BACKGROUND TO THE INVENTION

THIS invention relates to a method of producing a roll of paper and a dispenser for dispensing a roll of paper formed thereby. In particular the invention is concerned with a method of producing a roll of toilet paper and a dispenser for dispensing a roll of toilet paper formed by the method.

Toilet paper rolls are normally produced by winding sheets of paper onto cardboard cores. This is typically done by producing a long cardboard core and applying a suitable adhesive to the core. Hereafter a perforated sheet of paper is wound onto the core until the roll reaches a predetermined dimension. Finally the roll, with its core, is cut into smaller units and packaged for distribution.

Although this method is effective it has the disadvantage that production costs are increased by the use of a cardboard core. Another disadvantage is that a separate core manufacturing machine has to be utilised to produce cardboard cores. This machine necessitates a gluing step which adds to additional production costs. A further disadvantage of rolls having a cardboard core is that they are relatively rigid and can not be deformed to take-up less space for packaging purposes. This leads to an increase in transport costs and hence an increase in the total cost of providing toilet rolls to the end user. As paper is made from wood, and seeing that forests are being depleted at an alarming rate, it would be beneficial to provide alternatives to existing paper products - in this case finding alternatives to the cardboard cores used for producing toilet paper rolls.

Crime has taken alarming proportions in South Africa. In particular proprietors of public toilets have found that theft of toilet paper has shown a substantial increase over the last number of years. Although various toilet paper dispensers have been devised for securing toilet paper rolls, these have not proven to be either effective or hygienic.

Persons responsible for the maintenance of public toilets will be aware of the fact that vandals often deposit the cardboard cores of spent toilet paper rolls into toilet bowls. This often leads to plumbing systems being blocked and necessitates expenditure when drain cleaners are to be called-out to remove such cardboard cores.

It is an object of the present invention to address the above problems.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a method of producing a roll of paper comprising the steps of providing a core, winding paper onto the core to form a roll of paper and removing the core from the roll of paper.

In a first embodiment of the invention the core is collapsible in order to facilitate the removal thereof from the roll of paper. Preferably the collapsible core is produced from extruded polypropylene.

In a second embodiment of the invention the core is provided by an inflatable member which can be inflated for receiving windings of paper and which can be deflated to facilitate the removal thereof from a completed roll of paper.

According to a second aspect of the invention there is provided a dispenser for dispensing paper from rolls of paper wound about a first axis, the dispenser including:

a magazine for holding a number of paper rolls, controlling means for controlling movement of the paper rolls in the magazine between a storing portion and a dispensing portion; and

an outlet having a dispensing opening through which the paper can be dispensed, the dispensing opening having a central axis,

characterised in that the magazine is configured such that the first axis of a roll located inside the dispensing portion is parallel to the central axis of the dispensing opening.

Typically the dispenser includes an inlet, having a non-return opening, through which' the magazine ca.n be filled with rolls of paper.

Preferably the inlet is covered with a dome-shaped cover which can be moved between an open position and a closed position. Advantageously the cover can be secured in the closed position.

More preferably the dispenser includes controlling means for controlling movement of rolls of paper in the magazine.

In one embodiment the controlling means is formed by providing that the magazine is sized for holding rolls of paper in a friction fit and providing openings in a wall of the magazine such that a user can move a roll along the magazine by inserting his fingers in the openings and exerting a force on a roll. Preferably the openings should be covered with a flexible closure in order to prevent direct contact between the fingers of the user and rolls in the magazine.

In another embodiment the controlling means is provided in the form of a stopper which separates the magazine in the storing portion and the dispensing portion. By moving the stopper between a first and a second position a single roll is allowed to fall under the influence of gravity from the storing portion to the dispensing portion. In a further embodiment the controlling means is provided by an actuator which can be rotated in order to move rolls of paper along the magazine.

In yet a further embodiment the controlling means is formed by providing an elbow in the magazine, thereby separating the magazine in the storing portion and the dispensing portion, and an opening through which a user may insert a finger for moving a roll through the corner to be located in the dispensing portion.

Preferably a stopping formation is provided at the outlet for deterring a roll of paper from unwinding uncontrolled through the dispensing opening when no unwinding force is applied by a user.

Preferably the outlet includes a cutting formation for severing paper which is dispensed from a roll of paper inside the dispenser.

More preferably the cutting formation includes a gripping formation for gripping a portion of paper once a piece of paper has been severed from the roll.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:

Figure 1 shows a perspective view of a core for use in a method of producing a roll of paper in accordance with the present invention;

Figure 2 shows a front view of the core of Figure 1 onto which paper has been wound to form a roll of paper; Figure 3 shows a front view of the roll of paper of Figure 2 wherein the core has been collapsed;

Figure 4 shows a front view of the roll of paper wherein the core has been removed;

Figure 5 shows a front view of a first embodiment of a dispenser in accordance with the present invention;

Figure 6 shows a front view of a second embodiment of a dispenser in accordance with the present invention;

Figure 7 shows an embodiment of an outlet for a dispenser in accordance with the present invention;

Figure 8 shows an alternative embodiment of an outlet for a dispenser in accordance with the present invention;

Figure 9 shows a front view of a third embodiment of a dispenser according to the invention;

Figure 10 shows a front view of a fourth embodiment of a dispenser according to the invention;

Figure 11 shows a front view of a fifth embodiment of a dispenser according to the invention;

Figure 12 shows a front view of a sixth embodiment of a dispenser according to the invention;

Figure 13 shows a top view of the dispenser of Figure 12;

Figure 14 shows a front view of a seventh embodiment of a dispenser according to the invention; Figure 15 shows a perspective view of an eighth embodiment of a dispenser according to the invention;

Figure 16 shows a perspective view of a ninth embodiment of a . dispenser according to the invention;

Figure 17 shows a front view of a backing plate for use with the dispensers of the invention; and

Figure 18 shows a side view of the backing plate.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Figure 1 shows a perspective view of a core 10 for use in a' method of producing a roll of paper according to the invention. The core 10 is shaped as shown and is produced by extruding polypropylene. The core 10 includes two edges 12 and 14 which are connected to each other with a suitable adhesive, in this embodiment an adhesive tape 16. A portion of a length of paper which is to be wound onto the core 10 is indicated with the reference numeral 18.

Figure 2 shows a completed roll of paper 20 comprising a plurality of paper windings 22 wound unto the core 10. In order to remove the core 10 from the roll of paper 22 the adhesive tape 16 is severed to allow the edges 12 and 14 to be collapsed into the position shown in Figure 3. The core 10 can now be removed from the roll of paper 20 leaving a passage 24 which extends axially across the length of the roll of paper 20 as shown in Figure 4. A tab 26 is attached to the inner end of the wound paper and projects out of the passage 24. The tab 26 acts as a start lead and is used to initiate unwinding of the roll of paper 20 from the inside of the roll towards the outside. It will be understood that the tab 26 could take a number of forms. In this embodiment it is in the form of a piece of tape, but masking tape, cellophane tape or any other suitable alternative could be used. In this embodiment the paper which is to be wound comprises a plurality of sheets which are connected to each other via perforated portions, not shown in the drawings. In particular the method of the invention is concerned with the production of rolls of toilet paper, but it will be appreciated that the method could also be employed for producing various rolls of paper, for example rolls of paper hand towels.

It is envisaged that the core 10 could take a number of forms. For example, it could also be provided in the form of an inflatable member, not shown in the drawings, which can be inflated when paper is to be wound thereon. Once the roll of paper has been wound, the inflatable member can be deflated in order to facilitate removal thereof from the completed roll.

A benefit of providing a roll of toilet paper without a cardboard core is that the production cost of a roll of toilet paper can be reduced. Furthermore paper consumption in the form of cardboard cores can also be reduced.

After being wound the rolls are typically cut into suitable sizes. In existing rolls with cardboard cores such cores will have a detrimental effect on the durability of a blade of the cutting machine used. By having rolls without cardboard cores this problem is addressed resulting in that blades will last for longer with a consequential cost savings.

A further benefit is that by providing a passage in the centre of the roll of toilet paper, rolls can be deformed to a larger extent than is the case with existing rolls. This allows for more versatility in packaging and transporting toilet paper rolls and could lead to a reduction in transport costs, as more rolls can be transported from a producer to a distributor in a single trip.

Yet a further advantage of providing toilet paper rolls as described above is that there is no cardboard core which can be dropped into a toilet bowl to block the plumbing system. Toilet paper rolls are common articles and most persons are well familiar with the appearance and operation of standard toilet paper dispensers. Typically a roll of toilet paper is held on an axle which can pass through a passage in the cardboard core of a known roll of toilet paper. When toilet paper is to be dispensed the roll is rotated on the axle thereby allowing the toilet paper to be unwound. As existing toilet paper dispensers are however designed for accommodating rolls of toilet paper having a cardboard core, an alternative dispenser is required for dispensing rolls of paper manufactured in accordance with the method of the invention.

Figure 5 shows a dispenser 30 for dispensing a roll of paper. Typically the dispenser 30 will be used for dispensing rolls of paper formed by the method described above and in particular for dispensing toilet paper from rolls of toilet paper which do not include a cardboard core.

The dispenser 30 comprises a magazine 32 which is in the form of a cylinder as shown. The magazine includes a dome-shaped cover 34 which is moveable between an open position and a closed position in order to load the magazine 32 with rolls of paper 40. The dome-shape of the cover 34 is designed specifically for deterring a person from placing a cigarette butt thereon as it will roll from the cover under the influence of gravity. It will be appreciated that the cover need not be dome-shaped but could also be only slightly angled.

The dispenser 30 includes securing means, not show in the drawings, for securing the cover 34 in the closed position. Typically the securing means will be provided in the form of a lock and key. Towards its top end the magazine 32 includes a non-return opening 36 to ensure that once a roll of paper has been inserted into the magazine 32, it can not be removed through the non-return opening. In this embodiment the non-return opening 36 comprises a plurality of resilient obstructing members 38 which can be moved in a first direction but deters movement in a second direction. The inner diameter of the magazine 32 is sized such that it can grip the outside of a standard sized toilet roll in a friction fit. The reason for this is that rolls inside the magazine can now be stacked without resting on each other. As will be explained below, the bottommost roll will typically be dispensed first. As there is no central core, upon sufficient dispensing paper from the bottommost roll, this roll will collapse under the weight of the upper rolls thereby hampering further dispensing of paper. It is pointed out that the magazine 32 comprises a storing portion 33 where a roll of paper is stored before being moved to a dispensing portion 35 where paper is dispensed.

In order to control movement of the rolls 40 inside the magazine 32 between the storing portion 33 and the dispensing- portion 35, controlling means is provided. In this embodiment of the invention the controlling means comprises a number of openings 42 through which a user can locate one of his fingers in order to push a roll into a position inside the dispensing portion 35 from where paper can be dispensed from. It will be appreciated that this configuration could potentially be unhygienic and for this reason it is envisaged that the openings 42 could be covered by a flexible cover, not shown, produced from a plastics material. The openings also provide a janitor with a view inside the magazine 32 in order to establish whether the dispenser requires new rolls of toilet paper.

Towards its bottom end the dispenser 30 includes an outlet 44 which comprises a dispensing opening 46 through which the bottommost roll of paper, i.e. the roll located in the dispensing portion 35, can be unwound, a mouthpiece 48 having a cutting formation 50 which comprises a number of serrated teeth which can severe paper which is dispensed from the bottommost roll of paper inside the magazine. It is pointed out that the size of the dispensing opening 46 can be produced of varying diameter. It is also envisaged that the mouthpiece 48 can be manufactured such that the size of the mouthpiece can be adjusted. The rate at which paper can be unwound can be controlled by the amount of friction between the dispensing opening 46 and the paper, a larger diameter for example causing less friction allowing a faster dispensing rate.

The cutting formation 50 further comprises a gripping formation 52, here in the form of a number of slits made above the cutting formation as shown. When a person has unwound a required amount of paper from the roll of paper, he can cut the unwound amount of paper from the paper remaining in the dispenser by jerking the paper in an upward direction such that the paper can be severed by the teeth of the cutting formation 50. To ensure that the paper is not severed at a position inside the magazine 32, thereby causing discomfort in retrieving the severed end for further unwinding, the severed end can be caught by the gripping formation 52. This feature will provide for ease of further unwinding. The gripping formation will furthermore deter the paper from unwinding uncontrolled and potentially reaching the floor thereby causing an unhygienic situation.

The mouthpiece 48 is rotatable relative to the magazine 32 such that the cutting formation 50 can be rotated into a position which allows a person to retrieve a severed end from inside the magazine without injuring his hand on the cutting formation 50.

An important feature of the invention is that the magazine 32 is configured such that a first axis 37 of a roll of paper 40, i.e. the axis about which a roll of paper is wound, when located inside the dispensing portion 35 of the dispenser 30 is parallel to a central axis 39 defined by the dispensing opening 46. In fact, in this embodiment the first axis 37 of the roll of paper 40 coincide with the central axis 39. This configuration is important as it allows the roll of paper to be unwound from its inside to its outside.

Although not shown in Figure 5 the dispenser 30 includes fastening means such that it can be attached to a wall. In the light of the high occurrence of toilet paper theft in public restrooms it is envisaged that the dispenser could also be secured inside a security unit 54. Typically the security unit will be produced from robust steel sheeting, steel tubing or steel bars. Although also not shown in the drawings, it is envisaged that the magazine may have a ribbed outer surface for providing added strength.

Figure 6 shows a second embodiment of a dispenser in accordance with the present invention, generally indicated with the reference numeral 60. The dispenser 60 differs from the dispenser 30 of Figure 5 in that its magazine 62 does not hold rolls of paper 64 in a friction fit. The controlling means of this embodiment is provided by a stopper 66 for separating the magazine 62 into a storing portion 68 and a dispensing portion 70. Only one roll of paper can be accommodated in the dispensing portion 70. This separation is required in order to prevent the roll which is being unwound from collapsing under the weight of the upper rolls.

The stopper 66 of this embodiment comprises a resilient tab which is movable between a first position in which the tab is retracted from the magazine 62 to allow a roll of paper to fall under the influence of gravity into the dispensing portion 70. The stopper 66 can now be allowed to return to its second position such that the weight of the rolls of paper in the storing portion 68 do not press down on the roll inside the dispensing portion 70.

As is the case with the dispenser 30 of Figure 5, the magazine 62 of the dispenser 60 is configured such that a first axis 65 of a roll of paper 40, again the axis about which the roll of paper is wound, when located inside the dispensing portion 70 is substantially parallel to the central axis 67 of a dispensing opening 69. As with the previous embodiment the first axis 65 coincides with the central axis 67.

Referring to Figure 7 and Figure 8 two embodiments of the outlet 44 is shown having different configurations defining the dispensing opening 46. It would however be appreciated that a wide range of configurations exist which could be used to from a dispensing opening which allows unwinding with of a roll of paper with relative ease but deters uncontrolled unwinding of the roll of paper. Central axes which are defined by the dispensing openings are indicated in Figure 7 and Figure 8 with the lines 47 and 49 respectively.

Figure 9 shows a third embodiment of a dispenser in accordance with the present invention, generally indicated with the reference numeral 72. Here the controlling means is provided by having a corner 74 as shown which separates the magazine 62 into the storing portion 68 and dispensing portion 70. The controlling means further comprises an opening 76 such that a user can use a finger to move a roll of paper located in the corner 74 into the dispensing portion 70.

Figure 10 shows a fourth embodiment of a dispenser 80 having a magazine 82 which is sized such that it can grip the outside of a standard sized toilet roll in a friction fit. In this embodiment controlling means 84 is provided by a plunger for pushing a roll of paper from a position in which it is stored in the magazine to a position from which paper can be dispensed through a mouthpiece 86 in a manner as described above. The plunger 84 of the embodiment is produced from high-density polyethylene. The magazine 82 is also produced from high-density polyethylene and is enclosed in a steel security unit 88. It is pointed out that the plunger 84 could be of telescopic construction.

Figure 11 shows a fifth embodiment of a dispenser 90 in accordance with the invention wherein two magazines 92 are provided in a side-by-side configuration and attached with attaching means 94. Having two magazines makes it possible to store more rolls in a single cubicle of a public toilet.

Figure 12 and Figure 13 show a sixth embodiment of a dispenser, generally indicated with the reference numeral 100 having a controlling means in the form of a roller 102 for dividing the magazine 104 of the dispenser in a storing portion 106 and a dispensing portion 108. By inducing rotation in the roller 102 a roll of paper can be moved from the storing portion to the dispensing portion from where paper can be dispensed through a mouthpiece in a manner as described above.

Figure 14 shows a seventh embodiment of a dispenser in accordance with the present invention, generally indicated with the reference numeral 110. The dispenser 110 includes an inlet having a non-return opening 1 12 through which a magazine 114 of the dispenser 110 can be filled with rolls of toilet paper 1 15. The rolls 115 are stored in a storing portion 1 16 and can be moved to a dispensing portion 118 by a user inserting his fingers in openings 120. The openings 120 constitute the controlling means of the present embodiment.

A feature of the dispenser 110 is that a roll of paper which is inserted in the magazine 1 14 will fall a small distance under the influence of gravity such that it can not be reached by a person pushing his fingers through the non¬ return opening 112. This enhances the security of the rolls of paper stored inside the dispenser 110 and obviates the need for a lock and key. People responsible for filling dispensers will appreciate that keys are often misplaced and often causes inconvenience. This embodiment addresses this problem.

Figure 15 shows an eighth embodiment of a dispenser 130 in accordance with the present invention wherein a number of toiler paper rolls 132 are stored in a horizontal configuration.

Figure 16 shows a ninth embodiment of a dispenser 140 in accordance with the invention having a magazine 142 shaped as shown. In this embodiment the controlling means is provided by a plunger 144 which moves in slots 146 in walls of the magazine. The magazine includes protrusions, here in the form of dimples 148 in walls of the magazine, which divide the magazine in a storing portion and a holding portion. The dimples 148 support the rolls in the storing portion and ensure that the roll of paper which is located in the dispensing portion will not collapse under the weight of the rolls held in the storing portion. The plunger 144 is controlled in that it cannot move past the level of the protrusions 148 and thus can not crush the bottommost roll.

Dispensers are normally attached to walls with the use of screws which are placed inside plugs located in drilled holes inside the walls, It has however been found that dispensers which are attached in this manner can be worked loose and removed from walls. Figure 17 and Figure 18 show a backing plate 160 for use in dispensers made in accordance with the present invention addressing this problem. The backing plate 160 includes a plurality of flanged holes 162. When glue is spread over the area of the backing plate opposite the flanged portions, indicated with the reference numeral 164, the glue will pass through the holes 162 and adhere to flanged portions 166. It has been found that such a formation provides a very effective bond.

It is envisaged that a roll of paper of the invention can also be tightly wound without any central passage. It is therefore envisaged that the dispenser may include a magazine having a storing portion and a dispensing portion wherein the dispensing portion has a diameter greater than that of the storing portion such that the roll can undergo some expansion inside the dispensing portion to allow ease of unwinding.

Although not specifically mentioned in the description of each specific embodiment of the dispenser above, it is a common feature of all the magazines that they are configured in such a manner that when a roll of paper is located inside the dispensing portion of the relevant magazine, the axis about which such a roll of paper is wound is parallel, or substantially parallel, with the central axis of the dispensing opening.

It is further envisaged that the dispenser may include a dispenser for spraying a fluid onto paper that is to be dispensed from the dispenser. The fluid could for example be in the form of a fragrance, a lubricant or a hygienic antiseptic lotion. It is also envisaged that a cylinder may be placed in the bottom of the magazine of the dispenser to support the weight of rolls located on top of the bottommost roll thereby preventing the bottommost roll from collapsing as it is unwound.

It is furthermore envisaged that the controlling means may comprise an actuator, for example a screw, such that rotation of the actuator induced movement of the rolls along the magazine. It is finally envisaged that the magazines of the invention could be sold separate from the dispenser such that a user can simply discard the magazine and replace it with a fresh one filled with rolls of paper.

A method of producing a roll of paper and a dispenser for dispensing such a roll of paper address the problems highlighted in the background portion of the specification.