[0001] This disclosure generally relates to a paper product dispensing system.

BACKGROUND

[0002] Systems dispensing consumable products are ubiquitous in many environments today. For example, bath tissue dispensers are commonplace in many private, semi-private and public washrooms. Given this widespread adoption, discouraging excessive use of the paper products dispensed by such dispensers helps control the cost of operating facilities in which these dispensers are located, including, for example, reducing the amount of paper products required to be purchased and reducing the costs associated with servicing and maintaining the dispensers, e.g., refilling the dispensers with additional paper products.

SUMMARY

[0003] In general, the subject matter of this specification relates to a paper product dispenser for roll-based sheet-by-sheet dispensing. One aspect of the subject matter described in this specification can be implemented in systems that include a dispenser having a body including an outer surface, a dispensing mechanism and a product holding area configured to hold a rolled product; wherein the dispensing mechanism includes a first dispensing opening proximate the product holding area and a second dispensing opening on the outer surface, wherein, an interior region is defined between the first dispensing opening and the second dispensing opening and, during a dispensing operation, the rolled product first passes through the first opening into the interior region and then through the second opening; and the second dispensing opening includes a primary dispensing orifice and an auxiliary access hatch that, when the auxiliary access hatch is opened, increases a size of the primary dispensing orifice. Other embodiments of this aspect include corresponding apparatus and methods.

[0004] Yet another aspect of the subject matter described in this specification can be implemented in a paper product dispensing system comprising a rolled product having a plurality of sheets separated by perforations, each of the plurality of sheets having a length of 185 to 230 millimeters and a width of 85 to 1 10 millimeters; and a dispenser comprising a body, the body including a dispensing mechanism and a product holding area to hold the rolled product; wherein the dispensing mechanism includes a first dispensing opening and a second dispensing opening, and wherein the first dispenser opening is closer to the rolled product than the second dispenser opening, and the second dispensing opening includes a primary dispensing orifice and an auxiliary access hatch that, when opened, increases a size of the primary dispensing orifice. Other embodiments of this aspect include corresponding apparatus and methods.

[0005] In some implementations, the systems and apparatuses described herein have one or a combination of the following features. The rolled product comprises a plurality of product sheets separated by perforations and such perforations have a break force, and wherein the primary dispensing orifice is configured to apply a force greater than the break force to separate, one-by-one, the plurality of sheets as they are dispensed. The break force is between 250 and 400 grams and preferably between 300 and 360 grams. Each of the plurality of sheets have a length of 185 to 230 millimeters and a width of 85 to 110 millimeters. The first dispensing opening is configured to apply less than the break force as the rolled product passes through it.

[0006] The auxiliary dispensing hatch opens into the interior region and allows access to the first dispensing opening. The second dispensing opening comprises a conical shape with a large end of the conical shape or cylindrical shaped in the interior region. The primary dispensing orifice and the auxiliary access hatch, when closed, lie in a same plane of the outer surface. The auxiliary access hatch is positioned above or below the primary dispensing orifice. The auxiliary access hatch, when closed, forms a lower boundary of the primary dispensing orifice. The primary dispensing orifice and the first dispensing opening are aligned along a horizontal axis.

[0007] The interior region, as measured along the horizontal axis, has a length of at least 20 millimeters. The auxiliary access hatch is biased in a closed positioned by a resilient member such as a spring. A diameter of the first dispensing opening is greater than that of the second dispensing orifice.

[0008] Particular embodiments of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages. For example, the dispenser, by virtue of single sheet dispensing, promotes portion control and reduces excessive use of the paper products, e.g., bath tissue, which also reduces the cost associated with operating the dispenser.

[0009] Given the nature of single sheet dispensing, if the sheet being pulled perforates from the next sheet before the next sheet is pulled through the dispenser opening then a user may have difficulty or be unable to access or otherwise reach the next sheet, which prevents further dispensing. To this end, the dispenser includes an access hatch that allows the user to reach through the opening and inside the dispenser to access the next sheet to continue dispensing. As the user pulls the next sheet the access hatch closes to return to its normal position. Thus rather than the dispenser becoming inoperable if a sheet perforates, the dispenser allows the user to access the prematurely perforated sheet and continue with the dispensing process.

[0010] The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.

DESCRIPTION OF DRAWINGS

[0011] Fig. 1 A is a representation of an example product dispenser.

[0012] Fig. 1 B is a representation of an example roll of paper product.

[0013] Fig. 1 C is a representation of the example product dispenser with the front cover opened to show the product holding area with paper product therein.

[0014] Fig. 2A is a side cross sectional view of the dispenser.

[0015] Fig. 2B is a detailed view of the dispensing mechanism.

[0016] Fig. 2C is another detailed view of the dispensing mechanism.

[0017] Fig . 3A is a representation of a side cross sectional view of the second dispenser opening.

[0018] Fig. 3B is a representation of the example dispenser dispensing product in a first state.

[0019] Fig. 3C is a representation of the example dispenser dispensing product in a second state.

[0020] Fig. 3D is a representation of the example dispenser dispensing product in a third state.

[0021] Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

[0022] The present disclosure generally relates to a dispenser that provides single sheet (e.g., one at a time) dispensing from a roll, e.g., bath tissue roll.

[0023] Dispensers aimed at curbing excessive consumption of the paper product are sometimes referred to roll portion control dispensers. One technique to achieve such portion control is by dispensing only a single sheet at a time. This may require coordination between the paper product roll design (e.g., the type of perforations separating the individual sheets on the roll and the size and shape of the sheets) and the dispenser opening through which the sheets are dispensed. [0024] To that end, the dispenser described herein has a dispenser opening that is matched to the paper product, e.g., sheet length, width, bulk and/or composition, to apply sufficient force to cause the sheets, which are separated by perforations, to tear apart as they are pulled out of the dispenser for single sheet dispensing. For example, the user grabs a portion of a sheet from the roll protruding from the dispenser opening and pulls the sheet. The force required to pull the protruding sheet through the opening exceeds the force required to tear the perforations thereby separating it from the next sheet on the roll. Thus as the sheet is pulled through the opening it separates from the next sheet, for single sheet dispensing, and leaves the next sheet partially protruding from the dispenser opening for the user to grab for the next dispensing operation.

[0025] If the next sheet on the roll is not partially pulled through the dispenser opening during the dispensing process of the previous sheet then the user may have difficulty grabbing the next sheet, e.g., as it may have separated (prematurely) inside of the dispenser and the dispenser opening may not be large enough for the user to reach through. As such, the dispenser described herein includes an access hatch in its outer cover, which increases the size of the dispenser opening (or creates another port) through which the user can reach and grab the prematurely perforated sheet to continue dispensing. The dispenser is described in more detail below with reference to Figs. 1A, 1 B andl C.

[0026] Fig. 1A is a representation of an example product dispenser 100. The dispenser 100 can be, for example, a bath tissue dispenser 100, a hand towel dispenser 100, or the like for rolled paper products. Paper products describes sheet materials made from cellulose fibers (e.g., wood pulp), synthetic fibers (e.g., polypropylene) or some combination thereof, and include, for example, bath tissue and paper towels. A rolled product is a product that is wound around a core 130, and a center pull product is a product that is unwound from its core outward towards its periphery. The dispenser 100 can, for example, be used to dispense rolled, center pulled paper products.

[0027] Fig. 1 B is a representation of an example roll of paper product 106 (e.g., a rolled paper product that is center pulled). The paper product 106 includes a plurality of product sheets 106a separated by perforations 106b. As described below in greater detail, the perforations 106b have a break force, which is exceeded when the product 106 is pulled through the dispenser 100 in a dispense operation to separate, one-by-one, the sheets 106a for single sheet dispensing. In some implementations, the paper product 106 (in roll form) has an outer diameter (OD) of 200- 250 millimeters and starting inner diameter (ID) of 60-90 millimeters, a basis weight of 13.5-35 grams, one or two plies combination, per square meter, a per sheet length (L) of 185-230 millimeters, a per sheet width (W) of 85-1 10 millimeters, and a perforation cut length (PCL) of 3-5 millimeters and a perforation bond distance (PBD) of 1 -2 millimeters. The sheets 106a are pulled through the dispenser 100 and dispensed along the axis parallel to their length L.

[0028] The dispenser 100 includes a body 102, e.g., a composite or metal housing, with an outer surface 103 (e.g., an exterior surface of the body 102, as shown in Fig. 1A). The dispenser 100 also includes a product holding area 104 to hold (e.g., rolled) paper product 106, as shown in Fig. 1 C, which is a representation of the dispenser 100 with the front cover 102a of the body 102 opened to show the product holding area 104 with paper product 106 therein.

[0029] In some implementations, the product holding area 104 is a space or cavity within the body 102 in which the product 106 can be positioned for dispensing, and can be accessed by rotating the front cover 102a away from the back cover 102b (e.g., the wall mounted portion) by a hinge or the like. The dispenser 100 also includes a dispensing mechanism 110, which operates to dispense a portion of the product 106 (e.g., one sheet 106a at a time), as described with reference to Figs. 2A, 2B, and 2C. Fig. 2A is a side cross sectional view of the dispenser 100, Fig. 2B is a detailed view of the dispensing mechanism 110 and Fig. 2C is another detailed view of the dispensing mechanism 110.

[0030] In some implementations, the dispensing mechanism 110 includes a first dispensing opening 1 10a proximate the product holding area 104 and a second dispensing opening 110b on the outer surface 102a. The first dispensing opening 110a on one side opens into the product holding area 104 such that product 106 in the product holding area 104 can be unwound (e.g., from its center) through the first dispensing opening 1 10a. On the other side, the first dispensing opening 1 10a opens into an interior region 114, defined between the first dispensing opening 110a and the second dispensing 1 10b. The interior region 114, in some implementations, has a depth, measured along horizontal axis 147, of between 15 and 40 millimeters and preferably about 26 millimeters. The dispenser 100 can, for example, hold a core 130 of the rolled product 106 along or parallel to the same horizontal axis 147 to facilitate dispensing. In some implementation, the first dispenser opening 1 10a is conically shaped with the largest diameter end facing the product holding area 104, and having a diameter of about 20-40 millimeters, and the smallest end facing the interior region 1 14, and having a diameter of about 8.0-15 millimeters.

[0031] On one side, the second dispenser opening 1 10b opens into the interior region 1 14, and on the other opens through the outer surface 103. In some implementations, the second dispenser opening 110b is cylindrical shaped or conically shaped with the largest diameter end facing (and/or opening into) the interior region 114, and having a diameter of about 6.0-30 millimeters, and the smallest end opening through the exterior surface 103, and having a diameter of about 6.0-12 millimeters. Thus as the product 106 is unwound for dispensing, it passes through the first dispensing opening 1 10a, then the interior region 1 14 and then out through the second dispensing opening 1 10b. In some implementations, the secondary dispenser opening 110b is cylindrically shaped or defined by an opening in the front cover 102a.

[0032] In some implementations, the second dispensing opening 1 10b includes a primary dispensing orifice 1 11 and an auxiliary access hatch 113 that, when opened, increases a size of the primary dispensing orifice 11 1 , as shown in Figs. 2B and 2C. More particularly, the primary dispensing orifice 1 11 has a first size 115 (see Fig. 2B) and, when the access hatch 1 13 is opened, a second size 1 16 (see Fig. 2C). In some implementations, the first size has a diameter of about 6.0-12 millimeters and the second size has a diameter or length (as the opening may not be circular) of about 20-35 millimeters. In some implementations, the primary dispensing orifice 11 1 and the auxiliary access hatch 113, when closed, lie in a same plane 145 of the outer surface 103. In others, the primary dispensing orifice 1 11 and the auxiliary access hatch 113, when closed, can lie in different planes and/or at different angles.

[0033] In some implementations, the material of the first dispensing opening 1 10a and/or the second dispensing opening 1 10b and/or the auxiliary access hatch 113 are mixed with antimicrobial/antibacterial plastic/polymer to inhibit the growth of the bacteria /microbial. These areas are likely to be frequently contacted by customers/end-users during dispensing process.

[0034] In some implementations, the second dispenser opening 110b is replaceable within the outer surface 103, e.g., it can be removed and a replacement one can be snap-fit or otherwise inserted into the outer surface 103. This allows, for example, the size of the primary dispensing orifice 1 11 to be changed to match different types of product 106 (with different properties (e.g., the type of perforations separating the individual sheets 106a on the roll 106 and the size and shape of the sheets 106a), which must be accounted for within (matched by) the primary dispensing orifice 1 11 to enable sheet-by-sheet dispensing as described herein) in the dispenser 100. For example, product A with length L1 and width W1 is matched to a primary dispensing orifice 1 11 with diameter D1 to enable sheet-by-sheet dispensing. If product B with length L2 and width W2 is attempted to be dispensed through the primary dispensing orifice 1 11 with diameter D1 , the interaction between product B and this orifice 11 1 may not generate enough friction to overcome the break force of the product, which does not result in single sheet dispensing. To address the issue, a new second dispenser opening 110b with a primary dispensing orifice 1 11 having a diameter D2, matched to product B, can be used in the dispenser 100. In this way the dispenser 100 can be adapted to accept multiple different types of products 106 and still enable sheet-by-sheet dispensing by using a second dispenser opening 1 10b with a primary orifice matched to the particular product 106 in use.

[0035] Fig . 3A is a representation of a side cross sectional view of the second dispenser opening 1 10. More specifically, Fig. 3A shows the access hatch 1 13 pivoting open, about a hinge 117 or pivot point 1 17, to allow access into the interior region 1 14 and, optionally, to the first dispenser opening 110a. In this way, the auxiliary access hatch 113, when closed, forms a lower boundary of the primary dispensing orifice 11 1. Thus if the product 106 breaks at the first dispensing opening 1 10a or in the interior region 114, a user can push the access hatch 1 13 open to reach the next sheet 106a, which would otherwise not be accessible through the primary dispensing orifice 1 11 , as it's too small for a user's fingers to reach into. The auxiliary access hatch 113 can be biased in the closed positioned, e.g., as shown in Fig. 2A, to cause the primary dispensing orifice 1 11 to have the first size 1 15, by a resilient member 121 such as a spring or the like.

[0036] In some implementations, the access hatch 113 can be opened outward (e.g., pulled away from the dispenser 100) and/or located above the primary dispensing orifice 11 1 , as opposed to below as shown in Fig. 3A.

[0037] Fig. 3B is a representation of the example dispenser 100 dispensing product 106 in a first state, Fig. 3C is a representation of the example dispenser 100 dispensing product 106 in a second state, and Fig. 3D is a representation of the example dispenser 100 dispensing product 106 in a third state. More particularly, Fig. 3B shows a sheet product 106a extending out through the primary dispensing orifice 1 11 for easy access by a user. In this normal operation the sheet 106a passes through the primary orifice 11 1 pulling the next sheet partially through the orifice 1 11 before perforating from that next sheet, which allows the next sheet to protrude from the primary dispensing orifice 1 11 to let a user easily grab it. Thus in this operation the next sheet is partially pulled through the primary dispensing orifice 1 11 before it perforates from the sheet 106a being pulled by the user.

[0038] To this end, the force applied by the primary dispensing orifice 11 1 on the sheets 106a as they pass through is designed to cause a sheet 106a being pulled by a user to perforate from the next sheet 106a (by exceeding the force required to perforate the sheets) only after the next sheet 106a has partially passed through the orifice 1 11 . In some implementations, this force is applied by friction between the sheet 106a and the primary dispensing orifice 11 1 and is based on the diameter of the primary dispensing orifice 1 11 relative to the size, basis weight and/or composition of the paper 106 passing through it. For example, with a conically shaped primary dispensing orifice 1 11 the narrowing of the orifice 111 as the product 106 passes through increases the frictional force applied on the product 106 as the diameter of the orifice 11 1 decreases as the sheet 106a is pulled through until the sheet 106a perforates. Thus, after perforation, it is desired that the next sheet 106a is partially in the interior region 1 14 and partially extending out through the primary dispensing orifice 11 1.

[0039] Because the dispenser 100 and product 106 are designed to work together to ensure proper dispensing, the dispenser 100 also discourages unauthorized roll use as rolls not made to the appropriate specifications, e.g., as described above, will either perforate prematurely (e.g., on a regular basis) or not perforate at all.

[0040] Fig. 3C shows an example of when a sheet 106a perforates prematurely (e.g., before it partially passes through the primary dispensing orifice 11 1). This may be caused, for example, by abnormalities in the roll product 106 or abrupt user pulls on a sheet 106a. Regardless, in this case, the user is not able to grab the sheet 106a through the primary dispensing orifice 1 11 because the opening of the primary dispensing orifice is too small, as is required to generate the necessary force to perforate the sheets 106a.

[0041] To continue dispensing from the state shown in Fig. 3C, the user pushes in the access hatch 113 to gain access to the sheet 106a in the interior region 114, as shown in Fig. 3D. With the larger opening provided by utilizing the access hatch 113 the user can grab the next sheet 106a and pull it out. As the user is pulling out the sheet 106a the access hatch 113 closes to its initial position (e.g., as biased by the spring 121 and as shown in Figs. 3B and 3C) and guides the sheet 106a into and through the primary dispensing orifice 111 , resulting in the state shown in Fig. 3B for normal operation.

[0042] In some implementations, the dispenser 100 includes roll support members 140, as shown in Figs. 3B - 3D, to support the roll product 106 and prevent it from collapsing as it is dispensed (e.g., as the roll product 106 is dispensed from its center outward). For example, the roll support members 140 can be ribs or other protrusions that extend from the dispenser 100 into the side of the roll product 106. In some implementations, the roll support members 140 are located on the inside of the front cover 102a in a circular orientation (e.g., aligning to a periphery of the roll 106) such that when a roll 106 is inserted into the dispenser 100 and the cover 102a is closed the roll support members 140 are driven into the roll 106 to securely hold it. [0043] In some implementations the roll support members 140 are spaced apart by 190 to 255 millimeters and each roll support member 140 is between 10 and 25 millimeters long and extruding from the front cover 102a (i.e., extending into the roll 106). The roll support members 140 can also act as a deterrent to using unauthorized roll products 106 in the dispenser 100 as the length and orientation of the roll support members 140 can be set to work best with roll products 106 of certain dimensions and if a roll product 106 without such dimensions is inserted into the dispenser 100 it may not fit (e.g., the roll support members 140 may not sufficiently engage the roll product 106 if it is too narrow resulting in roll collapse or prevent the front cover 102a from closes if the roll is too wide) or may otherwise have suboptimal dispensing.

[0044] Although the above description has focused on a center pulled rolled product with a dispensing mechanism 110 on the front cover 102a, in some implementations, the roll 106 is unwound from its periphery and the dispensing mechanism 110 is on the side of the dispenser 110.

[0045] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any inventions or of what may be claimed, but rather as descriptions of features specific to particular embodiments of particular inventions. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination. Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments.

[0046] This written description does not limit the invention to the precise terms set forth. Thus, while the invention has been described in detail with reference to the examples set forth above, those of ordinary skill in the art may effect alterations, modifications and variations to the examples without departing from the scope of the invention.