Patent Document

[0001]    This application claims priority under 35 USC §119(e) to provisional patent application 62/201,398 filed Aug. 5, 2015, incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to dispensers, and particularly to dispensers configured to dispense interfolded sheets of media, such as napkins, towels, and wipes. 
       BACKGROUND 
       [0003]    Dispensers for dispensing interfolded sheets are known. Some prior art dispensers are configured such that a pack of interfolded sheets can be installed through the same opening through which the sheets are dispensed through the use of various types of swinging or hinged doors, such as bomb bay-style doors. With such configurations, the height of the dispenser can be at least partially defined by the degree to which the doors extend into the interior space of the dispenser in order to allow the pack of interfolded sheets to move fully past the doors such that the doors can return to their normal position. Other designs require a separate access opening at either the bottom or sidewall of the dispenser. To facilitate these types of operations, a number of moving and non-moving parts can be required within the dispenser. 
       SUMMARY 
       [0004]    In general terms, this disclosure is directed to dispensers, and in particular dispensers configured to dispense discrete sheets of media from a pack of interfolded sheets of media. The sheets can be any type of media, for example, paper towels, wipes, or napkins. Various aspects are described in this disclosure, which include, but are not limited to, the following aspects. 
         [0005]    In one aspect of the disclosure, a dispenser for dispensing discrete sheets of interfolded media is disclosed. The dispenser can include a base and at least one sidewall extending from the base. The sidewall or sidewalls can extend from the base to a distal end to define an interior space for holding the interfolded sheets and to define an open end. In one aspect, an elastomeric cover can be provided which defines a perimeter and a cover opening located within the perimeter. The elastomeric cover can extend from the perimeter towards the cover opening and cover at least a portion of the open end. In one aspect, the elastomeric cover is resiliently deflectable between a resting state in which the elastomeric cover extends generally parallel to the base and a deflected state in which the elastomeric cover bends in a direction towards the base. 
         [0006]    The elastomeric cover can include at least a single elastomeric member extending from the perimeter towards the cover opening and covering at least a portion of the open end. 
         [0007]    The elastomeric cover may include at least two elastomeric members extending from the perimeter towards the cover opening and covering at least a portion of the open end, and wherein the at least two elastomeric members are resiliently deflectable between a resting state in which the elastomeric members are generally parallel to the base and a deflected state in which the elastomeric members bend in a direction towards the base. 
         [0008]    The elastomeric cover and the at least two elastomeric members can be a single continuous part. 
         [0009]    In example implementations, the elastomeric cover perimeter includes a first side and a second side opposite the first side, and wherein the at least two elastomeric members includes a first elastomeric member extending from the first side and a second elastomeric member extending from the second side. 
         [0010]    The elastomeric cover perimeter may include a third side and a fourth side opposite the third side, and wherein the at least two elastomeric members includes a third elastomeric member extending from the third side and a fourth elastomeric member extending from the fourth side. 
         [0011]    In some embodiments, the elastomeric cover and the first, second, third, and fourth elastomeric members are a single continuous part. 
         [0012]    In one or more examples, the first elastomeric member is separated from the third and fourth elastomeric members by a respective first and second gap and wherein the second elastomeric member is separated from the third and fourth elastomeric members by a respective third and fourth gap. 
         [0013]    The elastomeric cover can be formed such that the first, second, third, and fourth elastomeric members are at least partially connected to each other. 
         [0014]    In some examples, the cover opening is further defined by a first recessed area within the first elastomeric member and a second recessed area within the second elastomeric member. 
         [0015]    In some aspects, the dispenser may further include a cover support frame to which the elastomeric cover is attached, the cover support frame being constructed from a material that is less flexible than a material from which the elastomeric cover is formed. 
         [0016]    The cover support frame can be secured directly to the at least one sidewall. 
         [0017]    In some embodiments, the cover support frame is secured to the at least one sidewall by a projection extending from the at least one sidewall being received into a recess defined within the cover support frame. 
         [0018]    Some embodiments further include a platen within the interior space, the platen being spring biased with a spring located between the base and platen to support the interfolded sheets within the dispenser. 
         [0019]    In one or more embodiments, the at least one sidewall includes a first sidewall, a second sidewall, a third sidewall, and a fourth sidewall, wherein each of the first, second, third, and fourth sidewalls extend from the base and terminate at the distal end to define the interior space for holding the interfolded sheets. 
         [0020]    The first sidewall, a first portion of the third sidewall, and a first portion of the fourth sidewall can be formed by a first housing half and wherein the second sidewall, a second portion of the third sidewall, and a second portion of the fourth sidewall are formed by a second housing half connected to the first housing half. 
         [0021]    Some implementations further include a window insert provided with at least one transparent window to display a placard inserted between the window insert and one of the first and second sidewalls. 
         [0022]    In some examples, the window insert includes a first insert half adjacent the first sidewall and a second insert half adjacent the second sidewall, and wherein the at least one transparent window includes a first window defined by the first insert half and a second window defined by the second insert half. 
         [0023]    A method of inserting a pack of interfolded sheets into a dispenser is also disclosed. The method can include the step of providing a dispenser defining an interior space and an open end, wherein the open end is at least partially blocked by a resiliently deflectable elastomeric cover which extend generally parallel to the open end to in a resting state, the elastomeric cover defining a resulting opening area that is less than a surface area defined by the interfolded sheet. The method can also include the step of inserting the pack of interfolded sheets into the interior space of the dispenser by depressing the pack of interfolded sheets against a top surface of the elastomeric cover member to deflect the elastomeric cover into a bent state. Another step of the method can be further inserting the pack of interfolded sheets into the interior space until the pack of interfolded sheets moves past the elastomeric cover such that the elastomeric cover can return to the resting state. Once the sheets have reached this point, the method can include releasing the pack of interfolded sheets such that a biasing spring can support the pack of interfolded sheets within the dispenser and below the elastomeric cover. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]      FIG. 1  is a perspective view of a dispenser having features that are examples of aspects in accordance with the principles of the present disclosure. 
           [0025]      FIG. 2  is an exploded perspective view of the dispenser shown in  FIG. 1 . 
           [0026]      FIG. 3  is an exploded side view of the dispenser shown in  FIG. 1 . 
           [0027]      FIG. 4  is a top view of a cover assembly of the dispenser shown in  FIG. 1 . 
           [0028]      FIG. 5  is a bottom view of the cover assembly shown in  FIG. 4 . 
           [0029]      FIG. 6  is a first side view of the cover assembly shown in  FIG. 4 . 
           [0030]      FIG. 7  is a second side view of the cover assembly shown in  FIG. 4 . 
           [0031]      FIG. 8  is an exterior side view a housing part half of the dispenser shown in  FIG. 1 . 
           [0032]      FIG. 9  is an interior side view of the housing part half shown in  FIG. 8 . 
           [0033]      FIG. 10  is a first end side view of the housing part half shown in  FIG. 8 . 
           [0034]      FIG. 11  is a second end side view of the housing part half shown in  FIG. 8 . 
           [0035]      FIG. 12  is a top view of the housing part half shown in  FIG. 8 . 
           [0036]      FIG. 13  is an exterior side view an window insert half of the dispenser shown in  FIG. 1 . 
           [0037]      FIG. 14  is an interior side view of the window insert half shown in  FIG. 13 . 
           [0038]      FIG. 15  is a first end side view of the window insert half shown in  FIG. 13 . 
           [0039]      FIG. 16  is a second end side view of the window insert half shown in  FIG. 13 . 
           [0040]      FIG. 17  is a top view of the window insert half shown in  FIG. 13 . 
           [0041]      FIG. 18  is a first cross-sectional view of the dispenser shown in  FIG. 1  showing a horizontal cross-section through the first through fourth sidewalls of the dispenser. 
           [0042]      FIG. 19  is a second cross-sectional view of the dispenser shown in  FIG. 1  showing a vertical cross-section through the third and fourth sidewalls of the dispenser. 
           [0043]      FIG. 20  is a second cross-sectional view of the dispenser shown in  FIG. 1  showing a vertical cross-section through the first and second sidewalls of the dispenser. 
       
    
    
     DETAILED DESCRIPTION 
       [0044]    Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims. 
         [0045]    Referring to  FIGS. 1 and 2 , a dispenser  100  is shown which is configured for dispensing interfolded sheets from a media pack  10  from an interior space  102  through an opening  104 . The media pack  10  can include a variety of interfolded sheet types, for example, napkins, towels, and wipes. As shown, the dispenser  100  includes a base structure  110  including a base  112 , a platen  114 , and a spring  116  located between the base  112  and the platen  114 . In one example, the spring  116  is formed as a metal helical spring. The sheets  10  rest upon or are adjacent to the platen  114  and are supported at a generally constant top height by the force of the spring  116 . As configured, the length of the spring  116  is such that the bottommost sheet will be pressed to the opening  104  once the remaining sheets have been withdrawn from the interior space  102 . In one aspect, the platen  114  can be provided with upwardly extending sidewalls  114   a  to ensure the sheets  10  are secured onto the platen  114 . The base  112  may also include feet  118  secured to the base. The base  112  may also include a securing structure  115  about which the spring  116  can be fastened. As shown, the securing structure  115  is formed by a plurality of outwardly facing latches arranged in a circular pattern to match the shape of the base of the spring  116 . 
         [0046]    Although the dispenser  100  is shown as being vertically supported by the base  112  wherein the opening  104  is generally horizontal, the dispenser  100  can be rested on a side such that the opening  104  is vertical and the base  112  forms a vertically extending sidewall. In such a configuration, the sheets would be inserted and removed from the side rather than from the top, as shown. 
         [0047]    As most easily seen at  FIGS. 8-11 , the dispenser  100  is provided with a housing assembly  120  having a first housing part  120   a  and an identical second housing part  120   b . As the constructions of the first and second housing parts  120   a ,  120   b  are similar,  FIGS. 8-11  are fully applicable to each housing part  120   a ,  120   b . In one aspect, the first and second housing parts  120   a ,  120   b  are connected to each other in a snap-fit type arrangement with tabs  122  of one housing part  120   a ,  120   b  being received by complementary recesses  124  of the other housing part  120   b ,  120   c . Other means for connecting the first and second housing parts  120   a ,  120   b  may be utilized without departing from the concepts presented herein, including attachment with fasteners and/or adhesives. Alternatively, the housing assembly  120  may be formed as a single molded part rather than joining two separately formed housing parts  120   a ,  120   b.    
         [0048]    As shown, the housing assembly  120  defines a first sidewall  122   c , a second sidewall  122   d , a third sidewall  122   e , and a fourth sidewall  122   f . As constructed, the first housing part  120   a  includes the first sidewall  122   c  and portions of the third and fourth sidewalls  122   e ,  122   f  while the second housing part  120   b  includes the second sidewall  122   d  and the remaining portions of the third and fourth sidewalls  122   e ,  122   f.    
         [0049]    In one aspect, the first and second housing parts  120   a ,  120   b  each includes a downwardly extending member  126  and flange portion  126   a . The extending member and flange portion  126   a  are received within the base  112  and are for supporting the housing parts  120   a ,  120   b . The first and second housing parts  120   a ,  120   b  are secured to the base  112  via a plurality of tabs  127  having latch members  127   a  configured to form a snap-fit type connection with corresponding latch recesses  112   a  formed in the base  112 . As shown, four latched tabs  127  are provided on the housing assembly  120  (two per housing part  120   a ,  120   b ) and four latch recesses  112   a  are formed provided on the base  112 . More or fewer tabs  127  and recesses  112   a  may be provided. The housing assembly  120  can also be additionally secured to the base  112  via other means, such as with adhesives and/or mechanical fasteners. In the example shown, the housing parts  120   a ,  120   b  are further secured to the base via fasteners  119  which engage with recesses  123  formed in the housing parts  120   a ,  120   b . The recesses  123  are shown as being open ended, but may be defined as enclosed apertures. Alternatively, the housing assembly  120  and base  112  may be formed as a single molded part rather than providing the three separate components (e.g.  112 ,  120   a ,  120   b ) shown. 
         [0050]    With continued reference to  FIGS. 8-11 , it can be seen that the first and second housing parts  120   a ,  120   b  are additionally provided with an upwardly extending member  128  and flange member  128   a  that are located at the upper end of the housing parts  120   a ,  120   b  and opposite the downwardly extending member  126  and flange member  126   a . The upwardly extending member  126  and flange member  126   a  are for respectively supporting a cover assembly  130  ( FIGS. 4-7 ) that covers the open end defined by the housing parts  120   a ,  120   b  opposite the base  112 . As configured, the upwardly extending member  128  and flange member  128   a  are received into a corresponding recess  132   a  extending around a perimeter of a support frame  132  of the cover assembly  130 . 
         [0051]    The first and second housing parts  120   a ,  120   b  are also provided with a plurality of tabs  129  having latch members  129   a  configured to form a snap-fit type connection with corresponding latch recesses  132   b  in the support frame  132 . As shown, four latched tabs  129  are provided on the housing assembly  120  (two per housing part  120   a ,  120   b ) and four latch recesses  132   b  are formed provided on the support frame  132 . As shown, the latched tabs  129  are collinear with the upwardly extending member  125  while the recess  132   a  is collinear with the latch recesses  132   b . To facilitate such a construction, the recesses  132   a ,  132   b  are separated from each other by ribs  132   c  while the upwardly extending member  128  and latched tabs  129  are separated from each other by gaps  128   b . Of course, other configurations are possible without departing from the concepts presented herein. For example, more or fewer tabs  129  and latch recesses  132   b  may be provided. The housing assembly  120  can also be attached to the cover assembly  130  via other means, such as with adhesives and/or mechanical fasteners. 
         [0052]    Referring to  FIGS. 4-7 , the cover assembly  130  is shown in further detail. As previously mentioned, the cover assembly  130  is provided with a support frame  132 . The support frame  132  is configured to support an elastomeric cover  134  at a perimeter  136 , wherein the elastomeric cover  134  defines a cover opening  130   a  located within the perimeter  136 . In one example, the elastomeric cover  134  is over molded onto the support frame  132  and is formed from a material that is more flexible than the material from which the support frame  132  is formed. For example, the elastomeric cover  134  can be formed from a thermoplastic elastomer, such as thermoplastic polyurethane, while the support frame can be formed from a more rigid plastic material, such as a polycarbonate. In one example, the elastomeric cover  134  is separately formed and later attached to the support frame  132 . In one example, no support frame  132  is provided and the elastomeric cover  134  is either over molded onto the housing assembly  120  or separately formed and later attached to the housing assembly  120 . The elastomeric cover  134  may also be formed as a single, continuous part, as shown in the drawings, or may be formed as individual extension members that are either pre-formed and attached to the support frame  132  and/or housing assembly  120 , or that are over molded onto the support frame  132  and/or housing assembly  120 . 
         [0053]    As shown, the elastomeric cover  134  is provided with a first extension member  134   a , a second extension member  134   b , a third extension member  134   c , and a fourth extension member  134   d . Each of the extension members  134   a - 134   d  is shown as being connected to the adjacent extension member  134   a - 134   d  by a small amount of material  134   e  at the corners of the cover  134  while the members  134   a - 134   d  are otherwise separated at a gap  134   f  extending from the central opening  130   a  to the material  134   e . This configuration allows for each of the extension members  134   b  to independently deflect downwardly into the interior space  102  and towards the base  112 . The first and second extension members  134   a ,  134   b  can also be provided with a recessed portion  134   g  to allow a user&#39;s hands to more readily grasp the paper sheet  10  being held by the dispenser  100 . 
         [0054]    The extension members  134   a - 134   d  are provided with sufficient strength and rigidity such that the extension members  134   a - 134   d  extend generally in the same plane as the opening  130   a  and parallel to the base  112  in a resting state. As the purpose of the elastomeric cover  134  is to provide for a dispenser that does not have to be opened for loading of the interfolded sheets  10 , the extension members  134   a - 134   d  are also sufficiently flexible such that they can be readily bent out of the way of a media pack  10  being inserted through the opening  130   a . Accordingly, a user can push a media pack of interfolded sheets  10  against a top surface  134   h  of the cover  134  and the extension members  134   a - 134   d  will readily deflect out of the way of the media pack  10 . Once the media pack  10  is sufficiently inserted past the extension members  134   a - 134   d , the extension members  134   a - 134   d  return to their rested state and the platen  114  supports the media pack  10  at or below the bottom surface  134   k  of the extension members  134   a - 134   d . The dispenser  100  is then ready for dispensing at which point a user can pull individual sheets of the media pack  10  through the opening  130   a  and past the extension members  134   a - 134   d.    
         [0055]    The disclosed configuration of the cover assembly  130  and cover member  134  is advantageous in numerous ways. For example, paper can be easily added to the dispenser without first requiring the opening of the dispenser to access the interior. Another advantage is that the disclosed configuration reduces “pilfering” of the sheets by users because users are not able to easily gain access into the unit due to the cover member  134 . The disclosed design also significantly reduces the number of required parts in comparison to prior art designs which have various types of hinged door structures. The disclosed dispenser is thus more easily cleanable. 
         [0056]    Another advantage is that the configuration of the cover member  134  with the elastomeric extension members  134   a - 134   d  results in a reduced required height or length of the dispenser (i.e. distance between the base  112  and the cover member  134 ). This reduction is accomplished because the extension members  134   a - 134   d  are pliable to such a degree that they do not have a fixed hinge point, thereby allowing the extension members  134   a - 134   d  to curve or bend out of the way to only the extend necessary for the pack to move past the opening  130   a . This same flexibility feature also allows for less required head space  11  above the media pack  10 . The head space  11  is the gap between top of the media pack  10  and bottom of cover member  134  that is generally defined by the design of the spring  116  and is most easily viewed at  FIGS. 1 and 19-20 . As the extension members  134   a - 134   d  are pliable enough to easily flex, the extension members  134   a - 134   d  provide a smooth, curved surface against which the sheets, which generally have low tensile strength, can be pulled. 
         [0057]    The extension members  134   a - 134   d  can be formed with sufficient pliability such that no head space  11  need be provided, wherein the media pack  10  directly abuts the bottom surface  134   k  of the cover  134 . Such a configuration can be easily accomplished by providing a spring  116  which provides a pre-load force on the media pack  10  against the cover  134 . Of course, the dispenser  100  could be provided with the same amount of head space as a standard dispenser with the expectation of even further improved dispensability over prior art designs. In one example configuration, the dispenser  100  is designed to hold a media pack  10  having a stacked height of about five inches which results in the disclosed dispenser  100  being able to store about 50 additional sheets in comparison to other prior art designs while still maintaining an acceptable head height. The disclosed design is thus advantageous over prior art designs in which a minimum headspace must be maintained to prevent tearing of the sheets and designs in which the use of tabs or other members are required to hold the media pack to maintain a fixed head space distance. 
         [0058]    Referring to  FIGS. 13-17 , the window insert  140  is shown in further detail. The window insert  140  is for providing an advertising space for placards  150  so that the dispenser  100  can have further utility. As shown, the window insert  140  is formed from a first insert half  140   a  and an identically shaped second insert half  140   b  that is connected to the first insert half  140   b  such that a shell is formed about the housing  120 . In one example, the window insert parts  140   a ,  140   b  are formed from a transparent and/or translucent material such that a respective placard  150   a ,  150   b  installed between the housing  120  and the window insert  140  can be readily viewed. 
         [0059]    As the constructions of the first and second window insert parts  140   a ,  140   b  are similar,  FIGS. 13-17  are fully applicable to each insert half  140   a ,  140   b . In one aspect, the first insert half  140   a  has a first wall  140   c  including a first window  142  and a second wall  140   d  including a second window  144 . The first insert part  140   a  is installed into the first housing part  120   a  such that the first window  142  is on the exterior side of the first sidewall  122   c  while the remaining portion of the first wall  140   c  is on the interior side of the first sidewall  122   c . The first housing part  120   a  includes a placard support portion  120   m  surrounded by a gap  120   n  that allows for the insertion of the first insert part. Once assembled, the first placard  150  can be inserted from the exterior side of the dispenser  100  between the first window  142  and the placard support portion  120   m , wherein the placard can rest on a ledge  120   p . This configuration is resistant to tampering in that the placard  150  cannot be easily removed from the exterior of the dispenser  100  once it has been fully inserted between the first window  142  and the placard support portion  120   m  as very little clearance exists for access to the placard  150 . To remove the placard  150 , the sheets of the media pack  10  must be first removed from the dispenser, such that a user can grasp an exposed portion of the placard  150  at a recessed portion  120   r  of the placard support portion  120   m  from the interior side of the dispenser  100 . 
         [0060]    Once installed, the second window  144  of the first insert part  140   a  is received into a recess  120   n  defined between the first and second housing parts  120   a ,  120   b  when they are mated together. The second window  144  allows for viewing into the interior of the dispenser  100  such that the amount of remaining sheets of the media pack  10  within the dispenser can be readily viewed from either the third or fourth sides  122   e ,  122   f . The construction and insertion of the second insert part  140   b  with respect to the second housing part  120   b  is the same and need not be described further. 
         [0061]    Another feature of the first and second window inserts parts  140   a ,  140   b  is the presence of guides  146  which extend the height of the insert parts  140   a ,  140   b . The guides  146  extend into the interior space of the dispenser  100  and hold the ends of the sheets of the media pack  10  therebetween to ensure that the media pack  10  is sufficiently guided as the pack is initially inserted and as the sheets of the media pack  10  are individually removed. The cross-sectional view provided at  FIG. 18  best illustrates the location and function of the guides  146 . 
         [0062]    The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims.

Technology Category: 1