Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a Continuation-In-Part Application claiming priority to U.S. patent application Ser. No. 12/784,801, filed May 21, 2010, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to cleaning wipes, and more particularly to hygienic tissues for bathroom use. 
     BACKGROUND OF THE INVENTION 
     Towelettes, or wipes, find multiple uses in a bathroom or lavatory. In addition to housekeeping use, they can be used to cleanse or dry skin. Dry wipes are sometimes inadequate, however, when sensitive or stubbornly soiled skin is involved. Wet wipes are needed for this purpose but are rarely in a handy location, particularly when a need arises at the toilet. Wet wipes require container storage to protect against evaporative losses. The containers are generally placed on a surface remote from the handy wall location of the toilet tissue roll and may not be within reach for a person in need at the toilet. 
     The prior art lacks a comprehensive solution. In U.S. Pat. No. 6,503,326 to Mikelionis, two rolls, one dry and one wet, are placed side-by-side on the customary toilet roll spool. Each roll is folded so that it is half width, and presumably, half length as well. Because they share the same spool, dispensing one potentially moves the other synchronously. The biggest problem, however, is that the consumer is forced to buy specially-configured toilet tissue at a premium to the ubiquitous, and commodity-priced, toilet tissue roll. 
     U.S. Pat. No. 5,950,960 to Marino avoids synchronous movement by placing dry and wet rolls in two separate but connected containers. The containers are suspended in a conventional wall bracket above and below a toilet roll spool. While hinged covers give access to the rolls, continually lifting the covers can be a nuisance. Also, the containers take up space, which can be at a premium near a toilet. To further the inconvenience, the equipment involves an installation. 
     U.S. Pat. No. 3,848,822 to Boone teaches placement of a roll of wet tissues inside of a drum-like container located in the core of a toilet roll. The drum-like container replaces the conventional wall bracket spool. While this solution provides a handy location and a good utilization of space, there are several deficiencies. Boone does not teach a means for separating individual sheets. Also, the leading end of the tissue exposed through the slit-like opening in the end of the drum would act like a wick to dry out the moisture inside of the drum. Lastly, because the drum is immobilized, and because toilet roll cores are notoriously out-of-round, there is a risk that the toilet roll will bind on the drum while unwinding. 
     These shortcomings are addressed by the novel solutions of the present invention. 
     SUMMARY OF THE INVENTION 
     It is accordingly an object of the present invention to provide a convenient way to dispense wet wipes in a bathroom. It is a further object to make wet wipes available to a person seated on a toilet. It is a further object to combine the dispensing of wet wipes with that of ordinary dry toilet tissue. It is a further object to accomplish this in a way that does not involve a requirement to purchase specialty toilet tissue rolls. It is a further object to utilize existing installations of toilet roll brackets without requiring modifications or new equipment. It is a further object to fully utilize the space in the core of a common toilet tissue roll for the purpose of dispensing the wet wipes. It is a further object to maintain a moisture barrier to prevent evaporative losses from a storage environment of the wet wipes. It is a further object to maximize the capacity inside the core of a mounted toilet tissue roll by eliminating the existing toilet roll spool. It is a further object to provide a means for singlating individual wet wipe sheets which are connected together to dispense sequentially. It is a further object to facilitate dispensing by providing a means to withdraw an end of the next sheet from the storage environment without prematurely exposing the sheet. It is further object to provide a convenient refill put-up to replenish the wet wipes. It is a further object to provide a means for unwinding the toilet roll from around a closely-fitting core insert without rotating the insert. 
     These objects, and others to become hereinafter apparent, are embodied in a toilet roll dispenser for moisturized sheets comprising a cylindrical dispenser, having a rotational axis, configured to fit within the core of a toilet roll. The toilet roll dispenser further comprises a plurality of moisturized sheets contained within the cylindrical dispenser, said moisturized sheets connected by perforations to dispense sequentially from, at least, one end of the core. The toilet roll dispenser further comprises a means for singlating individual sheets by initiating a tear at one of the perforations. The toilet roll dispenser further comprises a means for connecting the cylindrical dispenser to a wall bracket having two arms with recesses to receive a conventional toilet roll spool. With the toilet roll dispenser so configured, a roll of toilet paper rotatably mounted on the cylindrical dispenser and suspended within the wall bracket by the means for connecting can unwind conventionally about the rotational axis, while the moisturized sheets can dispense from the interior of the core. 
     In a preferred embodiment, the means for connecting comprises end caps placed at each end of the cylindrical dispenser. The end caps have bosses configured to fit the recesses and a means for articulating the bosses to removably and securely mount the cylindrical dispenser between the two arms of the wall bracket. At least one of the end caps comprises a dispensing aperture centered on the rotational axis in communication with the interior of the cylindrical dispenser. The bosses lie along an axis parallel to and offset from the rotational axis such that the dispensing aperture can be made accessible from below the wall bracket. The means for articulating each boss comprises a flexible beam with the boss positioned at a distal end thereof, a proximal end thereof anchored at the end cap, the beam positioning the boss to articulate into the recess by flexing the distal end. 
     In another aspect of the preferred embodiment, the means for singlating comprises a horn positioned in the aperture, the position such that a downward pull on an exposed sheet effectively forces the horn into the sheet and snags an elongated slit in the perforation. The snag initiates a tear which leaves the next sheet flush with the aperture after the exposed sheet is separated by tearing. The dispensing aperture can then be closed by a means for covering to prevent moisture loss from the interior of the cylindrical dispenser. In a particularly preferred embodiment, the means for covering is a snap-fit cap. In an alternative embodiment, the means for covering is a plug having a means for extracting the next sheet. 
     In another aspect of the preferred embodiment, the cylindrical dispenser comprises a hermetically-sealed refill unit having moisture vapor barrier protection. The refill unit is comprised of a closed end at one end of the cylindrical dispenser, an open end at the other end of the cylindrical dispenser, and a means for hermetically sealing the open end. In a particularly preferred embodiment, the means for hermetically sealing comprises a bonded foil membrane. 
     In another aspect of the preferred embodiment, the toilet roll dispenser comprises a means for unwinding the toilet roll without causing rotation of cylinder and consequence in twisting or displacement of the next sheet in the aperture. In a particularly preferred embodiment, the means for unwinding comprises at least two bearing rings rotating freely in circumscribing races near the ends of the cylinder, the rings configured to frictionally fit the core of the toilet roll and provide clearance for the cylinder. 
     As this is not intended to be an exhaustive recitation, other embodiments may be learned from practicing the invention or may otherwise become apparent to those skilled in the art. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood through the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: 
         FIG. 1  is a perspective view of the toilet roll dispenser of the present invention with a roll of toilet paper disposed thereon; 
         FIG. 2  is a perspective view of the toilet roll dispenser; 
         FIG. 3  is an end elevation view of the toilet roll dispenser showing an open aperture; 
         FIG. 4  is sectional view taken along the lines  4 - 4  of  FIG. 3 ; 
         FIG. 5  is a partial perspective view of the toilet roll dispenser showing a closed aperture; 
         FIG. 6  is a cut-away plan view of an end cap component showing internal structure; 
         FIG. 7  is an exploded perspective view of the toilet roll dispenser; 
         FIG. 8  is a perspective view of an alternative embodiment of the toilet roll dispenser; 
         FIG. 9  is an end elevation view of the alternative embodiment; 
         FIG. 10  is a sectional view taken along the lines  10 - 10  of  FIG. 9 ; 
         FIG. 11  is an exploded perspective view of the alternative embodiment; 
         FIG. 12  is a cut-away elevation view of an end cap assembly of the alternative embodiment showing step  1  of extraction; 
         FIG. 12A  is an inside perspective view corresponding to  FIG. 12 ; 
         FIG. 13  is a cut-away elevation view of an end cap assembly of the alternative embodiment showing step  2  of extraction; 
         FIG. 13A  is an inside perspective view corresponding to  FIG. 13 ; 
         FIG. 14  is a cut-away elevation view of an end cap assembly of the alternative embodiment showing step  3  of extraction; 
         FIG. 14A  is an inside perspective view corresponding to  FIG. 14 ; 
         FIG. 15  is a cut-away elevation view of an end cap assembly of the alternative embodiment showing step  4  of extraction; 
         FIG. 15A  is an inside perspective view corresponding to  FIG. 15 ; 
         FIG. 16  is an exploded perspective view of a refill assembly; and 
         FIG. 17  is a perspective view of toilet roll wall bracket and spool. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in  FIGS. 1 ,  2  and  17 , a toilet roll  2 , wound around a core  3 , is conventionally suspended in a wall bracket  5  by a spool  7  placed through the core and into recesses  6  of a pair of bracket arms  8 . The toilet roll  2 , thusly mounted in the wall bracket  5 , can dispense sheets of toilet paper by unwinding from around the spool  7 . In the present invention, the spool  7  is replaced by a toilet roll dispenser  1 . The toilet roll dispenser  1  provides the additional capability of dispensing a plurality of moisturized sheets  4 . The moisturized sheets  4  are conveniently located together with the dry sheets while both are close at hand for toilet use. 
     Referring to  FIGS. 2-5  and  7 , the toilet roll dispenser  1  is comprised of a cylindrical dispenser  10  and a means for connecting  20  the cylindrical dispenser  10  to the wall bracket  5 . The cylindrical dispenser  10  provides a housing for the moisturized sheets  4 , which are contained there within. The cylindrical dispenser  10  protects the moisturized sheets  4  from the evaporation of moisture there from. The cylindrical dispenser  10  is formed as a unitary container with a closed end  13  ( FIG. 4 ). The other end, an open end  12  ( FIG. 7 ), provides access for the moisturized sheets  4  and is the only aperture to the container requiring some form of sealing to complete the protective envelope. The container is comprised of a moisture-vapor barrier material. The cylindrical dispenser  10  has a rotational axis  11  about which the toilet roll  2  unwinds. 
     The means for connecting  20  is comprised of end caps  21  placed over each end of the cylindrical dispenser  10 . Each end cap  21  has a boss  22  configured to fit within the recess  6  of the bracket arm  8 . The bosses  22  lie along an axis parallel to, and offset from, the rotational axis  11 . A preferred offset distance  26  ( FIG. 4 ) is comparable that of the axis of core  3  to the axis of spool  7  when the toilet roll  2  is conventionally mounted. The reader is reminded that the diameter of the spool  7  is significantly less, typically, than the diameter of the core  3 ; consequently, the axis of the hanging roll is offset from that of the spool, and the preferred offset distance  26  permits access to the moisturized sheets  4  from below the bracket arms  8 . 
     The end caps  21  are further comprised of a means for articulating  30  the bosses  22  to removably, and securely, mount the cylindrical dispenser  10  between the bracket arms  8  of the wall bracket  5 . In the preferred embodiment, the means for articulating  30  is comprised of a flexible beam  32 . The flexible beam  32  connects the boss  22  at a distal end  34  thereof to the end cap  21  at a proximal end  33  thereof. The flexible beam  32 , supported from the proximal end  33 , arcuately articulates ( FIG. 2 ) the distal end  34  to move the boss  22  from a bypass position  24  to a seated position  25  in the recess  6 . A close-tolerance fit of the end caps  21  on the ends of the cylindrical dispenser  10  forms a firm base for each flexible beam  32 . The flexible beam  32  may provide a pre-load at the seated position  25  to bias the boss  22  in its engagement to the recess  6 . Support spring  35  ( FIG. 4 ) may also be added to further stiffen the flexible beam  32 . In a preferred embodiment, support spring  35  is tapered in both thickness and side cut to provide a graduated response to deflection of the beam. 
     The moisturized sheets  4  are connected by lines of perforations  54  to form a continuous web, which takes up a compact configuration inside the cylindrical dispenser  10 . The compact configuration may be a roll, from which the web is pulled inside out, or may otherwise be a non-entangling coil. At least one end cap  21  is provided with a dispensing aperture  38  through which the moisturized sheets  4  are dispensed from the open end  12  of the cylindrical dispenser  10 . The dispensing aperture  38  is aligned with the rotational axis  11  to centrally dispense the moisturized sheets  4 . The dispensing aperture  38  is comprised of a means for slinglating  50  an exposed sheet  52  from a next sheet  53 . In the preferred embodiment, the means for singlating  50  comprises a horn  51 . The horn  51  is placed in the throat of the dispensing aperture  38  and is configured to snag one of the perforations of the passing web. As an exposed sheet  52  is pulled down over the horn  51 , a tapered end  56  is insinuated into the folded conformation of the exposed sheet  52  and penetrates one of the perforation slits to nucleate, thereby, a tear. In a preferred embodiment, at least one of the perforation slits is a centrally-disposed elongated slit  55 . The elongated slit  55  facilitates the penetration of the tapered end  56  while not appreciably weakening the tensile strength of the web. The tapered end  56  may be smoothly chamfered to avoid undue abrasion of the exposed sheet  52 . 
     If the next sheet  53  is prematurely exposed, it would act like a wick to evacuate moisture from the interior of the cylindrical dispenser  10 . Instead, the next sheet  53  preferably remains in the throat of dispensing aperture  38 , where it is positioned to be drawn out in sequence as exposed sheet  52 , and where it is prevented from interfering with a means for covering  60  the dispensing aperture  38 . The means for covering  60  provides a means for preventing moisture loss  100  by sealing the containerized environment of the moisturized sheets  4 . The means for preventing moisture loss  100  additionally comprises a luer taper  101 . The luer taper  101  forms a seal between the end cap  21  and the open end  12  by removably force-fitting the open end  12  into the luer taper  101 . In the preferred embodiment, the means for covering  60  comprises a removable snap-fit cap  61 , as shown in both open and closed positions in  FIGS. 3-5 . Snap-cap  61  is retained in a closed position by snapping together interconnecting lugs  62 . 
     In the preferred embodiment, the flexible beam  32 , the dispensing aperture  38 , the horn  51  and the snap-fit cap  55  are formed as a part of an end-cap insert  31 . The end-cap insert  31  provides a means to avoid undercuts in the molding of these features while simplifying some assembly steps. Tooling access port  39  ( FIG. 5 ) additionally allows the support spring  35  to be molded without an undercut. The end-cap insert  31  can be fitted to an annual aperture  23  in the end cap  21 , as best shown in  FIG. 7 . The end-cap insert  31  is secured to the end cap  21  by a ring of ledges  36 . The ring of ledges  36  can be resiliently compressed by means of slots  37  to narrow the ring diameter so as to pass through the annular aperture  23 . The ring of ledges  36 , once passed through, snaps the ledges into place where an interference of structures locks the assembly together. The compression can be achieved in a single assembly step by forcing the ring of ledges  36 , facilitated by a chamfering of the edges, into the space of the annular aperture  23 . During assembly, an insert key  27  is guided to a selected slot  37  to rotationally fix the end-cap insert  31  to the end cap  21 . 
     An alternate embodiment of the means for covering  60  is shown in FIGS.  6  and  8 - 11 , where primed (′) reference characters indicate identical features with the preferred embodiment. The alternate embodiment of the means for covering  60  comprises a plug  63 . The plug  63  is slidably and rotatably inter-positioned in the dispensing aperture  38 ′. The plug  63  slides from a closed position  65 , where it seals the dispensing aperture  38 ′, to an open position  64 , where it gives access to dispense moisturized sheets  4 . Both open and closed positions are marked by stops where structural interference occurs. 
     In a particular alternate embodiment, the plug  63  is comprised of a means for extracting  70  the next sheet  53 . The means for extracting  70  is comprised of at least two resilient arms  71 . The resilient arms  71  extend parallel to the axis  11 ′ from the plug  63  to encircle the leading end of the next sheet  53  at the closed position  65 . The extension of resilient arms  71  is equivalent to the distance of a preferred extraction stroke  76 . The resilient arms  71  are arrayed in opposition to close upon and grab the next sheet  53  when forced together by cam followers  73  positioned at the free ends of resilient arms  71 . The cam followers  73  extend radially outward from the resilient arms  71  to slidingly interact with a cam structure  72  ( FIG. 6 ). The cam structure  72  is formed integrally with the end cap  21 ′ and provides a path for the cam followers  73  to cause the next sheet  53  to be dragged into exposure by the extraction stoke  76 . As the cam followers  73  reach spring-back gaps  74  along the path, the resilient arms  71  spring open to release the then exposed sheet  52 . The extraction stoke  76  is stopped at the open position by abutment of the cam followers  73  against a facing wall of the end cap  21 ′. The plug  63  can then be rotated to orient the cam followers  73  to retraction channels  75 . The retraction channels  75  provide retraction pathways through the cam structure  72  for the cam followers  73  to return to the closed position  65 . The return stroke of the cam followers  73  bypasses the then next sheet  53  in parallelism and avoids dislodging it from position in the throat of the dispensing aperture  38 ′. A reverse rotation of plug the  63  resets the mechanisms and sealingly locks the closed position  65 . 
     A sequence of extraction actions  80 , corresponding to the foregoing recitation of structure, is illustrated in  FIGS. 12-15 , where cut-away portions of the end cap  21  sub-assemblies are shown.  FIGS. 12A-15A  are corresponding perspective views from the inside of the sub-assemblies.  FIGS. 12 and 12A  show the closed position  65  where the next sheet  53  is in position in the aperture  38 ′.  FIGS. 13 and 13A  show a pull stroke  81  where the resilient arms  71  are bent inwardly by the cam followers  73  to grip the next sheet  53  and drag it forward.  FIGS. 14 and 14A  show a release action  82  at the open position  64  where the cam followers  73  are aligned with the spring-back gaps  74 ; and where the exposed sheet  52  is accessible for a tear-off  85 .  FIGS. 15 and 15A  show a rotation  83  of the plug  63  and a push stoke  84 , wherein the cam followers  73 , in alignment with the retraction channels  75 , are returned to the closed position  65 . 
     A refill unit  40  is shown in  FIG. 16 . The refill unit  40  is comprised of the cylindrical dispenser  10  and a means for hermetically sealing  41 . The means for hermetically sealing  41  is preferably a foil membrane  42 . The foil membrane  42  is bonded to the open end  12  by heat sealing, or other means common in the art. The foil membrane  42  may be frangible, or otherwise strippable, to facilitate its removal from the open end. A disposable cap  43  is required to protect the frangible membrane from an inadvertent puncture. 
     Referring to back to  FIGS. 4 and 7 , a means for unwinding  90  is provided to facilitate the unwinding of the toilet roll  2  while avoiding a synergistic rotation of the cylindrical dispenser  10 . Rotation of the cylindrical dispenser about axis  11  might twist the web of moisturized sheets  4  into an entangling conformation, or might dislodge the next sheet  53  from the dispensing aperture  38 . In the preferred embodiment, the means for unwinding  90  is comprised of bearing rings  91  ( FIG. 7 ), which are constrained to rotate in races  92  ( FIG. 4 ). The races  92  are formed by a gap between the end caps  21  and at least two spacer bars  14  on the peripheral surface of the cylindrical dispenser  10 . The inside diameter of the bearing ring  91  is sized to freely circumscribe the cylindrical dispenser  10  at the gap, and the outside diameter is sized to form a close fit with the core  3  of the toilet roll  2  while providing a marginal clearance thereto for the cylindrical dispenser  10 . The toilet roll  2  spins the bearing rings  91  while the cylindrical dispenser  10  is rotationally locked about the rotation axis  11  by the insert key  27 . If the spin is sufficiently frictionless, any rotation about the offset boss axis, which might cause an interference with the wall bracket  5  in the case of a clockwise unwind, is thereby minimized. 
     All of the constituent components of the toilet roll dispenser  1 , except for the moisturized sheets  4  and the foil membrane  42 , are preferably injection molded. The thermoplastic resins of choice will have the properties of toughness, stiffness and low moisture permeability. The molded parts may be translucent, transparent or opaque. The wall thicknesses of the container should be sufficient to prevent critical moisture loss over the period of the preferred shelf life. The preferred resins are commodity-grade polyethylene, polypropylene, high-impact polystyrene, or polyolefin. The snap-fit cap  61  may be molded together with the end cap  21  in a living hinge construction. 
     The assembly of the toilet roll dispenser  1 , in a successive use scenario, involves removal of the disposable cap  43  from the refill unit  40 , removal of the foil membrane  42 , placement of the bearing rings  91  over each end of the cylindrical dispenser  10 , and placement of the end cap  21  subassemblies over each end. In placing the subassembly over the open end  12 , however, the leading end of the moisturized sheets  4  must be threaded through the dispensing aperture  38 . Also, care must be taken to force the open end  12  into the luer taper  101 . The end cap  21  subassemblies are assumed to have been pre-assemblies of the insert component  31 , the snap-fit cap  61  and the end cap  21 , in the case of the preferred embodiment, and the insert component  31 ′, the plug  63  and the end cap  21 ′, in the case of the alternate embodiment. 
     It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the preceding description or illustrated in the drawings. For example, the closed end  13  of the cylindrical dispenser  10  may be comprised of the foil membrane  42 . Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.

Technology Category: 1