or other fibrous, film, polymers, or filamentary products. 
   As used herein, the term “fasteners” means devices that fasten, join, connect, secure, hold, or clamp components together. Fasteners include, but are not limited to, screws, nuts and bolts, rivets, snap-fits, tacks, nails, loop fasteners, and interlocking male/female connectors, such as fishhook connectors, a fish hook connector includes a male portion with a protrusion on its circumference. Inserting the male portion into the female portion substantially permanently locks the two portions together. 
   As used herein, the term “hinge” refers to a jointed or flexible device that connects and permits pivoting or turning of a part to a stationary component. Hinges include, but are not limited to, metal pivotable connectors, such as those used to fasten a door to frame, and living hinges. Living hinges may be constructed from plastic and formed integrally between two members. A living hinge permits pivotable movement of one member in relation to another connected member. 
   As used herein, the term “couple” includes, but is not limited to, joining, connecting, fastening, linking, or associating two things integrally or interstitially together. 
   As used herein, the term “about” includes plus or minus 10 percent of the numeral stated at each end of the range. 
   These terms may be defined with additional language in the remaining portions of the specification. 
   SUMMARY OF THE INVENTION 
   In response to the difficulties and problems discussed herein, an apparatus adapted for use with a dispenser housing for rolled sheet material to provide reliable dispensing of sheet material therefrom is provided. The apparatus is adapted for a dispenser housing which includes a roll support configured to hold at least one cylindrical roll of sheet material and a dispensing assembly. The dispensing assembly includes an exit port to permit sheet material to be withdrawn therefrom. The cylindrical roll of sheet material is desirably mounted on a portion of the roll support. The roll includes opposing flat surfaces and an outer circumference, the apparatus comprises a guide roller including an elongated central portion positioned between two opposing ends and a flange positioned near each end of the guide roller. The central portion is configured to be positioned adjacent the outer circumference of a roll of sheet material when the roll is a new roll disposed in the dispenser housing. At least a portion of an inner surface of each flange is positioned adjacent a flat surface of the roll of sheet material when the roll is a new roll. The guide roller is positioned such that sheet material flows from the roll between the flanges and over the central portion of the guide roller to the dispensing assembly. The flow of sheet material is aligned on its path to the dispensing assembly such that bunching and jamming of non-aligned sheet material is eliminated. 
   In another aspect of the invention, a system adapted for use with a dispenser housing for rolled sheet material to provide reliable dispensing of sheet material therefrom is provided. The system includes a dispenser housing which includes a roll support configured to hold at least one cylindrical roll of sheet material and a dispensing assembly. The dispensing assembly includes an exit port to permit sheet material to be withdrawn from the dispensing assembly and housing. The cylindrical roll of sheet material is desirably mounted on a portion of the roll support. The roll includes opposing flat surfaces and an outer circumference. The system also includes a guide roller positioned between the roll support and the dispensing assembly. The guide roller includes an elongated central portion positioned between two opposing ends and a flange positioned near each end of the guide roller. The central portion is configured to be positioned adjacent the outer circumference of a roll of sheet material when the roll is a new roll disposed in the dispenser housing. At least a portion of an inner surface of each flange is positioned adjacent a flat surface of the roll of sheet material when the roll is a new roll. The guide roller is positioned such that sheet material flows from the roll between the flanges and over the central portion of the guide roller to the dispensing assembly. The flow of sheet material is aligned on its path to the dispensing assembly such that bunching and jamming of non-aligned sheet material is eliminated. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a prior art dispenser which may be used with the present invention; 
       FIG. 2  is a schematic cross sectional view of  FIG. 1  taken along lines  2 — 2 ; 
       FIG. 3  is a schematic cross sectional view similar to  FIG. 2 , but showing transverse movement of sheet material causing bunching and jamming of sheet material within a dispensing actuator roller assembly; 
       FIG. 4  is a side view of a guide roller of the present invention which may be used with a dispenser, such as the dispenser shown in  FIG. 1 ; 
       FIG. 5  is a front side view of the guide roller of  FIG. 4  positioned in the dispenser of  FIG. 1 ; 
       FIG. 6  is a front side view of the guide roller of  FIGS. 4 and 5  positioned in the dispenser of  FIG. 1 , but showing sheet material flowing over the guide roller; 
       FIG. 7  is a side perspective view of the guide roller of  FIGS. 4–6  positioned in the dispenser of  FIG. 1 , showing the rotationally coupled connection of the guide roller to an arm or a roll support 
       FIG. 8  is a schematic sectional view of  FIG. 6  taken along lines  8 — 8 ; and 
       FIG. 9  is a schematic sectional view similar to  FIG. 8 , but showing a roll of sheet material which is partially depleted. 
   

   DETAILED DESCRIPTION 
   Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention and is not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment or figure can be used on another embodiment or figure to yield yet another embodiment. It is intended that the present invention include such modifications and variations. 
   The present invention provides an apparatus for dispensing rolled material. Such rolled material may include, but is not limited to, woven materials, nonwoven materials, synthetic materials, natural materials, foils, polymer films, any combination thereof, and so forth. Desirably, the rolled material is provided as a sheet material within a roll. Exemplary sheet materials for which the present invention is suitable include, but are not limited to, absorbent sheet materials such as towels, wipers, tissue, and so forth. Suitable sheet materials are disclosed, by way of non-limiting examples only, in U.S. Pat. No. 5,048,589 to Cook et al., U.S. Pat. No. 5,399,412 to Sudall et al., U.S. Pat. No. 5,674,590 to Anderson et al., U.S. Pat. No. 5,772,845 to Farrington, Jr. et al., U.S. Pat. No. 5,904,971 to Anderson et al., U.S. Pat. No. 6,248,212 to Anderson et al., and U.S. Pat. No. 6,273,996 to Hollenberg et al., the entire contents of which are herein incorporated by reference. The sheet materials for which the present invention is suitable may be wound around a core (not shown). Alternatively, as illustrated in  FIG. 3 , the sheet materials are wound into a coreless roll. The sheet materials for which the present invention is suitable may have regularly spaced zones of weakness extending substantially across the width of the sheet material. The zones of weakness are used to separate or cut the sheet material into individual sheets and may be, for example, defined by a series of perforations, a zone of much lower basis weight, and so forth. 
   The present invention is desirably used with a dispenser which has a housing or dispensing module. One suitable dispenser having a housing or dispensing module is disclosed, by way of non-limiting examples only, in U.S. Pat. No. 6,314,850 B1 to Morand, the entire contents of which are herein incorporated by reference for all purposes. Other dispensers which are suitable for use with the present invention will be known by those skilled in the art. 
   One prior art dispenser having a dispensing module or housing  12  is shown in  FIG. 1 . The dispensing module or housing  12  is desirably positioned in an outer paper towel dispenser cabinet  14  (portions of which are illustrated in  FIGS. 5–7 ) and secured thereto by any suitable fasteners or mechanism(s). 
   A roll support  16  is operatively associated with the dispensing module  10  to rotatably support a cylindrical roll  18  of sheet material  20 . The roll support  16  includes two double-ended arms  22  spaced-apart from one another and a roll engagement member  19  positioned at the distal or upper ends  24  of each arm  22  for engaging each flat end  25  and/or an opening  25 ′ in the roll  12  and permitting rotation of the roll  18 . The roll  18  is directly rotatably supported by the roll engagement members  19 . The roll engagement member  19  may include a support roller (not shown). 
   The arms  22  are pivotally connected to the housing  12  by pivot connectors  26 . The pivot connectors  26  are located at the lower ends  28  of the arms. 
   A dispensing assembly or a dispensing actuator roller assembly  30  is positioned within the housing  12  and spaced-apart from the roll support  18 . The dispensing actuator roller assembly  30  receives the sheet material  20  from the roll  18  of sheet material  18 . When the dispensing actuator roller assembly  30  is actuated by a user, it rotates in a predetermined direction to provide a single sheet of sheet material  20  to a user. The dispensing actuator roller assembly  30  desirably has a cylindrically-shaped outer peripheral portion  32  which includes strips of material  34  which are desirably parallel, spaced-apart channels which are covered by a curved toweling guide plate  36 . A pivotably mounted cutter blade (not shown) is desirably mounted on the outer peripheral portion of the dispensing actuator roller. The blade is movable between a first position (not shown) in which the cutting edge of the place is positioned closely adjacent to the outer peripheral portion of the dispensing actuator roller and a second position (not shown) in which the blade is disposed at an angle relative to the outer peripheral portion with the cutting edge of the blade spaced from the outer peripheral portion of the dispenser actuator roller. The cutter blade when in the second position projects in a direction generally opposed to the direction of rotation of the dispenser actuator roller so that pulling force exerted on the sheet material by a user will bear against the cutting edge of the cutter blade to sever a single sheet from the sheet material (not shown). 
   A cylindrical member  38  may be provided with the dispensing actuator roller assembly  30  and it is desirably rotatably mounted between the side walls  40  of the housing  12  and positioned against the dispensing actuator roller assembly  30 . Springs  42  desirably extend between the housing  12  and the ends  44  of the cylindrical member  38  to bias the cylindrical member  38  against the outer peripheral portion  32  of the dispensing actuator roller assembly  30  and form a nip therebetween ( FIGS. 2 ,  3 ,  8  and  9 ). Other biasing apparatus, such as O-rings, bands, and so forth may be utilized as well. While the cylindrical member  38  may be considered as a separate element in the present embodiment, it will be understood that, alternatively, the cylindrical member  38  may be included as a portion of the dispensing assembly  30 . 
     FIG. 2  illustrates a cross-sectional view of  FIG. 1 , showing the sheet material  20  flowing from a new roll  50 , over the cylindrical member  38  through the nip and around a portion of the dispensing actuator roller assembly  30  and out an exit port  46 . A tail  48  of the sheet material  20  desirably extends from the exit port  46  for a user to grasp for withdrawal of a single sheet of sheet material  20 . 
   Problems, however, occur with this arrangement. The sheet material  20  from a roll  18 ,  50  (the number “18” applies to a roll having a number of sheets withdrawn therefrom; the number “50” applies to a new roll having fewer than three (3) sheets withdrawn therefrom) has room within the housing  12  and a tendency to move transversely therein. When this occurs, the sheet material  20  tends to bunch to one side or the other of the dispenser housing  12 , and moves past the cylindrical member  38  and through the nip and against the dispensing actuator roller assembly  30  in this bunched condition. Such bunching of the sheet material  20  due to its displacement to one side of the housing  12  results in a jam of sheet material  20  within the dispensing actuator roller assembly and inadequate dispensing and/or dispensing failure. The sheet material  20 , when bunched within the dispensing actuator roller assembly  30 , may break off and/or tear within the dispensing actuator roller assembly  30 . Such dispensing failure may result in a complete failutre, until maintenance personnel have cleared the blockage or jam. Therefore,  FIG. 2  illustrates the ideal movement of the sheet material  20  from the roll  18 ,  50  past the cylindrical member  38  and through the dispensing actuator roller assembly  30  to the exit port  46 .  FIG. 3  illustrates the common displacement problem described above. When the sheet material  20  from the roll  18 ,  50  moves transversely, it bunches up and jams on one side of the housing  12 . This bunching moves past the cylindrical member  38  into the nip and results in jamming of the sheet material  20  in the dispensing actuator roller assembly  30  and dispensing failure when sheet material is not available for withdrawal at the exit port  46  by a user. 
   As illustrated in  FIGS. 4–9 , the present invention uses a guide roller  52  to maintain the sheet material  20  in alignment with the cylindrical member  38  and/or the dispensing actuator roller assembly  30 . As shown in  FIG. 4 , the guide roller  52  includes an elongated central portion  54  positioned between two ends  56 . The central portion  54  may be constructed from two intersecting axially disposed plates  58  positioned generally at about a 90 degree relative to each other. The plates  58  may include a plurality of spaced-apart transversely disposed circular disks  60  positioned about or formed with the plates  56 . The configuration of the central portion  54  is intended to be non-limiting; any configuration that operates as described may be used. Each end  56  desirably has a flange  62  positioned adjacent thereto. The flange  62  is desirably slightly tapered outward from an inner surface  64  positioned adjacent the sheet material  20 , as illustrated best in  FIG. 4 . Each end  56  includes a pin  65  or similar apparatus which permits the guide roller  52  to be rotatably coupled to an aperture (not shown) in each arm  22  of the roll support  16 . 
   The guide roller  52  is positioned closely adjacent and desirably against an outer circumference  66  defined by the cylindrical body  67  of the new roll  50  of sheet material  20 , as illustrated in  FIGS. 5–8 . The guide roller  52  is desirably positioned such that sheet material  20  flows from the roll  50 ,  18  between the flanges  62  and over the central portion  54  of the guide roller  52  to the dispensing actuator roller assembly  30 , the flow of sheet material  20  aligned on its path to the dispensing actuator roller assembly  30  such that bunching and jamming of non-aligned sheet material  20  is eliminated, and dispensing failure is greatly reduced or eliminated. The flange  62  positioned near each end  56  of the guide roller  52  is desirably positioned such that at least a portion of the inner surface  64  of the flange  62  is closely adjacent or against the flat surface  25  of each end of the new roll  50 . In this manner, the flow of sheet material  20  is regulated from the roll  18 ,  50  to flow evenly and in alignment from the roll  18 ,  50  to the cylindrical member  38 , through the nip and the dispensing actuator roller assembly  30  and through the exit port  46 , as illustrated in  FIG. 8 . Such regulation and alignment reduces bunching of the sheet material  20  which results in jamming and/or dispensing failure from non-aligned sheet material. Without such alignment, as noted previously, the sheet material  20  may move transversely from the roll  18 ,  50  and/or other elements in the housing  12  into the dispensing actuator roller assembly  30 , resulting, at times, in bunching, jamming and/or dispensing failure ( FIG. 3 ). 
   The guide roller  52  is maintained in a rotatable position relative to the roll  18 ,  50  and the cylindrical member  38 , and it desirably rotates to facilitate flow of sheet material  20  thereover. The guide roller  52  is desirably adjacent or closely adjacent to the new roll  50  until the new roll  50  has dispensed about 100 sheets therefrom. It has been discovered that once the new roll  50  has been partially depleted by about 100 sheets and therefore reduced in size, the flanges  62  are not required to be positioned as closely to the flat surfaces  25  of the roll  18 . In fact, the flat surfaces  25  similarly are reduced in size with depletion of the roll  18  and are therefore positioned near but do not touch the flanges  62 , as shown in  FIG. 9 . Similarly, the central portion  54  of the guide roller  52  is positioned near but further away from the outer circumference  66  of the roll  18  as single sheets of sheet material  20  are withdrawn from the roll  18  and the roll is partially depleted. In this position, the central portion  54  does not touch the outer circumference  66  of the roll  18 . The sheet material  20  continues to be maintained in alignment, however, as the sheet material  20  continues to flow between the flanges  62  and over the central portion  54  of the guide roller  52  until the roll  50 ,  18  is completely depleted and all sheet material  20  is withdrawn therefrom. 
   Turning back to  FIG. 4 , each flange  62  is tapered  68  outward from the inner surface  64  positioned adjacent the flat surface  25  of a roll  18  or new roll  50  to the outer surface  70  positioned adjacent the housing  12 . The taper  68  of each flange  62  directs the sheet material into alignment with the dispensing actuator roller assembly  30 . Such taper  68  is desirably between about 0.3 inches and 0.05 inches. More desirably, such taper is between about 0.2 inches and 0.5 inches. Even more desirably, such taper is between about 0.15 inches and 0.8 inches. Yet even more desirably, the taper is between about 0.1 inches and 0.01 inches. 
   Each flange  62  desirably has a diameter  72  in a range of about 0.5 inch to about 4.0 inches. Even more desirably, each flange has a diameter in a range of about 1.0 inch to about 3.0 inches. Yet even more desirably, each flange has a diameter of about 1.5 inches to about 2.5 inches. 
   Each central portion  54  of the guide roller  52  desirably has a diameter  74  of about 1.5 inches to about 0.25 inches. Even more desirably, central portion has a diameter of about 1.0 inch to about 0.35 inch. Yet even more desirably, each central portion has a diameter of about 0.8 inch to about 0.4 inch. 
   Each central portion  54  desirably has a length  76  between flanges  62  which permits it to be positioned closely adjacent or against an outer circumference  66  of a roll  50  of sheet material  20  without either flange  62  touching the outer circumference  66 . Desirably, the length  76  of the central portion  54  permits each inner surface  64  of each flange  62  to be positioned closely adjacent to the flat surface  25  of the new roll  50 . “Closely adjacent” as used herein relative to each flange  62  means that at least a portion of each inner surface  64  of each flange  62  is positioned within about 0.25 to about 0.02 inches from the flat surface  25  of the new roll  50 . Alternatively, however, it will be understood that at least a portion of an inner surface  64  of at least one flange  62  may be positioned against a flat surface  25  of the new roll  50  or roll  18 . “Closely adjacent” as used herein relative to the center portion  54  of the guide roller  52  means that at least a portion of the center portion  54  is positioned within about 0.5 to about 0.01 inches from the outer circumference  66  of the new roll  50 . Alternatively, however, it will be appreciated that at least a portion of the center portion  54  of the guide roller  52  may be positioned against the outer circumference  66  of the new roll  50 . “New roll” as used herein means a roll which is provided to the dispenser which has fewer then three sheets withdrawn from the roll  50 . “Partially depleted roll” as used herein means a roll  18  having at least 100 sheets withdrawn from the roll  18 . 
   It will be appreciated, as illustrated in  FIGS. 8 and 9 , that the sheet material  20  follows a serpentine path  78  from the roll  50 ,  18  to the exit port  46 . This serpentine path  78  is desirably defined by three turns which are generally semi-circular turns  80  in the path  78 . In this manner, the flow of sheet material  20  is regulated and aligned on its path  78  to the dispensing assembly  30  such that non-alignment of sheet material  20  is eliminated. 
   A tapered flange  62  is desirable. However, it will be appreciated that a flange without a taper may be used as an alternative embodiment (not shown). 
   While certain characteristics are described in specific embodiments, any one or more characteristics, features, and/or elements may be used in any combination in any embodiment, or to create a particular embodiment from the disclosures, teachings, and/or suggestions provided herein. While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.