Distributor system

Abstract

The present invention provides a molded fiber end plug 3 and dispenser system including the same, the end plug for mounting a roll of sheet material to a dispenser and having a roll facing side that includes a configuration configured to be insertable into an opening in an end of the roll of sheet material and for securing the end plug to the roll of sheet material, the end plug further including an opposing dispenser facing side that includes a configuration configured to cooperate with a configuration of a roll holder portion of the dispenser in use for mounting the end plug to the dispenser. The configuration of the roll facing side configured to be insertable into an opening in an end of the roll of sheet material includes a plurality of domes 7. The configuration of the roll facing side for securing the end plug to the roll of sheet material includes a lobe 26 configured to provide an interference fit of the end plug to the roll.

Description

[0001] This application claims priority to French patent application 2008403, which may be cited by agent file number 65080048FR02, and to British patent application GB2017800.0, which may be cited by agent file number 65080048GB04.

[0002] This invention relates to an end plug for mounting a sheet roll to a dispenser, and to a method of manufacturing and using such an end plug. The invention also extends to a dispenser system including such an end plug, and to a system including a sheet roll having such an end plug inserted into an opening at one end of the roll.

[0003] End plugs are used to mount sheet rolls to a dispenser. An end plug can be associated with one or both ends of the roll and is used to connect the corresponding ends of the roll to the dispenser. Typically, one side of the end plug (the side facing the roll) is configured to insert into an opening in the corresponding end of the sheet roll, while the other side of the end plug (the side facing the dispenser) is configured to mount to the roll retainer portion of the dispenser. End plugs are available for various dispenser types and can be used with wall-mounted dispensers (whether manually operated or electronically "hands-free").

[0004] End plugs can help achieve a secure fit between the roll and the dispenser. The dispenser-facing side of the end plug can be configured such that it fits only a specific type of dispenser. For example, the dispenser-facing side of the end plug and the roll retainer portion of the dispenser can include complementary configurations, for example, designed to mate with each other. In this way, the end plug can be used to ensure that only one type of sheet roll intended for use with the dispenser can be inserted into the dispenser, thereby contributing to improved operation of the dispenser system. For example, the dispenser can be designed to operate most efficiently with certain types of rolls, for example, those containing materials with a specific basis weight and / or a given size. If a different roll type is used with the dispenser, the dispenser may not operate efficiently; for example, the material may become clogged, or it may feel of poor quality. In the case of electronic dispensers, using an inappropriate roll size can lead to motor overload or operation at suboptimal power consumption.

[0005] The sheet roll may have end plugs inserted at one or both ends. This allows for refilling by the dispenser.

[0006] A dispenser system for roll sheet products including end plugs is described in US 2012 / 0138723A1 (Lewis et al.) (which corresponds to WO 2012 / 073203A2 cited below), published on June 7, 2012.

[0007] However, the applicant has realized that it is possible to provide an improved end plug for mounting sheet rolls to a dispenser.

[0008] According to a first aspect of the invention, the following is provided:

[0009] A molded fiber end plug for mounting a sheet roll to a dispenser, wherein the end plug has a roll-facing side, the roll-facing side including a configuration that allows insertion into an opening in an end of the sheet roll, the roll-facing side including a configuration for securing the end plug to the sheet roll in use.

[0010] And the opposite dispenser-facing side, which includes a configuration configured to cooperate with the roll retainer portion of the dispenser in use for mounting the end plug to the dispenser.

[0011] Therefore, the present invention provides an end plug formed by molding a fibrous material. Compared to previous end plugs made of plastic materials (such as those described in US 2012 / 0138723A1 (Lewis et al.) above), the end plug of the present invention is provided by a molded fibrous structure. This provides a more sustainable end plug, which is advantageously biodegradable.

[0012] The end caps of this invention also offer advantages in terms of ease of recycling. Once the sheet roll has been depleted, the end cap is typically removed from the dispenser along with the core (if provided) for disposal. The end cap can retain the end inserted into the core. The core is typically made of cardboard, paperboard, or similar fiber-based materials. If the end cap is made of a plastic material, it may be necessary to remove the end cap from the core to ensure that the core can be recycled without the risk of contaminating the core recycling waste stream. The plastic end cap itself may or may not be recyclable, depending on the availability of plastic recycling in a given area. Even if recycling is possible, in many cases, the plastic end cap needs to be separated from the core to ensure that both the core and the end cap can be effectively recycled without contaminating a particular recycling waste stream. For example, whether disposed of by the user or subsequently during recycling, the recycling process typically requires separating plastic and paper materials into separate streams. Therefore, providing end caps that are not easily recyclable with the core may result in users being unable to recycle either component, instead placing the core and end cap together into a non-recyclable waste stream, or placing both components as a unit into a recycling waste stream unsuitable for one or the other of that material.

[0013] In contrast, the end caps of this invention can be discarded together with the core (if provided) into a single recycling waste stream without the risk of contamination. The end caps and cores can be recycled as a unit using widely available non-plastic material recycling services. This provides greater convenience to users, reduces environmental impact, and increases the likelihood of successful recycling. Even when using end caps without a core, the ability to easily recycle the end caps (e.g., with waste paper) compared to plastic end caps also provides improved sustainability.

[0014] In at least some implementations, the end caps are biodegradable and may be compostable, providing further advantages. This can facilitate disposal by consumers or by following commercial recycling processes.

[0015] The end plug of the present invention is a molded end plug for mounting a sheet roll to a dispenser. In use, the end plug connects the end of the roll to the roll retainer portion of the dispenser. The end plug can extend between the end of the roll and the roll retainer portion of the dispenser to connect the roll and the roll retainer portion of the dispenser. A portion of the end plug can be sandwiched between the end of the roll and a portion of the roll retainer portion of the dispenser.

[0016] The end plug has opposing sides facing the roll and facing the dispenser, the opposing sides facing the roll and facing the dispenser including configurations that are respectively configured to be inserted into the end of the sheet roll, and including configurations for securing the end plug to the sheet roll and for mounting the end plug to the retainer portion of the dispenser in use.

[0017] The end plug defines the axial and radial directions. The end plug has a central axis. The central axis of the end plug can be aligned with the central axis of the roll (and, where applicable, the central axis of the roll's core) when installed to it in use. The circumferential direction is defined relative to the axis of the end plug.

[0018] In this document, terms like "upper," "higher," "top," or "increased height" on the roll-facing side of the end plug refer to the direction / position on the dispenser-facing side away from the end plug. Conversely, references to "lower," "bottom," or "reduced height" refer to the direction / position on the dispenser-facing side closer to the end plug. The base on the roll-facing side corresponds to the area closest to the dispenser-facing side. The base may be defined by one or more planar portions on the roll-facing side. Points within the base area may all have the same height. The base may be a continuous area or may include more than one discontinuous area. When the end plug is inserted into the roll, the base may define the back side of the roll-facing side, i.e., the side furthest from the roll.

[0019] The end plug is a molded fiber end plug. This construction, associated with the roll-facing side and the dispenser-facing side of the structure, is a molded construction. The end plug is a monolithic molded end plug. The molding construction is a monolithic molded construction.

[0020] At least some of the configurations on the dispenser-facing side can produce the opposite configurations on the roll-facing side of the end plug, and vice versa. At least some of the configurations on the dispenser-facing side that cooperate with the dispenser configuration can be provided by the opposite side of the roll-facing side configuration.

[0021] The roll-facing side of the end plug includes a configuration for insertion into an opening in the end of the sheet roll. These configurations for insertion into the opening in the end of the sheet roll may be referred to as "roll-facing side configurations." These configurations include arrangements for securing the end plug to the sheet roll. The roll-facing side configuration for securing the end plug to the sheet roll may include a configuration configured to provide an interference fit for securing the end plug to the roll. The interference fit is located between the configuration and the outer periphery of the opening in the end of the roll. In embodiments using a cored roll, the interference fit may be defined by the core of the roll, or for a coreless roll, by a portion of the sheet of the roll in which the opening is defined. The configuration for providing the interference fit may include a convex angle. The convex angle is a radially projecting convex angle. Each convex angle is resiliently deflectable to provide the interference fit. The convex angle will deflect radially inward as the end plug is inserted into the opening, and then return to clamp the periphery of the opening and secure the end plug within the opening. The interference fit prevents the end plug from being easily removed from the roll. This may mean that during use, the end cap is typically discarded along with any remaining portion (e.g., core) of the depleted roll. This invention facilitates the recycling of the end cap along with such remaining roll components. Multiple protrusions are provided. The protrusions are discontinuous. Any suitable number of protrusions can be provided, such as 2-6 (two to six), 2-4 (two to four), and optionally four protrusions. The protrusions can be evenly spaced in the circumferential direction of the end cap. However, other arrangements are also possible.

[0022] The molding construction facing the roll is a three-dimensional molding construction. This construction may have contoured surfaces.

[0023] Preferably, the roll-facing configuration, which can be inserted into the opening of the roll, includes a plurality of domes. Each dome defines a protrusion on the roll-facing side of the end plug. In embodiments where the roll-facing configuration includes a plurality of domes, the surface on the roll-facing side may define an alternating pattern of peaks and valleys. This surface may define the alternating pattern of peaks and valleys in a radial direction, a circumferential direction, or preferably both. Domes may impart an alternating pattern of peaks and valleys to the surface. Peaks may be provided by the domes, and valleys may be provided by the areas between the domes.

[0024] In any embodiment where multiple domes are included on the roll-facing side, the domes are molded domes. The end plug may include recesses corresponding to the domes on the dispenser-facing side. Thus, the walls of the domes may have a first surface on the roll-facing side of the end plug and an opposing second surface on the dispenser-facing side of the end plug.

[0025] It has been found that providing a dome on the roll-facing side of the end plug is advantageous for providing end plugs made of molded fiber material, which can have similar strength properties to plastic end plugs. The dome can help strengthen the overall structure of the end plug. The dome provides the end plug with increased robustness and the ability to withstand forces that may arise during use when the end plug is used to mount the roll to the dispenser. For example, such forces can include those generated when the end plug rotatably mounts the roll to the dispenser roll retainer portion. Regardless of whether the end plug rotatably mounts the roll to the dispenser roll retainer portion, the dome helps stabilize the construction associated with the dispenser-facing side, such as an annular construction that cooperates with the dispenser's construction to mount the end plug to the dispenser. The dome also helps maintain the integrity of the end plug when it is pushed into the opening in the end of the roll during use. This step can be automated during the production of roll-refilled products for the dispenser. The end plug must be able to withstand considerable forces without deforming during handling and then being pushed into the end of the roll by the machine.

[0026] The dome can be any suitable shape and size. In the implementation, the domes are structurally identical. However, other arrangements may also be considered.

[0027] The number of domes provided on the roll-facing side can be selected as needed. There can be 2 to 6 (2-6) domes, and optionally 2 to 4 (2-4) domes. In a preferred embodiment, 4 domes are provided. The domes can be evenly spaced in the circumferential direction of the end plug. However, this is not necessary.

[0028] The dome can extend around the axis of the end plug at any desired angle.

[0029] The dome extends circumferentially and radially relative to the axis of the end plug. The dome also has a height that extends in the axial direction.

[0030] At least some of the surfaces of the dome can be contoured surfaces.

[0031] In some embodiments, each dome defines a planar surface at its apex. The side edges of the top surface of the dome may extend in different directions with respect to the axis of the end plug. However, in other embodiments, it is envisioned that the apex may be curved.

[0032] Each dome stands upright from the base on the roll-facing side of the end plug. Preferably, the end plug includes a flange surrounding its periphery. The flange may be a continuous flange. The base may include (or be defined by) the roll-facing surface of the peripheral flange of the end plug. The width of the flange may vary around the circumference of the end plug. The roll-facing surface of the peripheral flange may be a planar surface.

[0033] In one embodiment, the dome surrounds a central portion of the end plug on the roll-facing side. The central portion is recessed relative to the top of the dome. The central portion extends around and includes the axial center of the end plug. The material of the end plug may extend through the central portion, i.e., such that the central portion has no opening extending from the roll-facing side through the end plug to the dispenser-facing side. The central portion may define a planar roll-facing surface. The central portion may be substantially circular. The radially innermost portion of the dome may be separated by the central portion. The central portion is defined by the roll-facing surface of a portion (e.g., a wall) of the end plug.

[0034] The central portion may be located at a horizontal plane between the base of the end plug on the roll-facing side and the top of the dome. In one embodiment, the base of the end plug on the roll-facing side is defined by the roll-facing surface of the peripheral flange of the end plug. The base of the end plug on the roll-facing side may be located in a first plane, and the central portion may be located in a second plane, and the top of the dome may be located in a third plane, wherein the second plane is located between the first and third planes.

[0035] Each dome can be located between the central portion of the roll-facing side and the periphery of the roll-facing side. For example, each dome extends between the central portion of the roll-facing side and the periphery of the roll-facing side. The dome can extend between the central portion of the roll-facing side and the roll-facing surface of the peripheral flange of the end plug. The outer edge of each dome can be spaced inward from the peripheral edge of the roll-facing side of the end plug. This distance can correspond to the width of the flange at that point.

[0036] Each dome may include an inner wall (on the roll-facing side of the end plug) connecting the dome to the central portion and an outer wall (on the roll-facing side of the end plug) connecting the dome to the roll-facing side of the end plug. The inner wall and outer wall are radially inner and outer walls, respectively. The outer wall may have a greater height than the inner wall. The dome may include sidewalls connecting its inner and outer walls. The sidewalls may extend in different directions relative to each other with respect to the central axis of the end plug. Each wall (whether inner, outer, or sidewall) may include more than one section, which may be inclined relative to each other. The wall may include planar and / or curved portions. The wall may give the dome a profile shape.

[0037] The circumferential spacing between the domes can be selected as needed. For example, it is conceivable that the domes could be adjacent to each other. However, in an embodiment, the domes are spaced apart from each other circumferentially on the roll-facing side of the end plug. The domes can be spaced apart circumferentially by connecting portions on the roll-facing side of the end plug. The connecting portions can extend to a height less than the height of the base of the dome relative to the roll-facing side. Each connecting portion can extend (e.g., connect) between the central portion of the roll-facing side of the end plug and the base on the roll-facing side, for example, relative to the roll-facing surface of the peripheral flange of the end plug. The connecting portions can extend between the sidewalls of adjacent domes.

[0038] Each connecting portion may include one or more inclined portions. Therefore, at least a portion of each connecting portion may be inclined relative to the base of the end plug's roll-facing side, for example, inclined relative to the roll-facing surface of the end plug's peripheral flange. The inclined portion may be planar or curved (in one or both of the axial and circumferential directions). The inclined portion slopes radially inward with increasing height from the base and distance from the periphery of the end plug. As the height from the base of the roll-facing side of the end plug increases, the inclined portion of the connecting portion slopes inward toward the axial center of the end plug. The inclined portion may include converging side edges.

[0039] The connecting portion may define one or more inclined, roll-facing surfaces on its roll-facing side. Each such surface may be oriented relative to the inclined portion as described above.

[0040] The surface of the connecting portion (or the inclined, roll-facing surface of the connecting portion) may be continuous or discontinuous in the area of ​​the connecting portion.

[0041] At least some (and in some embodiments, each) of the connecting portions may include an opening. This opening extends from the roll-facing side of the end plug to the dispenser-facing side. The opening may provide a window through the connecting portion. Sloping portions of the connecting portions may include such openings. Sloping portions may be considered to include openings, thus having a slope defined by the plane in which the openings are located. In other embodiments, at least some (and optionally each) of the connecting portions do not have an opening extending from the roll-facing side of the end plug to the dispenser-facing side. Openings in one or more connecting portions through the material of the end plug can be used to control the strength of the end plug. In some embodiments, the openings may also be used to key-fit the end plug to the roll retainer portion of the dispenser, cooperating with the construction of the roll retainer portion to suppress rotation of the end plug relative to the roll retainer portion, as described below.

[0042] In some embodiments, the sloping portion of the connecting portion extends across the entire height of the connecting portion, regardless of whether the connecting portion includes an opening. In other embodiments, the connecting portion may include a base portion erected from the roll-facing side of the end plug, and an upper sloping portion. The base portion may extend substantially perpendicular to the roll-facing side of the base. Any smooth transition between the connecting portion and the roll-facing side of the base may be disregarded when determining the relative orientation of the base and the connecting portion. Alternatively or additionally, the sloping portion may extend across the entire width of the connecting portion in the circumferential direction of the end plug, or the connecting portion may include other portions on one or both sides, which may be sloped or not sloped in the same manner. For example, the sloping portion may be the circumferentially central portion of the connecting portion.

[0043] Each dome may include a base portion and an upper portion. The outer wall of the dome may define an inflection point at the transition between the base portion and the upper portion, or it may define a smooth transition between the base portion and the upper portion. The outer wall refers to the radial outer wall of the dome on the roll-facing side of the end plug. In an embodiment, the outer wall of the dome includes a first portion of the base portion of the dome that stands upright from the roll-facing side of the end plug, and a second inclined portion of the upper portion of the dome that is inclined relative to the first portion. The first portion of the outer wall may extend substantially perpendicular to the base. (The smooth transition between the outer wall and the base may be ignored when determining the orientation of the wall). As the height of the base from the roll-facing side of the end plug increases, the second inclined portion slopes inward toward the axial center of the end plug. The second inclined portion may extend from the top of the base portion to the top of the dome (which may be defined by a flat top surface). The included angle between the first and second portions of the wall may be selected as needed. For example, the angle may be in the range of at least 20 degrees, and may be in the range of less than 50 degrees or less than 40 degrees. In some exemplary embodiments, the angle is in the range of 20 to 40 degrees, such as 30 degrees. When a smooth transition is provided between the base portion and the upper portion, the transition area should be ignored when determining the angle defined between the base portion and the upper portion.

[0044] According to any embodiment that includes a dome on the roll-facing side of the end plug, the construction for securing the end plug to the roll can be positioned at any suitable location. In some embodiments, the construction includes a convex angle projecting outward from the dome (e.g., from the outer wall of the dome). Thus, each convex angle can project outward from a corresponding dome in the dome. For example, the convex angle can project from the base portion of the outer wall of the dome. In these embodiments, the dome can help hold the end plug in proper position within an opening in the end of the roll, thereby supporting the convex angle around the periphery of the engaging opening, for example, to provide an interference fit. The convex angle can be associated with any one or more domes, and preferably, the convex angle is associated with each dome. The convex angle can be located at any desired point along the outer edge of the dome. In some embodiments, the height of each convex angle extends over at least a portion of the height of the base portion of the dome. The height of each convex angle can be at least as large as the height of the base portion of the dome. This can provide a further advantage in terms of the dome's ability to support the convex angle, thereby contributing to a more robust interference fit. Therefore, each convex corner may extend over at least a portion (and optionally over the entire height) of the first portion of the outer wall of the dome, wherein the outer wall comprises the first and second portions as described above. The convex corner may optionally extend into the transition zone between the first and second portions of the outer wall (if present).

[0045] In an alternative embodiment, the construction for securing the end plug to the roll (e.g., a protruding corner) is located between the domes. For example, the construction of the protruding corner may project outward from the connecting portion extending between the domes. In cases where the connecting portion includes a base portion and an inclined upper portion, the protruding corner may extend, for example, over at least a portion of the base portion (and optionally over the entire height).

[0046] It should be understood that all components facing the roll (e.g., domes, protrusions for providing an interference fit, connecting portions, central portions, the roll-facing surfaces of the peripheral flanges, bases, etc.) can be considered as roll-facing constructions. These constructions are produced in the molding process used to manufacture the end plug. These constructions include those configured to be inserted into openings in the ends of the roll, such as domes, connecting portions, protrusions for providing an interference fit, central portions, etc. This construction includes constructions for securing the end plug to the roll. The roll-facing constructions can also provide the end plug with overall structural and strength characteristics.

[0047] The configuration of the end plug on the roll-facing side can be rotationally symmetric.

[0048] The dispenser-facing side of the end plug includes a configuration that cooperates with the roll retainer portion of the dispenser (i.e., the roll-facing side of the end plug) for mounting the end plug to the dispenser. This configuration of the dispenser-facing side allows the end plug to be mounted onto the roll retainer portion of the dispenser, which the end plug is intended for unrestricted use with, and also helps to provide an integral structure for the end plug.

[0049] The configuration of the dispenser-facing side of the cooperating end plug and the configuration of the roll retainer portion may include one or more configurations of the dispenser-facing side of the end plug and at least one corresponding set of one or more configurations of the roll retainer portion that are complementary to each other. The corresponding set of one or more configurations may each define one of a pair of complementary parts.

[0050] Unless otherwise specified, any structure of the dispenser-facing side of the end plug or any structure of the roll retainer portion (roll-facing side) may be defined by one or more constructions of that side of the end plug or roll retainer portion.

[0051] At least some of the corresponding cooperative configurations of the end plug and the coil retainer portion can be arranged to engage with each other to mount the end plug to the dispenser. For example, a mating engagement can be provided. The end plug can provide a mating concave member, while the coil retainer portion can provide a mating convex member. However, it should be understood that, in order to mount the end plug to the dispenser, not all of the cooperative configurations on the dispenser-facing side of the end plug and the cooperative configurations of the coil retainer portion must engage with each other.

[0052] At least some of the cooperative configurations of the dispenser-facing side of the end plug and the roll retainer portion can cooperate with each other because they do not interfere with the interaction between other cooperative configurations of the dispenser-facing side of the end plug and the roll retainer portion required for mounting the end plug to the roll retainer portion of the dispenser. The end plug is intended to be used with the roll retainer portion, for example, by enabling complementary sets of one or more configurations of the dispenser-facing side of the end plug and the roll retainer portion to properly engage with each other to provide a secure mount. For example, the cooperative configurations of the dispenser-facing side of the end plug and the roll retainer portion surrounding the dispenser-facing side of the end plug (which receives the protrusions of the roll retainer portion) can cooperate with each other such that the cooperative configuration does not preclude the protrusions from being fully received in the annular structure. In this process, the configurations of the dispenser-facing side and the roll retainer portion may or may not engage with each other. Where appropriate, the configurations of the dispenser-facing side of the end plug and the roll-facing side of the roll retainer portion can cooperate with each other to not preclude the protrusions from being fully received in the annular structure, while allowing the end plug to rotate relative to the roll retainer portion. It should be understood that the construction can be used in such a way as to ensure that the end plug can only be used with the roll retainer portion to which it is intended to be used, thereby preventing the end plug from being correctly fitted onto other dispensers. Various features of the construction of the dispenser-facing side of the end plug will now be described. These features can be described by referring to the features of the dispenser or the roll retainer portion of the dispenser, which interact with the dispenser or the roll retainer portion of the dispenser. The invention extends to the dispenser-facing side having a construction configured to interact with its dispenser / roll retainer portion in the aforementioned manner, and also extends to dispenser systems comprising end plugs and dispensers.

[0053] The configuration of the dispenser-facing side can be arranged such that the end plug can be rotatably mounted to the roll retainer portion. This will allow the end plug to rotate relative to the roll retainer portion as the sheet roll rotates during sheet dispensing.

[0054] However, alternatively, the configuration facing the dispenser can be arranged such that the end plug can be securely mounted to the roll retainer portion, i.e., preventing relative rotation between the roll retainer portion of the dispenser and the end plug. In such an embodiment, the roll retainer portion may be adapted to rotate relative to a cooperating portion (e.g., an adjacent portion of the dispenser) to allow the roll to rotate relative to at least a portion of the dispenser once it has been mounted for dispensing sheet. The cooperating portion of the dispenser may, for example, be the arm of the dispenser. The roll retainer portion may be mounted to the arm of the dispenser via a mounting portion (such as a hub) rotatable relative to the arm. The mounting portion may be located on the arm, for example at the distal end of the arm.

[0055] In some embodiments, the configuration of the dispenser-facing side may be configured to cooperate with the configuration of the roll retainer portion to allow the end plug to be mounted to the roll retainer portion in a fixed rotational orientation relative to the roll retainer portion. For example, the dispenser-facing side configuration may include a configuration that cooperates with the configuration of the roll retainer portion to provide a key connection between the end plug and the roll retainer portion. This can be implemented in any suitable manner. In some exemplary embodiments, the dispenser-facing side of the end plug includes one or more recesses for receiving a corresponding protrusion of one or more protrusions of the roll retainer portion, the edges of which cooperate with a corresponding protrusion of one or more protrusions of the roll retainer portion to provide a key connection between the roll retainer portion and the end plug. The edges of the recesses cooperate with the protrusions to prevent rotation of the end plug relative to the roll retainer portion.

[0056] The recess can be a closed end recess. Therefore, the recess will not extend from the dispenser-facing side through the end plug to the roll-facing side.

[0057] A key connection can be provided through cooperation between a recess on the dispenser-facing side of the end plug and a protrusion on the roll retainer portion. For example, the protrusion could be a sensor component of the roll retainer portion. In some embodiments, for example, where the roll-facing side of the end plug includes multiple domes, the dispenser-facing side of the end plug may include multiple recesses, each corresponding to the dispenser-facing side of one of the domes. Thus, each of one or more recesses is provided by the opposite side of a corresponding dome. In these embodiments, the recesses are closed end recesses. One or more of these recesses can cooperate with a corresponding protrusion of one or more protrusions of the roll retainer portion (e.g., as described above) to provide a key connection between the roll retainer portion and the end plug. This can be achieved by constructing a dome such that the dome can receive the protrusion of the roll retainer portion to provide the key connection. In some exemplary embodiments, the end plug includes multiple domes on the roll-facing side, one of a plurality of recesses on the dispenser-facing side of the end plug corresponding to the dome on the dispenser-facing side receives a protruding sensor component of the roll retainer portion to provide a keyed connection between the end plug and the roll retainer portion.

[0058] In other embodiments, the recess is an opening extending from the dispenser-facing side through the end plug to the roll-facing side. The opening may be an opening through a connecting portion extending between domes, wherein the roll-facing side of the end plug includes multiple domes, and the connecting portion is located between these domes. For example, such a recess may receive a sensor component of the roll retainer portion of the dispenser.

[0059] In any embodiment of an implementation that provides a keyed connection between the end plug and the sensor component of the roll retainer portion, whether or not this involves a recess in the form of an opening, or the reverse side of a dome for receiving the sensor component, the sensor component may, for example, include a magnet. The sensor component may form part of a sensor device of the dispenser for sensing rotation of the roll retainer portion, such as the number of times the roll retainer portion rotates during use. The sensor device may then include another portion associated with a cooperating portion of the dispenser, relative to which the roll retainer portion rotates. The cooperating portion may be the arm of the dispenser. Another portion of the sensor device may be associated with a mounting portion of the dispenser, such as a hub provided on the cooperating portion of the dispenser (e.g., the arm of the dispenser). The mounting portion is then rotatably fixed relative to the arm. The roll retainer portion rotates relative to the mounting portion, and therefore relative to the cooperating portion (e.g., the arm of the dispenser). Another portion of the sensor may be a probe for detecting the proximity of the magnetic portion of the sensor. The probe is rotatably fixed and can be used to detect the passage of the magnetic portion of the sensor, and thus the rotation of the roll retainer portion relative to the probe. The sensor component associated with the roll retainer portion can provide a target portion of the magnetic sensor device for sensing the rotation of the roll retainer portion, and the cooperating portion of the dispenser can include a probe portion of the sensor device.

[0060] A single recess on the dispenser-facing side of the end plug can cooperate with a single protrusion on the roll retainer portion to provide a key connection between the recess and the protrusion. Of course, the dispenser-facing side of the end plug may include additional recesses that do not necessarily cooperate with the protrusion on the roll retainer portion to facilitate a key connection. When providing, for example, recesses corresponding to a corresponding dome in a dome or multiple recesses in an open form, each recess can be configured to receive a protruding sensor component of the roll retainer portion, thereby making it easier to mount the end plug to the roll retainer portion without needing to ensure a specific orientation of the end plug. For example, when providing multiple domes with the same structure, each dome may have a recess on its opposite side configured to receive a protrusion of the roll retainer portion. Similarly, when providing multiple recesses in an open form, each recess can be configured to receive a protrusion.

[0061] Regardless of whether the end plug is configured to be rotatably mounted to the roll retainer portion of the dispenser, the dispenser-facing side of the end plug may include an annular structure defining a central hole for receiving a protrusion (e.g., a boss) defined by the roll retainer portion of the dispenser. The annular structure is defined by one or more constructions on the dispenser-facing side. The annular structure may be arranged to provide a tight fit with the protrusion. The protrusion of the roll retainer portion may project from a base of the roll retainer portion. The base may define a first face or front face of the roll retainer portion, such as a roll-facing surface. The protrusion of the roll retainer portion may be defined by one or more constructions of the roll retainer portion. The protrusion may be defined by a single construction (i.e., a single element). However, it is contemplated that a segmented structure formed by multiple constructions may be used. Thus, in these embodiments, the annular structure of the end plug and the protrusion of the roll retainer portion are each provided by a corresponding set of one or more constructions of one or more of the corresponding side of the dispenser-facing side of the end plug and the roll-facing side of the roll retainer portion, these constructions being complementary to each other. Each set of one or more constructions defines one of a pair of complementary components. In this example, the single construction of the end plug is complementary to the protrusion defined by one or more constructions of the coil retainer portion.

[0062] In embodiments where the end plug includes an annular structure on the dispenser-facing side, the annular structure is preferably provided by an annular construction on the dispenser-facing side. Therefore, the annular structure can be provided by a construction in the form of a single annular element. The annular structure can be a tubular structure, such as a cylindrical structure (e.g., an element).

[0063] In some embodiments, when the protrusion defined by one or more constructions of the roll retainer portion is received in an annular structure defined by one or more constructions of the end plug, the end plug is rotatable relative to the roll retainer portion. The annular structure can be arranged to provide a tight fit with the protrusion during such rotation. However, as described above, in other embodiments, one or more other constructions of the dispenser-facing side of the end plug can cooperate with one or more other constructions of the retainer portion to prevent such rotation.

[0064] In either case, the annular structure may define a central axis corresponding to the central axis of the end plug. The central hole and the annular structure may be coaxial with the axis of the end plug. The annular structure may be configured to receive a cylindrical protrusion defined by one or more constructions of the coil retainer portion. The cylindrical protrusion of the coil retainer portion may have a circular or elliptical cross-section. The cylindrical protrusion may be defined by a single construction of the coil retainer portion, or it may be defined by multiple constructions, such as a segmented cylinder. The cylindrical protrusion may be defined by the outer periphery of a group of constructions of the coil retainer portion. In other embodiments, the cylindrical protrusion of the coil retainer portion may be defined by a single element (e.g., a boss), which may be hollow or solid. However, regardless of whether the cylindrical protrusion is defined by one or more constructions of the coil retainer portion, it should be understood that the protrusion of the coil retainer portion need not be cylindrical. The cross-section of the protrusion may be a regular or irregular shape. The diameter of the protrusion may be defined by a circle connecting the outermost points of each construction in the constructions defining the protrusion. The outermost point refers to the radial outermost point of the structure.

[0065] Regardless of the structure of the protrusion cooperating with the annular structure, the central hole of the annular structure is preferably a closed end hole. The distal end of the hole (i.e., the end closer to the interior of the end plug) is closed. The end of the hole then cooperates with the end of the protrusion of the coil retainer portion to provide an end stop that limits the extent to which the end plug is pushed onto the coil retainer portion. The size of the annular structure can be selected as desired, depending on the size of the protrusion defined by one or more constructions of the coil retainer portion of the dispenser to which the end plug is intended. For example, the diameter of the hole can be selected with reference to the diameter of the protrusion so that the hole can receive the protrusion defined by one or more constructions of the coil retainer portion. This allows the end plug to be used such that it will only be suitable for a specific type of dispenser with a protrusion sized to be received by the hole.

[0066] As described above, in some preferred embodiments, the roll-facing side of the end plug includes a plurality of domes surrounding a central portion of the roll-facing side of the end plug. Preferably, the closed end of the orifice is provided by a dispenser-facing surface of a portion of the end plug (e.g., a wall), the opposite surface of which provides the central portion of the roll-facing side of the end plug. Thus, the dispenser-facing surface of the central portion provides a closed end for the orifice.

[0067] In some embodiments, the winding retainer portion is constructed including one or more structures defining an annular space that at least partially surrounds the protrusion of the winding retainer portion. The winding retainer portion may be constructed to define at least one circumferential extension that at least partially surrounds the protrusion to define the annular space. The circumferential extension may completely surround (i.e., encircle) the protrusion of the winding retainer portion. However, in other embodiments, the circumferential extension extends only around a portion of the circumference of the protrusion. The circumferential extension may be continuous or discontinuous. This structure may be defined by one or more structures of the winding retainer portion. However, in alternative embodiments, it is conceivable that radially extending structures may be used to define an annular space between the radially innermost end of the structure and the protrusion. These structures can then be arranged as spokes around the protrusion. Regardless of the definition, the annular structure of the end plug can be configured such that the annular structure can be inserted into the annular space. The radial dimension (i.e., wall thickness) of the wall of the annular structure (e.g., an element of the end plug) can be selected relative to the size of the annular space of the winding retainer portion intended to achieve this. This provides another feature: preventing the end plug from being used with dispensers that are not configured to use the end plug.

[0068] In cases where the roll retainer portion is constructed including one or more configurations defining a circumferential extension structure, the circumferential extension structure may include a circumferentially extending wall erected from the roll retainer portion, wherein an annular space is defined between the wall and the protrusion. The circumferential extension wall may be erected from the base of the roll retainer portion. The wall may be defined in an arc shape. The circumferential extension structure may also include a ramp structure extending radially outward from the top of the wall to connect the top of the wall to the base of the roll retainer portion. The ramp structure facilitates the user's installation of the roll to the roll dispenser portion.

[0069] The dispenser-facing side of the end plug may also include one or more (and optionally multiple) inclined surfaces configured to cooperate (e.g., engage) with the surface of the ramp structure of the dispenser's coil retainer portion, allowing the end plug to be mounted to the coil retainer portion, preferably for rotatable mounting. The ramp structure may be defined by one or more configurations of the coil retainer portion. The inclined surfaces may prevent the end plug from being mounted to an unsuitable dispenser, such as preventing annular structures from receiving protrusions of the dispenser. The inclination of the inclined surface may correspond to the inclination of the ramp structure of the coil retainer portion cooperating with the inclined surface. The inclined surface of the dispenser-facing side of the end plug is inclined in the radial direction. The inclined surface is inclined toward the axial center of the end plug. The inclined surface may extend radially from the periphery of the end plug toward the axis of the end plug. The inclined surface extends axially into the interior of the end plug (i.e., away from the front surface of the dispenser-facing side). Each inclined surface also extends circumferentially. Preferably, multiple such inclined surfaces are provided. These surfaces may be spaced apart from each other around the circumference of the end plug. Depending on whether the end plug is rotatably mounted on the roll retainer portion, this surface may cooperate with the same or different ramp structures of the roll retainer portion. For example, in some embodiments, the roll retainer portion includes a single ramp structure, and during rotation of the end plug relative to the roll retainer portion, different inclined surfaces of a plurality of inclined surfaces on the dispenser-facing side of the end plug engage with the ramp structure.

[0070] At least some of the configurations on the dispenser-facing side of the end plug may be provided by the opposite side (i.e., the dispenser-facing side) of the configuration on the roll-facing side of the end plug. In a preferred embodiment where the end plug includes multiple domes connected, for example, via connecting portions on its roll-facing side, the opposite side of the domes (and, where applicable, the connecting portions) may be formed on the dispenser-facing side of the end plug. The configurations on the dispenser-facing side of the end plug provided by the opposite side of the roll-facing side configuration (e.g., domes (and, where applicable, the connecting portions)) should be configured such that they at least do not interfere with the necessary engagement, such as between other configurations on the dispenser-facing side and the configuration of the roll retainer portion of the dispenser, so that the end plug can be suitably mounted to the roll retainer portion. In some embodiments, at least some of the configurations provided by the opposite side of the roll-facing side configuration (e.g., domes (and, where applicable, the connecting portions)) may engage the configuration of the roll retainer portion to facilitate mounting the end plug to the dispenser. The opposite side of the configuration facing the roll may define at least one set of one or more configurations on the distributor-facing side of the end plug, which is complementary to one set of one or more configurations of the roll retainer portion.

[0071] In cases where the end plug, on the dispenser-facing side, also includes one or more (and optionally multiple) inclined surfaces configured to cooperate (e.g., engage) with the ramp structure of the roll retainer for example, to be rotatably mounted to the roll retainer, these inclined surfaces may be provided by the opposite side of the configuration on the roll-facing side of the end plug. For example, in cases where the end plug includes multiple domes connected by connecting portions on its roll-facing side, the opposite side of the domes and / or connecting portions may provide one or more inclined surfaces on the dispenser-facing side of the end plug, these inclined surfaces being configured to cooperate with the ramp structure of the roll retainer.

[0072] In the case where the end plug includes multiple domes, including inclined portions, connected by connecting portions on its roll-facing side, each inclined surface of the end plug on the dispenser-facing side can be provided by the dispenser-facing surface of the inclined portion of one of the connecting portions. The dispenser-facing surface of the inclined portion can engage the ramp structure of the dispenser roll retainer portion as described above.

[0073] In the case where the construction of the roll retainer portion includes a circumferential extension structure that defines a raised circumferential extension structure relative to the base of the roll retainer portion, the ramp structure can connect the top of the circumferential extension structure to the base of the roll retainer portion.

[0074] The end plug may include a peripheral flange. The flange may define the outermost radial edge of the end plug. The flange may include a planar surface on its dispenser-facing side. The dispenser-facing side of the flange may define a front surface of the dispenser-facing side of the end plug. The flange is preferably a continuous flange extending around the entire circumference of the end plug. The maximum radial width of the flange corresponds to less than 20% or less than 15% of the end plug diameter.

[0075] The end plug may include a circumferentially extending peripheral wall (“flange support wall portion”) supporting a flange. The peripheral wall may extend into the interior of the end plug on the dispenser-facing side. The flange may be substantially perpendicular to the flange support wall. A smooth transition between the support wall and the flange may be negligible. The portion of the peripheral wall on the roll-facing side of the end plug may define the outer wall of a dome (if provided), and any connecting portions associated with the roll-facing side of the end plug.

[0076] The dispenser-facing side of the end plug may include multiple reinforcing ribs. The ribs may extend on the dispenser-facing side between the annular structure and the peripheral area of ​​the end plug. The ribs may connect the annular structure to the periphery of the end plug. When used to install the end plug to the dispenser, the ribs may reinforce the annular structure to help maintain its integrity and may also help enhance the overall structural resistance of the end plug. For example, in the following embodiment, the ribs may reinforce the dome (if present) on the roll-facing side.

[0077] The rib is a radially extending rib. This rib helps to enhance the strength of the end plug and reinforce the annular structure of the end plug's dispenser-facing side. The rib can extend between the radially outer surface of the annular structure and a portion of the peripheral wall of the end plug's dispenser-facing side. The peripheral wall can be a wall to which a peripheral flange of the end plug is attached. The flange can extend substantially perpendicular to this wall. At this point, any smooth transition zone at the interface between the flange and the peripheral wall is negligible. The rib can extend from the radially outer surface of the annular structure (e.g., the construction) to the radially inner surface of the peripheral wall portion.

[0078] In a preferred embodiment where the end plug includes multiple domes on the roll-facing side, each rib may extend across a recess in the end plug's dispenser-facing side, corresponding to the dispenser-facing side of the dome. The rib may reinforce the respective dome. One rib may be provided for each dome. The rib may have a first radially extending surface closer to the roll in use, and a opposing second radially extending surface further away from the roll in use. The first radially extending surface may extend along the dispenser-facing surface of the upper portion of the dome and may extend along the entire length of the dispenser-facing surface of the upper portion of the dome. The rib may be configured to extend to the dispenser-facing surface of the top of the dome. The use of reinforcing ribs is optional, and if present, it is optional whether the reinforcing rib extends across a recess in the end plug's dispenser-facing side, corresponding to the dispenser-facing side of the dome. For example, in cases where a recess corresponding to the opposite side of the dome is to receive a protrusion (e.g., a sensor component of the roll retainer portion), the recess may be without such a rib to avoid any potential interference with the insertion of the protrusion into the recess. In such an implementation, ribs may also optionally be provided between the domes on the side facing the dispenser.

[0079] In embodiments that include a plurality of domes (each dome comprising a base portion and an upper portion) located on the roll-facing side of the end plug, the peripheral wall portion to which the ribs on the dispenser-facing side of the end plug are connected may correspond to a wall portion defining the base portion of the dome on the roll-facing side of the end plug, for example, the wall portion may be a first portion of the outer wall of the dome.

[0080] Each rib may define a proximal end connected to the radially outer surface of the annular structure (e.g., the construction), and a distal end connected to the dispenser-facing surface of the peripheral wall portion. Each rib may extend at its proximal end beyond at least a portion of the height of the annular structure, such as 10% or at least 20% of the height of the annular structure, and / or may extend beyond 80%, 60%, or 50% of the height of the annular structure. Each rib may have at its distal end a height corresponding to at least a portion of the height of the peripheral wall portion, such as at least 10% or at least 20% of the height of the at least a portion. Each rib may extend to the base of the annular structure.

[0081] It should be understood that the dispenser-facing side of the end plug may define a first face. This first face may be referred to as the "front surface." The first face (e.g., the front surface) corresponds to a face of the end plug that engages a first surface or base of the roll retainer portion when the end plug is mounted to the roll retainer portion. This corresponds to the face of the end plug closest to the roll retainer portion when the end plug approaches it. The first face (e.g., the front surface) of the dispenser-facing side corresponds to a plane including the forwardmost point of the construction associated with the dispenser-facing side. The terms "forward" or "front" refer to the direction away from the roll when the end plug is used to mount the roll to the dispenser. In embodiments, the front surface of the dispenser-facing side is defined by the plane containing the dispenser-facing surface of the peripheral flange of the end plug. If provided, the annular structure of the dispenser-facing side may not extend beyond and may terminate at this plane. The reference to a "recessed" construction refers to a construction recessed relative to the front surface. The interior of the dispenser-facing side refers to the portion of the dispenser-facing side axially away from the front surface of the end plug.

[0082] This invention extends to a dispenser system comprising a molded fiber end plug according to any aspect or embodiment of the invention and a dispenser including a roll retainer portion comprising a configuration configured to cooperate in use with a portion of the end plug facing the dispenser for mounting the end plug to the dispenser. The roll retainer portion is configured with the roll-facing side facing the roll. The roll-facing side faces the end of the roll.

[0083] It should be understood that any other aspect of the invention may include any or all features of the invention described in relation to any other aspect and embodiment of the invention, provided that such features do not contradict each other. In particular, it should be understood that the second and other aspects of the invention may include any or all features described with respect to the method of the first aspect of the invention, and vice versa.

[0084] The invention is further extended to a dispenser system comprising:

[0085] A distributor for sheet rolls, the distributor including a roll retainer portion;

[0086] A sheet roll having an opening at its end;

[0087] And a molded fiber end plug according to any aspect or embodiment of the invention, the molded fiber end plug being fastened to the end of the sheet roll;

[0088] The end plug, configured to be able to be inserted into an opening at the end of the sheet roll, is inserted into the opening at the end of the sheet roll.

[0089] Furthermore, the configuration associated with the dispenser-facing side of the end plug cooperates with the configuration of the dispenser's roll retainer position to mount the end plug to the dispenser.

[0090] Therefore, the end plug attaches the end of the roll to the roll retainer portion of the dispenser. The roll retainer portion can be in the form of a hub.

[0091] The end plug, with its side facing the roll, is axially inserted into the opening at the corresponding end of the roll.

[0092] The configuration of the end plug in the opening in the end of the roll facing the roll includes a configuration for securing the end plug to the sheet roll. Therefore, the configuration in the opening in the end of the roll associated with the end plug facing the roll is inserted into the opening in the end of the sheet roll, and the configuration for securing the end plug to the end of the sheet roll secures the end plug to the end of the sheet roll. The configuration mentioned herein, which is inserted into the opening in the end of the sheet roll to secure the end plug to the end of the sheet roll, should be understood in this way.

[0093] It should be understood that the roll-facing side may include a construction that can be inserted into the opening, which may not necessarily directly contribute to securing the end plug to the roll, but may, for example, support securing the end plug to the roll by enhancing the construction integrity of the end plug.

[0094] These other aspects and embodiments of the invention may include, and are limited to, any features described with respect to earlier aspects and embodiments of the invention, to the extent that such features are not mutually exclusive. The end plug and its roll-facing side and dispenser-facing side may include any of the foregoing features. Similarly, the roll retainer portion and the roll may include any of the foregoing features and may cooperate with the end plug in any of the aforementioned manner.

[0095] According to these other aspects and embodiments of the invention, the sheet roll is rotatably mounted to the dispenser so that the sheet roll can rotate relative to at least a portion of the dispenser. In some preferred embodiments, the dispenser-facing side of the end plug cooperates with a roll retainer portion to rotatably mount the end plug to the retainer portion of the dispenser, i.e., allowing rotation between the end plug and the roll retainer portion. The roll-facing side of the end plug can securely mount the end plug to the end of the sheet roll, i.e., preventing relative rotation between the end plug and the roll.

[0096] In other embodiments, the end plug's distributor-facing side may cooperate with a retainer portion to securely mount the end plug to the distributor's roll retainer portion, i.e., prevent relative rotation between the end plug and the roll retainer portion. In such embodiments, the distributor's roll retainer portion may be rotatably mounted to a cooperating member, such as an adjacent portion of the distributor, whereby the roll, end plug, and roll retainer portion can rotate together to allow the roll to rotate relative to at least a portion (e.g., the body) of the distributor. The cooperating member may be the distributor arm of the distributor. Thus, the roll retainer portion may be provided at the distal end of the distributor arm and may be rotatably mounted to that distal end. The roll retainer portion may be in the form of a hub rotatably mounted to the distal end of the distributor arm. The roll retainer portion may be rotatably mounted to the distributor arm (e.g., mounted to the distal end of the distributor arm) via a mounting portion (e.g., a hub). The roll retainer portion is then rotatably mounted to the mounting portion. The mounting portion is securely mounted to the distributor arm. In this way, the roll retainer portion and the end plug are rotatably mounted to the distal end of the arm.

[0097] As described above, in embodiments where the end plug includes one or more recesses on the dispenser-facing side for receiving a corresponding protrusion from one or more protrusions of the roll retainer portion, the edge of the recess cooperates with a corresponding protrusion from one or more protrusions of the roll retainer portion to provide a key connection between the roll retainer portion and the end plug. In cases where the roll-facing side of the end plug includes multiple domes, the dispenser-facing side of the end plug may include multiple recesses, each corresponding to the dispenser-facing side of one of the domes, wherein one of the multiple recesses defined on the dispenser-facing side of the end plug corresponding to the dome receives a protrusion of the roll retainer portion to provide a key connection between the end plug and the roll retainer portion. The protrusion of the roll retainer portion may, for example, be a sensor component including a magnet.

[0098] The end of the sheet roll may be a first end of the sheet roll, the molded end plug is the first end plug, and the roll retainer portion is the first roll retainer portion of the dispenser. The sheet roll may also include an opening in a second end of the sheet roll, and a second molded fiber end plug fastened to the second end of the sheet roll according to any aspect or embodiment of the invention, wherein a configuration of being insertable into the opening in the end of the sheet roll, the roll-facing side, is inserted into the opening in the second end of the sheet roll. The roll-facing side configuration of the end plug inserted into the second end of the sheet roll fastens the end plug to the second end of the sheet roll. The first end plug and the second end plug are different end plugs. The first end plug and the second end plug may be the same. The configuration associated with the dispenser-facing side of the second end plug cooperates with the configuration of the second roll retainer position of the dispenser to mount the end plug to the dispenser. The end plug may rotatably mount the sheet roll to the dispenser such that the sheet roll can be rotated relative to at least a portion of the dispenser in any of the aforementioned ways. Each end plug can cooperate with its corresponding retainer portion in the same way, i.e., the end plug can be rotatably or fixedly mounted to the retainer portion.

[0099] The dispenser can be of any suitable type. It can be an electronic dispenser, such as for non-manual sheet dispensing, or it can be manually operated. The dispenser is operable to dispense sheets of a predetermined length. The dispenser can be a wall-mounted dispenser.

[0100] The roll retainer portion of the dispenser may be associated with a dispenser arm. For example, the roll retainer portion may be provided at the distal end of the dispenser arm. In other embodiments, as described above, the roll retainer portion may be rotatably mounted, for example, at the distal end of the dispenser arm to a mounting portion associated with the dispenser arm. In any case, the dispenser may include a pair of dispenser arms, each dispenser arm having a roll retainer portion associated with its distal end. A space may be defined between the roll retainer portions for receiving a roll of sheet. The dispenser arms may be resiliently mounted to a portion of the dispenser, for example, to opposite sides of the dispenser.

[0101] End plugs can be specific to the type of dispenser, such that the configuration associated with the dispenser-facing side of the end plug is configured to cooperate only with the configuration of that type of dispenser to install the end plug into the dispenser. Providing a roll with the end plug inserted into the end of the roll then helps ensure that the sheet roll can only be used with the type of dispenser intended for use with that sheet roll, for example, ensuring optimal operation.

[0102] When the end plug is inserted into the opening at its end during use, the peripheral flange of the end plug can engage with the end of the roll. The flange is located outside the opening in the roll. The flange can be clamped between the opposing surface of the roll and the roll retainer portion of the dispenser. The radius of the flange can correspond to less than 50%, less than 30%, less than 20%, or less than 10% of the sheet radius surrounding the opening at the end of the roll.

[0103] The end plug of this invention is associated with only a single roll.

[0104] On the other hand, the invention extends to a roll product comprising a sheet roll having an opening at its end, and a molded fiber end plug, according to any aspect or embodiment of the invention, fastened to the end of the roll. The end plug's configuration, which allows it to be inserted into the opening at the end of the sheet roll, secures the end plug to the end of the sheet roll.

[0105] It should be understood that any other aspect of the invention may include any or all features of the invention described in relation to any other aspect and embodiment of the invention, provided that such features do not contradict each other. In particular, it should be understood that the second and other aspects of the invention may include any or all features described with respect to the method of the first aspect of the invention, and vice versa.

[0106] The roll has a first end and a second end. The roll may include openings at both ends. Molded fiber end plugs according to any aspect or embodiment of the invention are fastened to at least one end of the roll, and preferably to each end of the roll, with the roll-facing side of each end plug inserted into an opening at the corresponding end of the roll. One end plug is fastened to each end of the roll. The end plugs may be identical.

[0107] The opening, or each opening, is defined at an axial end of the roll. The roll may define an opening at each of its axial ends, i.e., at a first end and a second end of the roll. The opening, or each opening, extends axially into the interior of the roll. The opening may be the end of a hole extending from one end of the roll to the other, or it may be, for example, a notch extending only a portion of the roll length. The opening may be any opening to which an end plug may be secured by a construction associated with its side facing the roll.

[0108] The opening, or each opening, may have a central axis aligned with the central axis of the roll.

[0109] The opening, or each opening, may be defined by the core of the sheet roll. Therefore, the roll may be a cored roll. In this case, the opening may be an end of a hole extending from one end of the cored roll to the other. However, the end plugs described herein can also be used with coreless rolls.

[0110] The length of the end plug corresponds only to a portion of the length of the roll in the direction connecting the ends of the roll. When the first and second end plugs are associated with the first and second ends of the roll, the end plugs are spaced apart from each other along the axis of the roll.

[0111] A sheet roll can be any type of sheet roll. A roll can be a roll in which sheet is distributed from the periphery of the roll. A roll can define an axial direction. The length of a roll is measured in the axial direction. The axis extends from one end of the roll to the other end. The roll is a central axis (i.e., a radial center).

[0112] The radius of the flange of each end plug may correspond to less than 50%, less than 30%, less than 20%, or less than 10% of the sheet radius of the opening at the end of the roll.

[0113] The roll can be cylindrical. If provided, the core can be a cylindrical core.

[0114] The sheet can be any suitable mesh material. For example, the material can be paper, such as when the roll provides tissues, toilet paper, or facial tissues; or it can be a nonwoven material, such as when the roll provides wipes; or it can be any other suitable mesh material. In some preferred embodiments, the sheet is a paper material used to provide tissues or toilet paper. The sheet roll may or may not be perforated.

[0115] Sheet rolls can be supplied to consumers with end plugs inserted into their ends, and preferably with end plugs inserted into openings at each end of the sheet roll for refill dispensers. The system can then provide refill to the dispensers. Rolls with end plugs inserted into their ends can be packaged in outer packaging (e.g., outer sleeves). Thus, roll products can provide roll product refill to dispensers. During the production of roll products by machine, end plugs can be inserted into the ends of the roll.

[0116] According to any aspect or embodiment of the invention, the end plug is preferably a one-piece end plug. The end plug is integrally molded. The end plug can be used without any additional parts to securely mount the roll to the dispenser roll retainer portion. Therefore, the end plug has sufficient integrity to be self-supporting in use.

[0117] The end plug has a predetermined shape.

[0118] In some embodiments, the end plug may not extend through the opening therein (i.e., from the dispenser-facing side to the roll-facing side), while in other embodiments, such an opening may exist in a region, for example, between domes, where the roll-facing side includes the domes.

[0119] The end plug can have any desired size to work with a given roll and dispenser. As an example only, the diameter of the end plug can be at least 3 cm or at least 4 cm. Alternatively or additionally, the diameter can be less than 8 cm, or less than 7 cm, or less than 6 cm.

[0120] Alternatively or additionally, the diameter of the axial hole defined by the annular structure on the dispenser-facing side of the end plug may be at least 0.8 cm, or at least 1 cm. Alternatively or additionally, the diameter may be less than 2 cm, or less than 1.5 cm.

[0121] Alternatively or additionally, the radial width of the wall of the annular structure may be less than 5 mm or less than 3 mm. Alternatively or additionally, the radial width of the wall may be at least 1 mm or at least 2 mm.

[0122] Alternatively or additionally, the height of the end plug may be at least 1 cm or at least 1.5 cm. Alternatively or additionally, the height of the end plug may be less than 2.5 cm or less than 2 cm.

[0123] End plugs can be designed with sufficient strength to prevent them from being removed from the roll without damage, such as from the core, after the roll is depleted. Therefore, end plugs can be intended for use only to load a single roll onto the dispenser, and then be discarded after the roll is depleted.

[0124] This method is extended to using end plugs according to any aspect or embodiment of the invention to mount a sheet roll to a dispenser. The method may include inserting a configuration of an opening in an end portion of the sheet roll, facing the roll, into the opening in the end portion of the roll to secure the end plug to that end, and mounting the dispenser-facing side of the end plug to a roll retainer portion of the dispenser such that the configuration of the dispenser-facing side cooperates with the configuration of the roll retainer portion to mount the end plug to the roll retainer portion, thereby mounting the roll to the dispenser. The configuration for securing the end plug to the roll-facing side of the sheet roll cooperates with the opening in the end portion of the roll to secure the end plug to the roll when the configuration of the insertable opening in the roll-facing side is inserted into the opening in the end portion of the roll. The roll and dispenser may include any of the features described herein.

[0125] It should be understood that any other aspect of the invention may include any or all features of the invention described in relation to any other aspect and embodiment of the invention, provided that such features do not contradict each other. In particular, it should be understood that the second and other aspects of the invention may include any or all features described with respect to the method of the first aspect of the invention, and vice versa.

[0126] The end plug according to any aspect or embodiment described herein may be formed of a material comprising a mixture of fibers and an adhesive. Any suitable adhesive may be used to bond the fibers together in a self-supporting structure. The adhesive is preferably biodegradable.

[0127] The adhesive is preferably a polymeric adhesive. The adhesive may contain one or more biodegradable biopolymers. The adhesive may comprise a single biodegradable biopolymer or any suitable mixture of biopolymers. As used herein, a biopolymer refers to a polymer derived from a natural source. Therefore, the adhesive may contain one or more natural polymers. In a preferred embodiment, the adhesive comprises starch. Any suitable starch, such as industrial starch, can be used. For example, in an exemplary embodiment, the starch may be selected from: potato starch, cassava starch, corn starch, wheat starch, tapioca starch, rice starch, or any combination thereof. In a preferred embodiment, the starch is potato starch or cassava starch, and most preferably, potato starch.

[0128] The adhesive can provide sufficient rigidity to the end plug so that it can maintain a given molded shape. The end plug can be semi-rigid.

[0129] The adhesive can provide a matrix that holds the fibers of the molded fiber end cap in place. The matrix can provide a skeletal structure defining the shape of the end cap. The adhesive can be any suitable material that can form such a matrix under the conditions used to manufacture the end cap. Any of the types of polymeric adhesives described above can function in this manner. In embodiments, the adhesive is a polymeric adhesive wherein the adhesive is crosslinked and / or gelled to provide the matrix. The crosslinking and / or gelling process causes the polymeric adhesive to solidify and provide the matrix. For example, in a preferred embodiment where the adhesive comprises starch, the starch gelles when mixed with water during the manufacture of the end cap. Alternatively or additionally, other polymers can be used that, for example, can be crosslinked upon heating during the manufacture of the end cap to provide the matrix.

[0130] In the implementation, a process is used to produce molded fiber end plugs, in which heat is applied, for example by baking, to crosslink and / or gel the polymeric material of the adhesive.

[0131] Molded fiber plugs can be produced by a process of molding and baking a mixture of fibers and adhesive. Baking can be performed in a mold. An exemplary process is described below.

[0132] The fibers used to manufacture the end plugs can be of any suitable type. The fibers are preferably biodegradable. The fibers are preferably natural fibers. The fibers may include virgin fibers, but for the purpose of increasing sustainability, they may include recycled fibers or be composed of recycled fibers. For example, the fibers can be obtained from waste paper or any other source of waste containing fibers. Waste paper or other wastes (such as wood or vegetable waste or any combination thereof) can advantageously provide a source of, for example, cellulose fibers for the production of the end plugs described herein.

[0133] The fibers can have any suitable length. By way of example and not limitation, the fibers may include or be composed of fibers with a length of up to 50 mm, up to 20 mm, up to 10 mm, or up to 5 mm. The fibers may have a length of at least 0.5 mm or at least 1 mm.

[0134] The end plug preferably comprises cellulose fibers. In an exemplary embodiment, the end plug is formed of a material comprising a mixture of cellulose fibers and starch. The cellulose fibers may comprise wood pulp or non-wood pulp fibers. Non-wood pulp fibers, such as bamboo, bagasse, straw, etc., can be used. These alternative non-wood pulp cellulose fibers are increasingly used in papermaking. Other types of natural fibers, such as wool, silk, etc., or other non-plant fibers, can be used. In an exemplary embodiment, regardless of whether the embodiment comprises cellulose fibers, the fibers of the end plug may comprise papermaking fibers.

[0135] End caps may include one or more additional substances. For example, these substances may be residues of substances used to facilitate manufacturing, and / or substances added to impart desired properties to the final end cap. End caps may include one or more of the following: at least one colorant, at least one preservative, at least one reinforcing agent, at least one stabilizer, at least one filler, and at least one leavening agent. Preferably, any such additional substance is a natural and / or biodegradable material. For example, end caps may include a starter culture in the form of yeast. Alternatively or additionally, end caps may include residual liquids from the manufacturing process, such as water.

[0136] The composition of the molded end plug can be selected as needed, depending on the required performance and other factors such as process requirements. End plugs may include at least 10% fiber based on total solids content. End plugs may include less than 40%, less than 30%, or less than 25% fiber based on total solids content. End plugs may include 10%-40%, 10%-30%, or 10%-25% fiber based on total solids content.

[0137] Alternatively or additionally, the end plug may include at least 50% adhesive based on the total solids content, and optionally at least 55% or at least 60% adhesive based on the total solids content. The end plug may include less than 75%, less than 70%, or less than 68% adhesive based on the total solids content. The end plug may include 50% to 75% adhesive based on the total solids content, optionally including 55% to 70% or 60% to 70% adhesive based on the total solids content. In some exemplary embodiments, the end plug includes 63% to 68% adhesive based on the total solids content, such as approximately 65% ​​adhesive based on the total solids content.

[0138] The total percentage of starch and fiber may be less than 100%. For example, in an exemplary embodiment, the end cap may include up to 25% or up to 22% of the residual additive material as described above, by dry weight percentage. The end cap may include at least 5%, at least 10%, or at least 12% of the total solids content based on the group of one or more additive materials. The end cap may include 12% to 23% of the total solids content based on the group of one or more additive materials, such as 15% to 20% of the total solids content based on the group of one or more additive materials.

[0139] The end plug is preferably free of plastic. The end plug is preferably free of thermoplastic fibers. The end plug preferably contains only natural fibers.

[0140] The material for molded end plugs can include foam structures.

[0141] Rapido Waagen-und Maschinenfabrik GmbH's patent application, US5849152A, entitled "Process for the production of shaped bodies from biodegradable material and shaped body," describes examples of materials that can be used to produce end plugs. By way of example only, a suitable material for molding end plugs is... It can be obtained from the Netherlands-based company. The company (currently located at Hermesweg 22, 3771ND Barneveld, Netherlands) acquired it.

[0142] The molded fiber end plugs in any aspect and embodiment of the present invention can be readily recycled, for example, using waste paper recycling streams.

[0143] Preferably, the end cap is biodegradable. For example, the end cap can be compostable, such as a household compostable one. The end cap allows it to be recycled along with the paper product. This enables the end cap to be recycled along with the core during use. Biodegradable and / or compostable implementations can provide further benefits in terms of sustainability.

[0144] Biodegradable end caps according to any aspect or embodiment of the invention may conform to any one or more of the following standards (and preferably each): EN 13432, ASTM D6868, TÜV Austria OK Industrial Compost, or TÜV Austria OK Home Compost. End caps may alternatively or additionally be certified as bio-based according to any one or more of the following: USDA certified bio-based product, TÜV Austria OK bio-based (Level 4). End caps may alternatively or additionally be UL verified as recyclable. End caps may be UL verified as recyclable with a 99% recyclability of available fibers.

[0145] The end plug is a molded end plug. Any suitable molding process can be used. The end plug can be a molded pulp end plug.

[0146] This invention extends to a method for manufacturing molded fiber end plugs according to any embodiment described herein.

[0147] Suitable methods include the so-called "pulp molding" process.

[0148] This invention extends to a method of manufacturing molded fiber end plugs according to any aspect or embodiment of the invention described herein.

[0149] This method includes providing molded fiber end plugs using a molding process. For example, the molding process could be an injection molding process. An injection molding process refers to the process of injecting material to be formed into a mold during the production of the end plug. In this embodiment, the molded fiber end plug is an injection molded end plug.

[0150] Methods for manufacturing end plugs may include:

[0151] Provides slurries containing fibers, adhesives, and liquids;

[0152] The slurry is introduced into the mold;

[0153] And heating the slurry in the mold to provide molded fiber end plugs.

[0154] In this additional aspect, the invention may include any or all of the features described with respect to other aspects and embodiments of the invention, provided that such features are not mutually exclusive.

[0155] In these additional aspects and embodiments, the method of forming molded fiber end caps may include providing a slurry comprising fibers, an adhesive, and a liquid. The adhesive may be in solid form, and preferably in powder form. The liquid may be an aqueous medium, and preferably water. In embodiments, the fibers are recycled fibers. The fibers may be obtained from waste paper or other waste materials. The fibers may be obtained from shredded waste materials (e.g., waste paper). Shredding the waste materials to provide fibers may be carried out in an initial step.

[0156] As described above, in exemplary embodiments, the fibers are biodegradable and / or natural fibers, such as cellulose fibers, and the binder comprises one or more biodegradable biopolymers, such as starch. The binder may be powdered starch. The fibers and binder may be any of the forms described above. The slurry may contain one or more additives to facilitate the molding process. For example, the slurry may include one or more colorants, one or more emulsifiers, one or more preservatives, one or more reinforcing agents, one or more fillers, and / or one or more leavening agents. One or more leavening agents are preferred. In exemplary embodiments, a yeast-based starter is included in the slurry. This can be helpful when a foam-type material is required. Any additives used are preferably biodegradable and / or natural substances. This may help optimize the sustainability of the resulting end caps.

[0157] The method may optionally include mixing the components of the slurry in a mixing tank to provide the slurry, and introducing the slurry into the mold only after a given period of time. While in the mixing tank, the slurry may be agitated, for example, by stirring. This period of time may range from 2 to 5 minutes, such as approximately 3 minutes. For example, the slurry may be in the form of a paste. The slurry may optionally be transferred from the mixing tank to a storage tank and / or transported to a molding station. Delaying the introduction of the slurry into the mold, along with the accompanying heating process, also allows any leavening agents to function, for example, where a "foamy" type material is required. This is similar to making waffles with batter.

[0158] According to any aspect or embodiment of the method, the method may include introducing a slurry into a mold and heating, for example, baking the mixture in the mold to provide a molded fiber end cap. The slurry can be introduced into the mold in any suitable manner, and is preferably injected into a closed mold under pressure. For example, the slurry can be pumped from a tank (e.g., a storage tank) into the closed mold. The heating step dries the slurry to provide the molded fiber end cap. During the heating step, at least some of the liquid contents of the slurry introduced into the mold may evaporate from the mold. Heating may bake the slurry in the mold. The step of baking the slurry in the mold can be similar to a waffle baking process. The material of the resulting molded end cap may include a foam structure. Heating the slurry in the mold to provide the final molded fiber end cap can impart an improved surface finish to the resulting end cap.

[0159] The heating process allows the adhesive material to form a matrix, thereby holding the fibers in place and retaining the resulting end plugs in their molded shape. In some embodiments, the heating step causes gelation and / or crosslinking of the polymeric adhesive material (e.g., an adhesive material comprising one or more biodegradable biopolymers). For example, in a preferred embodiment, the heating step causes gelation of an adhesive comprising starch. In cases where gelation occurs, it is envisioned that some pregelation could occur before the slurry is introduced into the mold, making it unnecessary for all gelation to occur in the mold (although this may be the case in some embodiments).

[0160] The composition of the provided slurry can be selected as needed, depending on a variety of factors, including the nature of the components, the parameters of the manufacturing process, and the performance required for the final molded end cap. In an embodiment, the slurry can have a paste-like consistency when introduced into the mold. This may be analogous to the process of making waffles using batter. Advantageously, this method does not include any step of dehydrating the slurry before it is introduced into the mold.

[0161] The following range refers to the consistency of the slurry (at least) when it is introduced into the mold. This advantageously corresponds to the consistency of the slurry when it is initially mixed, i.e., no dehydration occurs between the initial mixing of the slurry and its introduction into the mold.

[0162] For example, in some embodiments, the slurry may contain less than 20% by weight, less than 15% by weight, or less than 12% by weight of liquid. The slurry may contain at least 5% by weight or at least 8% by weight of liquid. In some exemplary embodiments, the slurry contains about 10% by weight of liquid.

[0163] The pulp may contain at least 10% by weight of fiber. The pulp may contain less than 30% by weight of fiber, or less than 25% by weight of fiber. The pulp may contain 10%-30% by weight or 10%-25% by weight of fiber. In some preferred embodiments, the pulp contains 12%-23% by weight (such as 15%-20% by weight) of fiber.

[0164] The slurry may contain at least 50% by weight of adhesive, and optionally at least 55% by weight or at least 60% by weight of adhesive. The slurry may contain less than 75% by weight, less than 70% by weight, or less than 68% by weight of adhesive. The slurry may contain 50% to 75% by weight of adhesive, optionally 55% to 70% by weight or 60% to 70% by weight of adhesive. In some exemplary embodiments, the slurry contains 63% to 68% by weight of adhesive, such as approximately 65% ​​by weight of adhesive.

[0165] The total percentage of starch, fiber, and liquid may add up to less than 100%. For example, in an exemplary embodiment, the slurry may contain up to 25% by weight or up to 22% by weight of one or more additive substances from the group described above. The slurry may contain at least 5% by weight, at least 10% by weight, or at least 12% by weight of one or more additive substances from the group. The slurry may contain 12% to 23% by weight of one or more additive substances from the group, such as 15% to 20% by weight of one or more additive substances from the group.

[0166] When introduced into the mold, the slurry can have any suitable consistency. In embodiments, the slurry can be in the form of a paste. When introduced into the mold, the slurry can include a certain amount of liquid within any of the above ranges. Thus, the slurry may contain less than 20% by weight, or less than 15% by weight, or less than 12% by weight of liquid. The slurry may contain at least 5% by weight or at least 8% by weight of liquid. In some exemplary embodiments, when introduced into the mold, the slurry contains about 10% by weight of liquid.

[0167] The step of introducing slurry into a mold may include injecting the slurry into the mold. The slurry is injected into a cavity defined between opposing mold components of the mold.

[0168] According to any aspect or embodiment of the invention, the mold for producing the end plug can be of any suitable form. The mold is configured to produce configurations associated with the roll-facing side and the dispenser-facing side of the end plug. The mold can include opposing mold components, each including internal configurations for producing the configuration associated with each side of the end plug. The mold can include a first component and a second component, the first component including internal configurations for producing the configuration associated with the roll-facing side of the end plug, and the second component including internal configurations for producing the configuration associated with the dispenser-facing side of the end plug. The configuration associated with the roll-facing side includes a configuration that can be inserted into an opening in the end of the roll. The configuration associated with the dispenser-facing side includes a configuration for cooperating with a configuration of the retainer portion of the dispenser. The internal configurations associated with the first and second mold components are complementary to the configurations produced on the respective sides of the end plug. The mold can be a two-piece mold. Therefore, the mold components can be half-molds. The mold can be converted between an open configuration and a closed configuration. Therefore, the mold components can be moved relative to each other to allow the mold to convert between open and closed configurations.

[0169] When the mold is in a closed configuration, a cavity is defined between the mold components. Slurry is introduced into this cavity. The minimum size of the cavity during the molding process will determine the wall thickness of the resulting molded end plug. It should be understood that after the slurry is introduced into the mold, the mold components can move relative to each other when the mold is in a closed configuration. This can reduce the size of the cavity defined between the mold components. Pressing the mold components together may help to fill all parts of the mold cavity with slurry. For example, one mold component can be pressed against another mold component. The spacing between the mold components can be gradually reduced, for example, after some initial evaporation of the liquid from the slurry, or reduced at a given point in the process. In this case, the wall thickness will be determined by the minimum size of the cavity obtained during the molding process. In other embodiments, the mold components may have a fixed spacing when the mold is in a closed configuration.

[0170] This method may include ejecting the molded fiber end plug from the mold once heating in the mold is complete. This ejection can occur when the mold is opened. Advantageously, the molded fiber end plug does not undergo any further heating steps. In an embodiment, only a single mold is used during the manufacture of the molded fiber end plug.

[0171] The mold can be made of any suitable material. In a preferred embodiment, the mold is a metal mold, such as an aluminum mold. This allows the mold to withstand high temperatures, which are advantageously used to heat (e.g., bake) the slurry in the mold to obtain the final end plug. The mold may include multiple openings to allow liquids and / or vapors to flow out of the mold, for example, during the evaporation of liquids from the slurry.

[0172] The method preferably includes heating a slurry in a mold to provide molded fiber end caps. A heating step dries the molded fiber end caps to a final degree of dryness within the mold. A heating step dehydrates the slurry and bakes it to provide the molded fiber end caps. Preferably, the method includes heating the slurry to a temperature of at least 100 degrees Celsius, and optionally to a temperature of at least 150 degrees Celsius, at least 180 degrees Celsius, or at least 200 degrees Celsius. The slurry may be heated to temperatures below 300 degrees Celsius, below 250 degrees Celsius, or below 220 degrees Celsius. In some exemplary embodiments, the slurry is heated to a temperature of approximately 400 degrees Fahrenheit (204 degrees Celsius). The duration of heating can be selected as needed and may depend on factors such as the viscosity of the slurry, the proportion of binder used, the properties of the slurry components, and the shape of the molded end caps to be produced.

[0173] The method may then include removing the molded fiber end plug from the mold. This may involve opening the mold to eject the molded fiber end plug.

[0174] Therefore, in these preferred embodiments, the final molded fiber end plug is made using a single mold from a slurry of fibers, binder, and water, within which the slurry is heated. This contrasts with some pulp molding techniques in which a first mold is used to dewater the initial fiber slurry, and the dewatered molding material is transferred to a second mold for drying to produce the final molded article. It has been found that using a single mold can be advantageous in providing molded fiber end plugs with improved shape accuracy and may enable the production of denser materials.

[0175] The term "end plug facing the roll" or "end plug facing the dispenser" as used herein includes "constructions" (e.g., constructions configured to be inserted into an opening in the end of a sheet roll, constructions for securing the end plug to the sheet roll, constructions configured to cooperate with a construction of the roll retainer portion of the dispenser in use to mount the end plug to the dispenser, etc.) which should be understood to encompass a roll-facing side or a dispenser-facing side including one or more, and optionally multiple, such constructions. Therefore, the roll-facing side of the end plug includes: one or more constructions configured to be inserted into an opening in the end of a sheet roll and including one or more constructions for securing the end plug to the sheet roll; and optionally includes multiple constructions configured to be inserted into the opening, including multiple constructions for securing the end plug to the sheet roll. The dispenser-facing side of the end plug includes one or more, and optionally multiple, constructions configured to cooperate with a construction of the roll retainer portion to mount the end plug to the roll retainer portion. Therefore, the dispenser-facing side of the end plug includes: a set of one or more configurations configured to cooperate with the configuration of the roll retainer portion of the dispenser for mounting the end plug to the dispenser; and optionally includes a plurality of configurations configured to function in this manner.

[0176] Any structure defined by the roll-facing or distributor-facing side of the end plug or the roll retainer portion of the distributor may be defined by one or more constructions on the respective side of the end plug or roll retainer portion, unless the context requires otherwise.

[0177] It should be understood that any other aspect of the invention may include any or all features of the invention described in relation to any other aspect and embodiment of the invention, provided that such features do not contradict each other. In particular, it should be understood that the second and other aspects of the invention may include any or all features described with respect to the method of the first aspect of the invention, and vice versa.

[0178] The various features of embodiments of the present invention will now be described in more detail. Attached Figure Description

[0179] Various implementation schemes will now be described by way of example and with reference to the accompanying drawings, wherein:

[0180] Figure 1 An exemplary embodiment of the dispenser is shown, with which the end plug described herein can be used;

[0181] Figure 2 This is a front view showing the front surface of a roll retainer portion, which includes a configuration that can cooperate with the dispenser-facing side of an end plug according to an embodiment of the invention to mount the end plug to the dispenser.

[0182] Figure 3 yes Figure 2 A side view of the roll retainer portion of the implementation scheme;

[0183] Figure 4 yes Figure 2 A perspective view of the roll retainer portion of the implementation scheme;

[0184] Figure 5 The method of mounting the end plug to roll 120 is shown, with the roll-facing side of the end plug being used for mounting the end plug to roll 120.

[0185] Figure 6 A molded fiber end plug for a dispenser system according to a first embodiment of the invention is shown from the side facing the roll;

[0186] Figure 7 yes Figure 6 A top view of the molded fiber end plugs from the side facing the dispenser;

[0187] Figure 8 Shown from one side Figure 6 and Figure 7 end plug, such as Figure 6 As shown, the side facing the roll is at the top;

[0188] Figure 9 It is along Figure 7 Line 9-9 shown passes through Figures 6 to 8 A cross-sectional view of the end plug of the embodiment shows the side of the end plug facing the roll and the side facing the dispenser;

[0189] Figure 10 It shows how end plug 1 moves in the direction of the arrow to engage according to... Figures 2 to 4 The distributor's volume retainer section is shown, and an exploded view of the collaborative features is shown in more detail;

[0190] Figure 11 It shows Figures 6 to 10 The end plug is installed once it is attached to the section view of the roll retainer portion;

[0191] Figure 12A molded fiber end plug according to another embodiment of the invention is shown, which is a perspective view of the end plug, wherein the side facing the roll is at the top.

[0192] Figure 13 yes Figure 12 A top view of the end plug facing the dispenser;

[0193] Figure 14 yes Figure 12 and Figure 13 A top view of the end plug facing the roll surface;

[0194] Figure 15 It is along Figure 14 The cross-sectional view of line 15-15;

[0195] Figure 16 yes Figures 12 to 15 A perspective view of the end plug facing the dispenser.

[0196] Figure 17 This is a perspective view of another embodiment of the molded fiber end plug according to the invention, with the side facing the roll at the top.

[0197] Figure 18 From Figure 17 A top view of the end plug facing the dispenser;

[0198] Figure 19 From Figure 17 and Figure 18 A perspective view of the end plug facing the dispenser.

[0199] Figure 20 This is a top perspective view of the surface of the molded fiber end plug facing the roll according to another embodiment of the invention;

[0200] Figure 21 yes Figure 20 A top view of the end plug facing the dispenser;

[0201] Figure 22 This is a top perspective view of the surface of the molded fiber end plug facing the roll according to another embodiment of the invention;

[0202] Figure 23 yes Figure 22 A top view of the end plug facing the dispenser;

[0203] Figure 24 It is along Figure 22 The line 24-24 was cut off Figure 22 and Figure 23 A cross-sectional view of the end plug of the implementation scheme;

[0204] Figure 25 It is suitable for and Figures 22 to 24 A perspective view of the roll retainer portion of the dispenser used with the end plugs of the embodiment, from its side facing the roll;

[0205] Figure 26 It shows the installation on Figure 25 On the coil retainer section Figures 22 to 24 Top view of the end plug;

[0206] Figure 27 It is along Figure 26 Sectional view of line 27-27;

[0207] Figure 28 It is suitable for and Figures 29 to 31 A perspective view of another roll retainer portion of the dispenser used with the end plug of another embodiment shown, from its roll-facing side.

[0208] Figure 29 It shows the installation on Figure 28 Top and side views of the end plug of another embodiment on the roll retainer portion;

[0209] Figure 30 It shows the installation on Figure 28 The end plug on the coil retainer section Figure 29 Top view of the arrangement shown;

[0210] Figure 31 It is along Figure 30 Sectional view of line 31-31;

[0211] Figure 32 This is a flowchart illustrating certain steps in the manufacture of a molded fiber end plug according to an exemplary embodiment of the present invention;

[0212] and Figure 33 schematically shown Figure 32 Certain steps.

[0213] Figure 1 An exemplary embodiment of a dispenser is shown, with which the end plug described herein can be used. This dispenser is provided only as an example to illustrate how the roll retainer portion cooperates with the end plug to mount a roll to the dispenser. It should be understood that other types of dispensers can be used. The configuration of the roll retainer portion of the dispenser and its relationship to other dispenser components (e.g., the configuration of any dispenser arm) may differ from that shown. Furthermore, while the invention will be illustrated with respect to a roll retainer portion that is not rotatable relative to the dispenser arm, in other embodiments, the end plug may securely mount the roll to the roll retainer portion as described above, which may be rotatable relative to another part of the dispenser. For example, the roll retainer portion may be in the form of a rotatable hub.

[0214] The dispenser shown is a wall-mounted dispenser, as can be found in, for example, restrooms or other handwashing facilities. However, the end cap can be used with other types of dispensers. The dispenser can be an electronic, non-manual dispenser, but this is not always the case.

[0215] Now, let's return to WO 2012 / 073203A2 (corresponding to US2012138723A1). Figure 1 In an exemplary arrangement, dispenser 100 includes a pair of dispenser arms 102, each dispenser arm having a roll retainer portion 104 at its distal end. A roll receiving space 106 is defined between the arms 102. During the insertion or removal of a roll, the dispenser arms 102 are resiliently deflected outward relative to each other, biased to return to their original, closer position.

[0216] The roll retainer portion of the dispenser used with the end plug of the present invention may be Figure 1 The configuration shown is either, in fact, any configuration described in WO 2012 / 073203A2 above, or in fact any other desired configuration.

[0217] In use, the end plug (already inserted into the end of the roll) is pushed to the front surface of the roll retainer portion to install the end plug, and thus the roll is mounted to the end plug.

[0218] The general principle of providing an installation between the end plug and the roll retainer section is described in WO 2012 / 073203A2, which utilizes the cooperative construction of the dispenser-facing side of the end plug and the roll retainer section of the dispenser.

[0219] Figure 2 An alternative example of a roll retainer portion 50 that can be used with an end plug according to some exemplary embodiments of the present invention is shown.

[0220] Figure 2 This is a front view showing the front surface of a roll retainer portion, which includes a configuration that can cooperate with a dispenser-facing side of an end plug according to an embodiment of the invention to mount the end plug to the dispenser. In this example, the configurations cooperate with each other to rotatably mount the end plug to the roll retainer portion. Figure 3 yes Figure 2 Side view of the roll retainer section. Figure 4 This is a perspective view of the roll retainer section.

[0221] The roll retainer portion 50 includes a base 52 defining a front surface of the roll retainer portion. A cylindrical protrusion 54 extends from the base 52. A circumferential extension structure 56 partially surrounds the protrusion 54 to define an annular space 58 between the circumferential extension structure and the protrusion. The structure 56 defines a circumferential extension wall 60 that defines an outer edge of the annular space 58. A ramp structure 62 extends from the top of the wall 60 to the base 52.

[0222] In this example, the roll retainer portion 50 includes a convex configuration, namely a cylindrical protrusion 54. The configuration of the dispenser-facing side of the end plug may include a concave member for receiving the cylindrical protrusion. The cylindrical protrusion 54 and the concave member of the dispenser-facing side of the end plug are complementary to each other. The dispenser-facing side configuration of the end plug is configured such that it can cooperate with the configuration of the roll retainer portion to mount the end plug to the roll retainer portion. For example, the dispenser-facing side configuration may be configured such that the concave member of this configuration can cooperate with the configuration of the roll retainer portion to allow the concave member to receive the convex member, such as the cylindrical protrusion. Thus, the concave member may be configured such that it fits into the annular space 58 to mount the end plug to the dispenser. The dispenser-facing side configuration of the end plug should ensure that it does not interfere with any configuration of the roll retainer portion (i.e., the roll-facing side of the end plug) to prevent the end plug and the roll retainer portion from being fitted together to provide a secure mount, and, where applicable, allow relative rotation between the end plug and the roll retainer portion.

[0223] Of course, the coil retainer portion may differ from that shown, and the end plug should be appropriately configured such that the configuration of the dispenser-facing side of the end plug can cooperate with the configuration of the specific coil retainer portion to which the end plug is intended to be used. For example, such a protrusion may be formed by multiple configurations rather than a single configuration defining the cylindrical protrusion 54 of the coil retainer portion. The cylindrical protrusion is then defined by a set of configurations of the coil retainer portion. This set of configurations and one or more configurations of the dispenser-facing side of the end plug (e.g., cooperating concave members defining the one or more configurations) may define some of the complementary members of a pair of complementary members of the dispenser-facing side of the end plug and the coil retainer portion. The configuration of the coil retainer portion does not need to define a cylinder. For example, assuming that the outer diameter corresponding to the outer circular boundary drawn around each configuration defining the protrusion can fit snugly within the annular configuration of the dispenser-facing side of the end plug, this arrangement can be used in conjunction with... Figures 2 to 4The same method applies to the example. Similarly, the annular space can be defined around the protrusion of the coil retainer portion in a manner different from that shown, for example, by multiple structures around the protrusion. This structure does not need to define a circumferentially extending structure. For example, a series of spoke-like structures extending radially on the surface of the coil retainer portion can be configured such that the proximal ends of these structures are spaced apart from the outer edge of the protrusion to define the annular space. Similarly, there can be more than one ramp portion.

[0224] End plugs can be used to ensure that a sheet roll is used only with a dispenser designed for use with that sheet roll, for example, to ensure optimal performance. For example, a dispenser, particularly but not necessarily an electronic dispenser, can be configured to most efficiently operate a particular type of sheet (e.g., basis weight) and / or roll. This ensures that the dispenser operates reliably without jamming, and if electronic, has higher energy efficiency, no risk of failure, and / or safety risks, etc. As can be seen from the examples above, the configuration of the dispenser-facing side of the end plug can be configured such that this configuration only allows the end plug to be mounted to a specific dispenser having a roll retainer portion with a suitable complementary configuration.

[0225] While the illustrated embodiment allows relative rotation between the end plug and the roll retainer portion, enabling the end plug to rotate with the roll during dispensing, in an alternative embodiment, the configuration of the dispenser-facing side of the end plug can cooperate to provide a keyed connection with the roll retainer portion, maintaining a fixed rotational relationship between the roll retainer portion and the end plug. The roll retainer portion can then be rotatably mounted to an adjacent portion of the dispenser so that the roll and the roll retainer portion can rotate relative to another portion of the dispenser during dispensing. For example, the keyed connection can be made with a protruding sensor component of the roll retainer portion. A recess on the dispenser-facing surface of the end plug can cooperate with the sensor component to provide a keyed connection. For example, the recess can be an opening in the end plug or the opposite side of a dome on the end plug. The roll retainer portion can then be rotatably mounted to the arm of the dispenser, such as via a mounting portion (e.g., a hub fixed to the distal end of the arm). In such an embodiment, the roll retainer portion is rotatable relative to the mounting portion. The mounting portion of the dispenser can include another sensor component that forms a sensor device together with the sensor component of the roll retainer portion. For example, the roll retainer portion may include a magnet, thereby providing a "target" for a sensor device to sense rotation, such as counting the number of rotations of the roll retainer portion relative to the dispenser arm. The mounting portion may include a probe portion of the sensor device that detects the proximity of the magnet as it moves past the probe when the roll retainer portion rotates.

[0226] Figure 5The figure illustrates a manner in which the roll-facing side of the end plug can be used to mount the end plug to roll 120. This figure shows an exemplary embodiment of a roll that can be used with the end plug. This figure according to WO 2012 / 073203A2 is merely a general example of the manner in which the end plug is used. The end plug 101 includes a roll-facing side 105 and a dispenser-facing side 103, the roll-facing side having a configuration for insertion into the end of the sheet roll to secure the end plug to the roll, and the dispenser-facing side having a configuration that cooperates with the roll retainer portion of the dispenser to mount the end plug to the dispenser. The configuration associated with the roll-facing side 105 and the dispenser-facing side 103 of the end plug according to the invention, made of molded fiber material, can differ from... Figure 5 The structure shown, Figure 5 A plastic end cap 101 is shown. Examples of this difference are discussed below with respect to certain exemplary embodiments. However, the operating principle of the end cap is the same. The roll is a sheet roll 108, such as a tissue. However, the sheet can be any other type of mesh material suitable for dispensing from the roll. For example, the roll can be a roll of paper material, such as for providing hand towels, facial tissues, or toilet paper, or a roll of nonwoven material, such as for providing wipes, etc. The sheet may or may not include perforations. The roll dispenses the sheet from its periphery 109 and is rotatably mounted to a dispenser such that the roll can be rotated to allow dispensing of material in use.

[0227] The roll has ends 121, 123. Roll 120 includes a central hole 126 extending from one end to the other along its central axis 110. In the illustrated embodiment, the hole 126 is defined by a central hole in the core 122 of the roll. The core 122 can be any suitable material, such as cardboard, corrugated cardboard, etc. For example, the core can be a spirally wound core. However, it should be understood that the end plug described herein is not limited to use in the case of cored rolls, but can be used with any roll having an opening in its end into which a configuration facing the roll 105 can be inserted. For example, a coreless roll may include an opening in the form of a notch that extends only a small distance along the axis of the roll at each end into which the configuration facing the roll 105 can be inserted, or may similarly have a central hole extending from one end to the other. When the end plug is used with a cored roll, the end plug may be referred to as a "core plug".

[0228] End plug 101 is inserted into the opening provided by the end of hole 126 located at end 121 of the roll, with the side 105 facing the roll in front, as shown. Figure 5 As schematically shown, a configuration extending from the base 107 towards the roll is inserted into the end of a hole 126 located at the end 121 of the roll. This configuration includes a structure that cooperates with the periphery of the hole 126 (in this case, provided by the radial inner surface of the core 122) to provide an interference fit between the end plug 101 and the roll 120.

[0229] As part of the manufacturing process, the end plug 101 can be installed into the roll after the roll is manufactured by pushing it into the end of the hole 126 to provide a refilled product including the roll fitted with the end plug, which can be supplied to the user. Thus, in this arrangement, the end plug is inserted by a machine. The roll can be packaged with end plugs inserted at both ends for supply to the user.

[0230] Although the insertion of the end plug has been described with reference to end 121 of the roll, it should be understood that another end plug having the same structure will be inserted into the opposite end 123 of the roll, in which case it cooperates with the opposite end of the center hole 126. Although the invention has been described with reference to the case where the roll includes end plugs at both ends, depending on the configuration of the dispenser intended to be used with such end plugs, it is conceivable that the end plug can be inserted into an opening at only one end of the roll to mount the roll to the dispenser.

[0231] Some embodiments of end plugs having a configuration particularly advantageous when using molded fiber materials will now be described. However, it should be understood that providing molded fiber end plugs is advantageous in itself, for example, compared to plastic end plugs described in WO 2012 / 073203A2, and the invention is not limited to using the types of structures described below.

[0232] Figure 6 A molded fiber end plug 1 for a dispenser system according to a first embodiment of the invention is shown from the roll-facing side.

[0233] End plug 1 has a side 5 facing the roll (this side facing the roll is located at...) Figure 6 The topmost side) and the side facing the dispenser 3 (this side facing the dispenser is at the bottom). Figure 7 The features of the side facing the roll can be seen more clearly in the middle. Figure 7 This is a top view from the side facing the dispenser. Figure 8 Shown from one side Figure 6 and Figure 7 end plug, such as Figure 6 As shown, the side facing the roll is at the top.

[0234] Now refer to Figures 6 to 8 The features of the end plug 1 are described. The roll-facing side 5 of the end plug 1 includes an opening configured to be inserted into the end of the sheet roll during use to secure the roll cover 1 to the roll. These configurations provide an interference fit to the outer periphery of the opening.

[0235] like Figure 6As shown, the side 5 facing the roll includes four domes 7. The domes 7 have the same structure, and the characteristics of each dome will be described with reference to one of the domes. It should be understood that the end plug does not necessarily include four domes. For example, the number of domes can be in the range of two to six, such as three to five domes.

[0236] The dome 7 surrounds the central portion 12 on the side of the end plug facing the roll. The central portion 12 is centered on the axis XX of the end plug 1. The central portion 12 may be substantially circular.

[0237] Each dome 7 includes a planar top surface 9, an inner wall 11, and an outer wall 13. The inner wall 11, outer wall 13, and radial inner and outer walls relative to the central axis XX of the end plug are also present. Each dome includes a base portion 2 and an upper portion 4. The outer wall 13 includes a first portion 15 in the base portion of the dome and a second inclined portion 17 in the upper portion of the dome. The inclined portion 17 is inclined relative to the base portion 15. The angle θ defined between the inclined portion 17 and the first portion 15 of the outer wall 13 can be selected as needed. For example, the angle θ can be in the range of 20 degrees to 40 degrees, and in some exemplary embodiments it is 30 degrees.

[0238] The end plug includes a peripheral flange 20. A dome 7 stands upright on a base 18 facing the roll from the end plug. The base 18 is defined by the roll-facing surface 22 of the peripheral flange 20.

[0239] The first portion 15 of the outer wall 13 of the dome stands upright from the base 18 and can extend substantially perpendicular to the base 18. When determining the orientation of the first portion 15 of the outer wall relative to the base 18, the smooth transition zone from the base to the bottom of the outer wall 13 can be ignored.

[0240] The inner wall 11 of the dome extends between the top surface 9 of the dome and the central portion 12 of the end plug 1. The central portion 12 is located at the horizontal plane between the top 9 of the dome 7 and the base 18 of the end plug. The top surface 9 of the dome, the central portion 12, and the base 18 are all located in different planes.

[0241] The dome also includes a sidewall 10 that connects its inner wall 11 and outer wall 13.

[0242] Connecting portions 24 separate the domes from each other. Each connecting portion 24 extends between the central portion 12 of the end plug on the roll-facing side and the base 18 of the end plug. Each connecting portion includes an inclined portion that defines an inclined surface 37 on the roll-facing side of the end plug, and... Figure 6 The implementation scheme uses an inclined connection portion. In Figure 6 In the illustrated embodiment, the connecting portion is sloped along its entire length. It should be understood that the connecting portion may have a slope similar to... Figures 6 to 8Different configurations are shown in the embodiments. For example, the connecting portion may include an upper inclined portion and a lower portion that is, for example, substantially perpendicular to the base, or it may include multiple panels oriented differently from each other in the circumferential direction, or it may include an opening in the connecting portion, etc. Although the inclined portion defines a planar inclined surface 37 in the illustrated embodiment, other embodiments are also possible, such as presenting a curve.

[0243] The dome has the outline shape shown in the figure and may include smooth transition zones between its walls. Each wall may consist of multiple parts, which may define smooth transition sections or inflection points between them. Any part of the wall may be planar or curved. Figure 6 The proposed implementation is just one possible example of a dome shape.

[0244] The configuration and / or relative spacing of the domes may differ. Figures 6 to 8 As shown in the implementation scheme. For example, the domes may be more or less closely spaced and do not necessarily have a flat top surface. The slope of the outer wall may differ from the slope shown, for example, including curved sections or more than inflection points, etc.

[0245] The outer wall 13 of the dome 7 includes a protruding corner 26. Each dome provides a protruding corner 26 and serves to provide an interference fit to the periphery of an opening in the end of the sheet roll during use. The protruding corners 26 are discontinuous. Each protruding corner 26 is resiliently deflectable to provide this interference fit. The protruding corners project radially from the radial outer wall of the dome for engaging the periphery of the opening in the roll during use. Figures 6 to 8 As shown, the height of the convex corner is at least as large as the height of the base portion 15 of the outer wall, and can extend through the transition between the base of the wall 13 and the upper region (2,4 / 15,17).

[0246] The number, configuration, and / or location of the protrusions may differ from the illustration. For example, the protrusions may have a smaller height, need not be provided relative to each dome, and / or may be provided in association with the connecting portion 24 instead of the dome. In some exemplary arrangements, 2 to 6 protrusions may be provided. Where the protrusions are associated with domes, the domes can help support the protrusions and facilitate a secure connection with the roll.

[0247] The dome, connecting portion, and all constructions located inside flange 18 are inserted into the opening at the end of the roll during use to secure the end plug to the roll. Flange 18 will be pressed against the material defining the end of the roll and surrounding the opening.

[0248] Now refer to Figure 7 and Figure 9 Describe the features of the distributor-facing side 3 of end plug 1. Figure 9 It is along Figure 7 The cross-sectional view shown by line 9-9 passing through the end plug illustrates the side of the end plug facing the roll and the side facing the dispenser.

[0249] The peripheral flange 20 defines a surface 30 facing the dispenser. This surface facing the dispenser lies in the plane that defines the front surface of the side 3 facing the dispenser (this plane can also be used to define the base of the side facing the dispenser).

[0250] The roll-facing side includes an annular structure 32, which is shown as a cylinder. The annular structure 32 includes a central hole 34 coaxial with the central axis XX of the end plug. The central hole 34 is closed at its distal end (i.e., the end closer to the interior of the end plug). The closed end 36 of the hole is provided by a portion of the end plug wall's dispenser-facing surface, which in turn provides the roll-facing central region 12. In other words, the closed end of the hole corresponds to the dispenser-facing surface of the central portion 12.

[0251] The annular structure 32 is configured to receive the protrusion of the roll retainer portion of the dispenser in use to mount the end plug to the roll retainer portion, which will be described in more detail below.

[0252] The dispenser-facing side also includes an inclined surface 38 provided by the dispenser-facing surface of this portion of the end plug wall, and an inclined surface 37 provided by the roll-facing surface of this portion for the roll-facing connecting portion 24. The inclined surface 38 is configured to engage the ramp structure of the roll retainer portion when the end plug is installed to the roll retainer portion in use, as will be described in more detail below.

[0253] Reference Figure 7 It can be seen more clearly that the dome 7 forms a corresponding recess 40 on the side 3 facing the dispenser.

[0254] Figures 6 to 9 The end plug shown can be used with Figure 1 or Figures 2 to 4 The dispensers shown are used together. These are merely examples of some implementations of the dispenser, and the end plugs described herein can be used with this dispenser. It should be understood that other types of dispensers can be used.

[0255] Now will describe Figures 6 to 9 The configuration of the end plug facing the dispenser in the implementation scheme can be consistent with... Figures 2 to 4 The roll retainer portion of the dispenser shown is constructed in a manner that allows the end plug to be mounted onto the roll retainer portion.

[0256] Figure 10 It shows how the end plug 1 moves in the direction of the arrow to engage the coil retainer section and shows an exploded view of the cooperative features in more detail. Figure 11This is a cross-sectional view showing the end plug once it is installed into the roll retainer section.

[0257] The width d of the wall of the annular structure 32 on the dispenser-facing side of the end plug allows the annular structure to be inserted into the annular space 58 to rotatably mount the end plug to the roll retainer portion. A protrusion 54 is received in the annular structure 32. Therefore, the diameter of the hole 34 within the annular structure 32 allows the annular structure to receive the protrusion 54 in close contact. Thus, the annular structure and the protrusion define complementary parts that mate with each other. The inclination of the inclined surface 38 facing the dispenser surface allows these surfaces to engage against the ramp 63 when the end plug rotates relative to the roll retainer portion, while allowing the annular structure 32 to be fully inserted into the annular space 58. The configuration of the dispenser-facing side of the end plug does not necessarily need to engage the ramp (if provided), as long as the configuration of the dispenser-facing side is properly configured not to impede the proper fitting of the end plug to the roll retainer portion to achieve a secure mounting to the roll retainer portion, whether or not this is a rotatable mounting. Furthermore, it should be understood that the use of a ramp is not required, but in some cases a ramp may be necessary to facilitate the user loading the roll. A suitable toroidal space, similar to toroidal space 58, can be similarly defined in places where ramps are not used.

[0258] As described above, the configuration of the roll retainer portion may differ from the configuration shown. The end plug's distributor-facing side should be appropriately configured to cooperate with the construction of the roll retainer portion of the dispenser intended to be used with the end plug.

[0259] End plugs are used to ensure that a sheet roll is used only with a dispenser designed for use with that sheet roll, for example, to ensure optimal performance. For example, a dispenser, particularly but not necessarily an electronic dispenser, can be configured to most efficiently operate a particular type of sheet (e.g., basis weight) and / or roll. This ensures that the dispenser operates reliably without jamming, and if electronic, has higher energy efficiency, no risk of failure, and / or safety risks, etc. As can be seen from the example above, the roll retainer portion of the dispenser can be constructed in a specific way such that the correct end plug with an appropriate construction that can cooperate with those features is mounted onto it. The end plug and roll retainer portion should cooperate with each other so that any complementary constructions can fit together as intended without interfering with the intended installation of the end plug onto the roll retainer portion. This can be ensured by appropriately controlling the dimensions of the cooperating constructions; for example, the walls of the annular construction of the end plug must have a certain thickness so that the annular construction can provide a tight fit with the protrusions of the roll retainer portion, but so that the annular construction can still fit and rotate within the annular space provided on the surface of the roll retainer portion. Similarly, as described below, the sloping construction of the end plug must not interfere with any ramp structure of the coil retainer portion to prevent the protrusion from being properly received in the annular construction of the end plug, thereby providing a secure installation.

[0260] While the cooperation between the molded fiber end plug and the roll retainer portion of the dispenser has been illustrated with respect to a case where relative rotation between the end plug and the roll retainer portion is permitted, allowing the end plug to rotate with the roll relative to the roll retainer portion during dispensing, in alternative embodiments, the configuration of the dispenser-facing side of the end plug can cooperate with the configuration of the roll retainer portion to provide a keyed connection with the roll retainer portion, such that the roll retainer portion and the end plug maintain a fixed rotational relationship. The roll retainer portion can then be rotatably mounted to an adjacent portion of the dispenser so that the roll and the roll retainer portion can rotate relative to another portion of the dispenser during dispensing. For example, the roll retainer portion can be rotatably mounted to the dispenser arm via a mounting portion (e.g., a hub fixed to the dispenser arm), with the roll retainer portion rotating relative to the mounting portion. Depending on the configuration of the roll retainer portion, some modifications to the molded fiber end plug may be required to provide a keyed connection. Figure 20 and Figure 21 An exemplary embodiment is shown that can provide a molded fiber end plug that is keyed to the dispenser roll retainer portion.

[0261] For reference Figures 6 to 11 As shown in the exemplary embodiments, the molded fiber end plug according to the present invention can be referenced Figure 5 Mounted to the volume in the manner described. Although Figure 5 The molded fiber end plug according to the invention is not shown, but the operating principle is the same.

[0262] End plug 1 is inserted into an opening provided by the end of hole 126 located at end 121 of the roll, with the roll-facing side 5 facing forward. A construction extending from base 22 on the roll-facing side (including dome 7) is inserted into the end of hole 126 located at end 121 of the roll. Protrusion 26 cooperates with the periphery of hole 126 (in this case provided by the radial inner surface of core 122) to provide an interference fit between end plug 1 and roll 120.

[0263] As part of the manufacturing process, the end plug 1 can be installed into the roll by pushing it into the end of the hole 126 after the roll is manufactured, to provide a refilled product including the roll fitted with the end plug, which can be supplied to the user. Thus, in this arrangement, the end plug is inserted by a machine. The roll can be packaged with end plugs inserted at both ends for supply to the user.

[0264] Although the insertion of the end plug has been described with reference to end 121 of the roll, it should be understood that another end plug having the same structure will be inserted into the opposite end 123 of the roll, in which case it cooperates with the opposite end of the center hole 126. Although the invention has been described with reference to the case where the roll includes end plugs at both ends, depending on the configuration of the dispenser intended to be used with such end plugs, it is conceivable that the end plug can be inserted into an opening at only one end of the roll to mount the roll to the dispenser.

[0265] The use of end plug 1 will now be described.

[0266] Reference Figures 6 to 11 The end plug 1 is referred to Figure 5 The same method is used to insert the end plug into an opening at one end of the sheet roll to be installed into the dispenser. Typically, another such end plug is also inserted into an opening at the other end of the sheet roll. This can be done during the manufacturing of the refilled roll product. The end plug's roll-facing construction provides a strong interference fit with the roll. The roll and its end plug provide a single unit for the (re)fill dispenser. The user can remove any outer packaging from the roll refilled product before installing the roll into the dispenser. The dispenser can be, but is not necessarily, a refiller. Figure 1 or Figures 2 to 4 The examples illustrate the types.

[0267] To load the roll into the dispenser, the user first removes any depleted roll and its end cap from the dispenser. Then, the user pushes the end cap at one end of the roll, facing the dispenser, onto the roll retainer portion of the dispenser, as shown in the reference. Figure 1 or Figures 2 to 4 As described above. Figure 1In the case of the dispenser of the type shown, the dispenser arm 102 is deflected outward to allow the roll to be pushed onto the roll retainer portion. The configuration associated with the dispenser-facing side 3 cooperates with the configuration of the roll retainer portion 104 to mount the end plug to the dispenser arm, and thus, for example, with... Figure 10 and Figure 11 The method described herein is used to attach this end of the roll to the dispenser arm. In the case where the end plug is associated with the other end of the roll, as with... Figure 1 When dispensers of the type shown are used together, the configuration of the end plug at this end of the roll facing the dispenser similarly cooperates with the configuration of the roll retainer portion of the other dispensing arm to mount this end of the roll to the dispenser. The ends of the roll can be mounted sequentially or substantially simultaneously. In this way, in the illustrated embodiment, the end plug securely mounts the end of the roll to the dispenser to allow rotation between the roll and the roll retainer portion of the dispenser.

[0268] During use, the end plug is securely held in place at the end of the roll during the use of the dispenser (e.g., while the roll rotates relative to the roll retainer portion). Once the roll is depleted, the roll and end plug can be removed from between the dispenser arms in the reverse of the initial installation process. In the case of a cored roll, the remaining portion of the roll product will be the core, and the end plug is inserted into the end of the core. The end plug can be configured to not be removed from the roll without damage, such that once the roll is depleted, the end plug is discarded rather than reused. The end plug of the present invention is made of a fiber-molded material, and therefore can be recycled together with the core in the paper recycling stream. This avoids the problems associated with conventional plastic end plugs, which need to be removed from the core so that the plastic end plug and the paper core can be properly recycled in separate streams. Even if the roll is not a cored roll, the end plug of the present invention can be easily recycled in a standard paper stream.

[0269] The end caps of this invention are advantageously biodegradable. This provides further sustainability advantages, regardless of whether the end caps are recycled in the paper stream. For example, the end caps can be composted, both at home and in industry.

[0270] It is believed that the dome structure of the end plug described herein is particularly advantageous in providing a sustainable fiber end plug that can function reliably in the same manner as a plastic end plug. It is understood that plastic materials can have higher inherent strength than the molded fiber materials used in the embodiments described herein. It has been recognized that, in order to provide a corresponding level of strength, it is advantageous to modify the shape of the end plug compared to the shape of an end plug formed from plastic, particularly on the roll-facing side.

[0271] It has been found that dome structures can help provide fiber end plugs with advantageous strength properties, enabling them to reliably hold the roll mounted to the dispenser, even during periods of use that may generate forces during dispensing, such as when the end plug rotates relative to the roll retainer portion of the dispenser. The dome structure helps maintain a firm fit with the roll and also helps support the construction of the dispenser-facing side, which cooperates with the construction of the roll retainer portion, such as an annular structure receiving protrusions of the roll retainer portion. The dome also provides overall structural integrity for the end plug. This structure can also help provide strength to the end plug to maintain its integrity when it is pushed into the roll, for example, during the manufacture of a roll-refilled product.

[0272] The surface of the dome facing the roll has an alternating pattern of peaks and valleys. These peaks and valleys are believed to contribute strength to the overall structure of the end plug.

[0273] Of course, providing a fiber-molded end plug is advantageous in itself. Therefore, the present invention generally lies in providing such an end plug, and the dome structure shown in the exemplary embodiment is an advantageous feature, but not a necessity.

[0274] Figures 12 to 16 A molded fiber end plug 200 according to another embodiment of the invention is shown.

[0275] Figure 12 A perspective view of the end plug is shown, with the side facing the roll at the top.

[0276] End plug 200 is similar to end plug 1 described above, and the corresponding feature is marked as addition 200. End plug 200 is used in the same manner as end plug 1. Only significant differences will be described. As in the previous embodiment, the roll-facing side 205 includes four domes 207 with protruding corners 226 and peripheral flanges 220. The domes have a top 209 and sidewalls 210. A central portion 212 is defined between the domes. This embodiment shows different configurations that the domes can have. In this embodiment, each dome extends at an angle greater than the central axis of the end plug. Figures 6 to 11 The angle is larger in the previous embodiments, and the range of the connecting portion 24 is correspondingly reduced. As in the previous embodiments, the connecting portion 224 includes an inclined portion that defines an inclined surface 237 on the side facing the roll.

[0277] Figure 13 This is a top view of side 203 facing the dispenser. Figure 14 It is a top view of the surface facing the roll, and Figure 15 It is along Figure 14 The cross-sectional view of line 15-15 shows the inclined surfaces 238 and 237 more clearly. Figure 16This is a perspective view facing the dispenser.

[0278] This embodiment illustrates an optional feature of the reinforcing rib 250, which can be associated with the dispenser-facing side 205. If desired, this rib can be used with end plugs of other structures, including any of the embodiments described above and below.

[0279] exist Figure 13 and Figure 16 The reinforcing ribs are more clearly visible in the middle. Figure 13 and Figure 16 These are a top view and a perspective view of the dispenser-facing side 203. The dispenser-facing side includes a construction similar to that of the previous embodiment, including an annular structure 232. A recess 240 is defined on the opposite side of a dome corresponding to the roll-facing side. An inclined surface 238 is defined on the opposite side of the inclined portion of the connecting portion 224, which in turn defines an inclined surface 237 on the roll-facing side. The inclined surface 238 cooperates with the ramp structure of the roll retainer portion in the previous embodiment, while the annular structure 232 receives the protrusions of the roll retainer portion.

[0280] Reference Figure 16 Each rib defines a proximal end 252 and a distal end 254. The proximal end engages at the base of the annular structure 232 on the dispenser-facing side with the radially outer surface of the wall of the annular structure. The distal end 254 connects to the inner surface of the peripheral wall on the dispenser-facing side, corresponding to the dispenser-facing surface of the first portion 215 of the outer wall of the dome 207 in the base region of the dome. The first radially extending surface 256 of the rib 250 is closer to the roll in use. The opposing second radially extending surface 258 of the rib, located away from the roll, extends along the interior of the dome 207 on the dispenser-facing side, i.e., along the surface of the recess defined by the dome on the dispenser-facing side of the end plug. Each rib has the same structure.

[0281] The ribs serve to reinforce the end plug. The ribs help stabilize the annular structure 232, enabling it to better withstand the forces generated during use, and also stabilize the dome, which extends along the dome's surface facing the dispenser.

[0282] It should be understood that the number and location of the ribs may differ from those shown. For example, it is not necessary to provide one rib for each dome. The width and height of the ribs may vary. For example, the height at which the proximal and distal ends of the ribs extend on the peripheral wall and / or the wall of the annular structure on the dispenser-facing side may vary. Although rib 250 is shown extending across recess 240 on the dispenser-facing side of dome 207, alternatively, rib 250 may be provided on the dispenser-facing side between domes 207.

[0283] Figures 17 to 19 Another exemplary embodiment of the end plug 300 according to the present invention is shown.

[0284] Figure 17 This is a perspective view of the end cap, with side 305 facing the roll at the top. Figure 18 This is a top view of side 303 facing the dispenser, and Figure 19 This is a perspective view facing the dispenser.

[0285] As mentioned earlier, the use of and Figures 6 to 11 The reference numerals used in the first embodiment are correspondingly increased by 300. This embodiment shows another possible configuration of the connection portion between the dome and the dome. The end plug 300 is used in the same manner as in the previous embodiment. In this embodiment, the convex angle 326 for providing an interference fit is associated with the connection portion 324, rather than with the exterior of the dome. Each dome includes a recessed portion 321 defined along its outer surface. As previously described, the dispenser-facing side includes an annular structure 332 for receiving the protrusion of the roll retainer portion, and the dispenser-facing surface 338 of the inclined portion of the connection portion 324 (which defines an inclined surface 337 on the roll-facing side) can cooperate with the ramp structure of the roll retainer portion, as in the previous embodiment. In this embodiment, the inclined portion of the connection portion on the roll-facing side bends with increasing height from the base (and therefore the inclined surface 338 on the dispenser-facing side also bends accordingly).

[0286] Figure 20 and Figure 21 Another embodiment of the fiber end plug 400 according to the invention is shown. This other embodiment is similar to the preceding embodiment, and corresponding features use the same reference numerals as in the first embodiment, increased to 400. Only significant differences will be described.

[0287] Figure 20 This is a top-down perspective view of the surface facing the roll. Figure 21 This is a top view of surface 403 facing the dispenser.

[0288] As in the preceding embodiments, the end plug 400 includes a plurality of domes 407 surrounding a central portion 412 and separated by connecting portions 424. In this embodiment, the connecting portions include sloped portions comprising sloped surfaces 437 as described above; however, in this embodiment, each connecting portion 424 includes an opening 480. Providing openings in this manner helps control the overall strength of the end plug. Introducing openings can be used to reduce the strength of the end plug if a desired level of strength is required. The opposite side of the connecting portion 424 defines a sloped surface, such as 438, on the dispenser-facing side.

[0289] The dispenser-facing side 403 includes various configurations provided on the opposite side of the configuration facing the roll. Thus, a recess 440 is provided corresponding to the dome 407, and an inclined surface is defined by the opposite portion of the connecting portion 424. As previously described, the configurations on the dispenser-facing side ensure that they do not impede the ability to securely mount the end plug to the dispenser, whose protrusion is received in the hole 434 of the annular configuration 432. The various surfaces on the dispenser-facing side can engage the ramps of the dispenser, i.e. Figures 2 to 4 , Figure 10 and Figure 11 The type shown is used while still allowing the end plugs to be correctly installed into the dispenser roll retainer section.

[0290] Figure 20 and Figure 21 The end plug is also suitable for use with other types of dispensers, where the end plug needs to be non-rotatably mounted to the dispenser. One or more openings can receive a corresponding configuration of the roll retainer portion to hold the end plug in a fixed rotational position relative to the roll retainer portion. The edges of the openings can cooperate with the configuration of the roll retainer portion to prevent relative rotation between the roll retainer portion and the end plug. For example, the edges of the openings can cooperate in such a way with a protruding sensor component of the roll retainer portion. See below. Figure 20 and Figure 21 An example describing this type of roll retainer portion is given. Of course, other arrangements can be envisioned to provide a keying fit, such as using a recess in the end plug that is not necessarily open, which can receive the roll retainer portion to provide a keying fit between the end plug and the roll retainer portion. Examples are as follows. Figures 23 to 31 As shown.

[0291] It should be understood that, if necessary, Figure 20 and Figure 21 The opening shown in the embodiment can be incorporated into any other embodiment shown. One or more openings can be provided, even where a key connection between the coil retainer portion and the end plug is not required, thereby customizing the strength of the end plug for the desired application. Therefore, Figure 20 and Figure 21 The implementation scheme is not limited to arrangements requiring a non-rotatable connection between the end plug and the coil retainer section. Similarly, if higher strength is required, Figure 20 and Figure 21 The implementation scheme can be manufactured without openings in the connecting portion. If keying with the dispenser is required, keying with the dispenser can be provided in other ways, such as through cooperation between a protrusion of the roll retainer portion and a recess in recess 440 provided by the reverse side of the dome. See below. Figures 21 to 31 An example describing this arrangement.

[0292] While in some exemplary embodiments above, the opposite side of the connecting portion of the dome is shown as inclined and cooperates with the ramp structure of the dispenser roll retainer portion to allow the end plug to be mounted to the roll retainer portion, it should be understood that, more generally, the configuration of the dispenser-facing side should be configured not to interfere with the desired mounting of the end plug to the roll retainer portion, whether or not the mounting is rotatable. Therefore, any surface defined on the dispenser-facing side (which may be provided by the opposite configuration on the roll-facing side) should be configured not to interfere with the intended mounting of the end plug. Such a surface may include an inclined surface and may be provided, for example, by the opposite side of the dome and / or the connecting portion.

[0293] The use of end plugs in other implementation schemes is as follows: Figures 6 to 11 The first embodiment is described. The only difference is that in some embodiments, the coil retainer portion can rotate relative to the cooperating portion of the dispenser together with the end plug. For example, the coil retainer portion can rotate relative to the mounting portion (e.g., the hub fixed to the arm of the dispenser).

[0294] Figures 22 to 25 Another embodiment of the fiber end plug 500 according to the invention is shown. This other embodiment is similar to the preceding embodiment, and corresponding features use the same reference numerals as in the first embodiment, increased to 500. Only significant differences will be described.

[0295] Figure 22 This is a top-down perspective view of the surface facing the roll. Figure 23 This is a top view of surface 503 facing the dispenser. Figure 24 It is along Figure 22 Line 24-24 passes through the sectional view of end plug 500.

[0296] As in the preceding embodiments, the end plug 500 includes a plurality of domes 507 surrounding a central portion 512 and separated by a connecting portion 524. In this embodiment, the connecting portion includes an inclined portion comprising an inclined surface 537 as described above. In this embodiment, with Figure 21 and Figure 22 Compared to the previous implementation, the connection section has no opening. This allows for a more robust end plug.

[0297] The dispenser-facing side 503 includes various configurations provided on the opposite side of the configuration facing the roll. Thus, a recess 540 is provided corresponding to the dome 507, and an inclined surface is defined by the opposite portion of the connecting portion 524. As previously described, the configurations on the dispenser-facing side ensure that they do not impede the ability to securely mount the end plug to the dispenser, and the protrusion of the roll retainer portion is received in the hole 534 of the annular configuration 532.

[0298] Various surfaces on the side facing the dispenser can be joined to the dispenser's ramps or other structures, i.e. Figures 2 to 4 , Figure 10 and Figure 11 The type shown is used while still allowing the end plugs to be correctly installed into the dispenser roll retainer section.

[0299] Similar to Figure 20 and Figure 21 end plug, Figures 22 to 24 The end plug is also suitable for use with other types of dispensers where the end plug needs to be non-rotatably mounted to the roll retainer portion (which in turn is rotatably mounted to the mounting portion of the dispenser). One or more recesses 540 provided on the dispenser-facing side of the dome 507 can receive a corresponding configuration of the roll retainer portion to hold the end plug in a fixed rotational position relative to the roll retainer portion. The edges of the recesses can cooperate with the configuration of the roll retainer portion to prevent relative rotation between the roll retainer portion and the end plug. In the illustrated embodiment, each dome in the dome has the same configuration, and thus a recess 540 is defined on the opposite side of that dome, which is configured to receive the cooperating configuration of the roll retainer portion. This provides greater ease of use because the end plug can be mounted to the roll retainer portion by positioning a protrusion of the roll retainer portion in the recess defined by any one of the domes. Of course, each recess defined on the opposite side of the dome may not necessarily be able to receive the protrusion of the roll retainer portion, as long as the protrusion, or each protrusion, of the roll retainer portion can be suitably fitted into the recess associated with the dispenser-facing side of the end plug to provide the desired connection between the roll retainer portion and the end plug. The dome may be configured in a specific configuration to receive the protrusions associated with the roll retainer portion intended for use with the end plug, thereby preventing the end plug from being used with an unintended dispenser.

[0300] In the illustrated embodiment, the dispenser-facing side of the end plug 500 does not include a reinforcing rib extending across the recess 540 defined by the dome-shaped side of the dispenser. This prevents the rib from obstructing the insertion of the protrusion of the coil retainer portion into the dome-defined recess 540. It can be seen that the rib 550 is instead provided in the area between the domes on the dispenser-facing surface. This rib is optional. It is also contemplated that the rib may be associated, for example, with some of the domes (e.g., in addition to one or more domes for receiving the protrusion), and / or located elsewhere besides in the dome-defined recess.

[0301] Figures 22 to 24The embodiment illustrates how the opposite side of the dome can be used to provide a keyed connection to the protruding portion of the roll retainer section through a suitable configuration of the dome. Therefore, this universally constructed end plug can be used to provide either a keyed or rotatable connection to the roll retainer section. Some dimensional variations may be required to fit a given roll retainer section. Of course, the end plug of the aforementioned embodiment (refer to...) Figures 1 to 21 Any one of them can be similarly used to provide a key connection to the coil retainer portion by properly constructing the opposite side of the dome relative to a portion of the coil retainer portion to which the end plug is to cooperate.

[0302] The use of end plugs in other embodiments is as described with respect to the preceding embodiments. In some embodiments, as will now be illustrated by example, the coil retainer portion may rotate together with the end plug.

[0303] Figure 25 These are front and side perspective views showing the front surface of the coil retainer portion 569, which can be used with the end plug 500. The coil retainer portion 569 is in the form of a hub. The front surface includes components that can be used with... Figures 22 to 24 The configuration of the end plug on the dispenser-facing side of the embodiment cooperates to mount the end plug to the dispenser configuration. In this example, these configurations cooperate with each other to provide a keyed connection between the end plug and the roll retainer section. Figure 26 This is a front view showing the end plug mounted on the roll retainer section, and Figure 27 This illustrates the cooperation between the construction of the roll retainer portion 569 and the construction of the end plug 500 facing the dispenser side. Figure 26 Sectional view of line 27-27.

[0304] The coil retainer portion 569 includes a cylindrical protrusion 575. An annular structure 581 circumferentially surrounds the protrusion 575 to define an annular space 573 between the annular structure and the protrusion. The structure 581 defines a circumferentially extending wall that defines a radially outer edge of the annular space 573. The coil retainer portion 569 includes a peripheral flange 571 that defines a front surface of the coil retainer portion from which the annular structure 581 and the cylindrical protrusion 575 stand upright.

[0305] In this example, the cylindrical protrusion 575 of the roll retainer portion 569 is received in the hole 534 of the annular structure 532 of the end plug. The annular structure 532 of the end plug is fitted within the annular space 575 of the roll retainer portion.

[0306] The roll retainer portion 569 also includes a protruding sensor component 577, which includes a magnet. The sensor component 577 forms part of a sensor device for sensing the rotation of the roll (together with the end plug and roll retainer portion) relative to the dispenser arm during use. The sensor device can be used to detect the number of roll revolutions. This can be used, for example, to determine the remaining amount of product. The remainder of the sensor device is associated with a portion of the dispenser in which the roll retainer portion rotates relative to it. For example, in one embodiment, the roll retainer portion 569 is rotatably mounted to a mounting portion, such as a hub fixed to the distal end of the dispenser arm. This arrangement would resemble... Figure 1 The arrangement shown includes a mounting portion provided at the position of the roll retainer portion 104 as shown, and the roll retainer portion 569 is rotatably mounted to the mounting portion. The mounting portion may include a probe portion of a sensor device for detecting the proximity of the magnet portion of the dispenser associated with the roll retainer portion 569. The probe portion is thus rotatably fixed relative to the dispenser arm. In some exemplary arrangements, the probe portion may be electrically connected, for example, to a sensor module of the sensor device using a wired connection. The sensor module may form part of a dispenser module for controlling the operation of the dispenser, wherein the dispenser is an electronic dispenser. The sensor module may include a processor. In this way, during use, as the roll retainer portion rotates relative to the mounting portion, the probe can detect when the magnet passes the probe, and thus the number of roll revolutions can be determined.

[0307] Reference Figure 27 When the end plug 500 is mounted to the roll retainer portion 569, the sensor component 577 is located within the apex of a recess 540 provided by the opposite side of the dome 507 to provide a key connection between the end plug 500 and the roll retainer portion 569. The apex is provided by the opposite side of the top 509 of the dome 507. The roll-facing side of the roll retainer portion and the dispenser-facing side of the end plug are configured such that the end plug 500 can be fitted onto the roll retainer portion 569, thereby allowing the sensor component 577 to be located within a apex defined on the opposite side of the dome.

[0308] Reference Figures 28 to 31 Another embodiment of the end plug 600 according to the present invention is described. Figure 28 This is a front perspective view of the roll retainer portion 669, with an end plug that can be used with the roll retainer portion to provide a keyed connection. Figure 29 This is a perspective view showing the end plug 600 mounted on the roll retainer portion 669 from the side facing the roll, while Figure 30 The end plug 600 mounted on the roll retainer section 669 is shown from above.

[0309] End plug 600 has the same characteristics as the reference. Figures 22 to 27The end plug 500 has a similar configuration and can be used in a similar manner. The end plug 600 differs primarily in dimensional details to accommodate the sensor portion of the roll retainer portion 669, which has a different configuration than the roll retainer portion 569. The end plug 600 includes a dome 607, a convex corner 626, a central portion 612, and a flange 671.

[0310] End plug 600 includes a dome 607 and other features corresponding to those in the preceding embodiments. Reference numerals indicating corresponding features have been increased by 600 relative to the first embodiment. End plug 600 is configured to cooperate with roll retainer portion 669 such that the sensor portion 677 of roll retainer portion 669 fits within a apex defined on the opposite side of one of the domes of dome 607 (i.e., defined by a recess 640 on the opposite side of the dome) to provide a keyed connection. The dispenser-facing side of end plug 600 has a configuration similar to that of end plug 500, namely including an annular structure defining an aperture for receiving a cylindrical protrusion of the roll retainer portion.

[0311] The roll retainer portion 669 is similar to the roll retainer portion 569, having a cylindrical protrusion 675 (which is also shown as a hollow cylinder) and an annular structure 681 surrounding the protrusion 675, the annular structure having a radial inner wall defining an annular space 673 between the annular structure 681 and the protrusion 675.

[0312] Figure 29 and Figure 30 An end plug 600 is shown mounted on the roll retainer portion 669. A cylindrical protrusion 675 is received in an annular hole on the roll-facing side of the end plug 600. Figure 31 It is along Figure 30 The cross-sectional view taken by line 31-31 shows how the protruding sensor 677 is received in the apex defined by a recess 640 on the opposite side of one of the domes 607 to provide a key connection between the coil retainer portion and the end plug. The coil retainer portion 669 is rotatably mounted to the dispenser, as described above with respect to the coil retainer portion 559. Thus, the coil retainer portion 669 can be rotatably mounted to a mounting portion, such as a hub fixed to the arm of the dispenser, and includes the probe portion of the sensor device. Of course, the same end plug 600 can alternatively be used to provide a rotatable connection to the coil retainer portion, wherein the dispenser-facing sides of the coil retainer portion and the end plug 600 are suitably constructed such that a key connection is not provided, for example, the coil retainer portion does not include a protrusion located within the dome to provide a key connection.

[0313] The end plug in any embodiment of the present invention is a fiber end plug.

[0314] The end plug is formed from a mixture of fibers and an adhesive. The adhesive provides a matrix that holds the fibers in place. Any suitable adhesive can be used, but it is advantageously biodegradable. The adhesive preferably contains one or more biodegradable biopolymers, and preferably contains starch. In an exemplary embodiment, the starch is potato starch.

[0315] The fibers used to manufacture the end plugs can be of any suitable type, and are preferably biodegradable fibers, such as cellulose fibers. Advantageously, the fibers are recycled fibers.

[0316] End caps may include one or more additional substances. For example, these substances may be residues of substances used to facilitate manufacturing, and / or substances added to impart desired properties to the final end cap. End caps may include one or more of the following: at least one colorant, at least one preservative, at least one reinforcing agent, at least one stabilizer, at least one filler, and at least one leavening agent. Preferably, any such additional substance is a natural and / or biodegradable material.

[0317] The material for molded end plugs can include foam structures.

[0318] As an example only, a suitable material for molded end plugs is It can be obtained from the Netherlands-based company. The company (currently located at Hermesweg 22, 3771ND Barneveld, Netherlands) acquired it.

[0319] The biodegradable end caps according to the present invention may conform to any one or more of the following standards (and preferably each standard): EN 13432, ASTM D6868, TÜV Austria OK Industrial Compost, or TÜV Austria OK Home Compost. The end caps may alternatively or additionally be certified as bio-based according to any one or more of the following: USDA certified bio-based product, TÜV Austria OK bio-based (Level 4). The end caps may alternatively or additionally be UL verified as recyclable. The end caps may be UL verified as recyclable with a 99% recyclability of the available fibers.

[0320] End plugs are obtained using a molding process. This process can be an injection molding process, in which the material to be formed into the end plug is injected into a suitably constructed mold.

[0321] The mold may include two components having desired configurations for producing the end plug, one facing the roll and the other facing the dispenser. When closed, the mold may define a mold cavity corresponding to the shape of the end plug to be produced.

[0322] Rapido Waagen-und Maschinenfabrik GmbH's patent application, US5849152A, entitled "Process for the production of shaped bodies from biodegradable material and shaped body," describes examples of materials that can be used to produce end plugs. By way of example only, a suitable material for molding end plugs is... It can be obtained from the Netherlands-based company. The company (currently located at Hermesweg 22, 3771ND Barneveld, Netherlands) acquired it.

[0323] Now refer to Figure 32 and Figure 33 An exemplary method for producing end plugs. Figure 32 This is a flowchart illustrating an exemplary method for manufacturing end plugs, and Figure 33 The step of molding the end plug is illustrated schematically in one exemplary embodiment, corresponding to Figure 32 Steps 2-4.

[0324] In step 1, a slurry comprising fibers, a binder, and a liquid is produced. In an exemplary embodiment, the fibers are cellulose fibers obtained from recycled materials, such as paper. The fibers can be obtained by pulverizing waste paper material. This material can be pulverized in an initial step prior to slurry production. In an exemplary embodiment, the binder is starch, such as potato starch. The liquid is water. Starch can be added to water in powder form to produce the slurry. One or more additives can be added to the mixture to provide the slurry. Additives can be used to impart desired properties to the material of the final end cap. For example, one or more colorants, one or more emulsifiers, one or more preservatives, one or more reinforcing agents, and one or more fillers. In an exemplary embodiment, the additives include leavening agents, such as yeast. This can provide a foam material. The additives are sustainable (e.g., biodegradable).

[0325] In one example, the slurry consists of: 65% starch (e.g., potato or cassava starch), 15%-20% fiber (e.g., cellulose fiber), 10% liquid (e.g., water), and 15%-20% additives, which may include additives of the types described above, and preferably include leavening agents such as yeast. The additives may be derived from... The resulting biodegradable materials are used to make sustainable premixes.

[0326] The components of the slurry are mixed together to bind them. In some exemplary embodiments, the slurry components are mixed by stirring in a tank for a given time, such as 3 minutes. This can help achieve the desired consistency of the slurry introduced into the mold and, in the case of using a starter culture such as yeast, can support the action of the starter culture.

[0327] In step 2, the slurry is introduced into mold 500. Prior to introduction into the mold, the slurry may optionally be transferred from the mixing tank to a storage tank and / or transported to the molding station.

[0328] When introduced into the mold, the slurry is in the form of a thick paste. In a preferred embodiment, the slurry is not dehydrated after its initial formation and before being introduced into the mold.

[0329] By under pressure, for example along Figure 33 The path indicated by the arrow in step 2 injects the slurry into the closed mold, introducing the slurry into the mold. It should be understood that the slurry may be introduced into the mold at more than one location, such as one or more locations, which will introduce the slurry into the mold cavity at a location corresponding to the center and / or periphery of the end plug to be produced.

[0330] The mold comprises two components 502 and 504, each having a desired configuration for producing the end plug, facing the roll and facing the dispenser, respectively. When closed, the mold defines a mold cavity corresponding to the shape of the end plug to be produced. Once slurry is injected into the mold, the mold components can move closer together relative to each other. This may facilitate slurry filling of the mold cavity. When the mold is in its closed configuration and the mold components are at their nearest distance, the dimensions of the cavity defined by the mold will define the wall thickness of the end plug. The mold is a metal mold, such as an aluminum mold.

[0331] In step 3, the slurry is baked in a mold. At least some of the liquid components of the slurry introduced into the mold can evaporate from the mold during the baking step. The liquid can evaporate through openings provided in the mold for this purpose. Heating can bake the slurry in the mold. The step of baking the slurry in the mold can be similar to the waffle baking process. The baking process can cause the binder material to form a matrix, thereby holding the fibers in place and maintaining the resulting end cap in its molded shape. For example, when the binder is starch, the heating step causes the starch material to gel and / or crosslink. The end cap material is heated in the mold until finally dry. In a preferred embodiment, no additional mold is used during the production of the end cap. During baking, the slurry can be heated to any suitable temperature, and in some exemplary embodiments, it is heated to a temperature of approximately 400 degrees Fahrenheit (204 degrees Celsius). The duration of heating can be selected as needed and can depend on factors such as the viscosity of the slurry, the proportion of binder used, the nature of the slurry components, and the shape of the molded end cap to be produced.

[0332] In step 4, the baked end plug 506 is ejected from the mold. The end plug is now complete and ready to be inserted into the end of the roll. This insertion may occur as part of a different process at different locations. Therefore, the end plug can be packaged and shipped for use in the production of refilled roll products. It is understood that... Figure 33 The mold and the end plugs produced by it are shown only schematically, and the dispenser and the construction on the side facing the roll are not shown.

[0333] It has been found that the method of producing end plugs by baking slurry in a mold, as described above, may be advantageous in providing improved clarity in the shape and surface properties of the end plugs.

[0334] Terms and Conditions:

[0335] 1. A molded fiber end plug for mounting a sheet roll to a distributor,

[0336] The end plug has a roll-facing side, the roll-facing side including a configuration that allows it to be inserted into an opening in the end of the sheet roll during use, the roll-facing side including a configuration for securing the end plug to the sheet roll.

[0337] And the opposite dispenser-facing side, which includes a configuration configured to cooperate with the roll retainer portion of the dispenser in use for mounting the end plug to the dispenser.

[0338] 2. The molded fiber end plug as described in Clause 1, wherein at least some of the configurations of the dispenser-facing side of the end plug are provided on the opposite side of the configuration of the roll-facing side of the end plug.

[0339] 3. The molded fiber end plug as described in Clause 1 or Clause 2, wherein the configuration, which enables insertion into the opening in the end of the sheet roll, comprises a plurality of domes on the roll-facing side.

[0340] 4. The molded fiber end plugs as described in Clause 3, wherein two to six and optionally two to four domes are provided.

[0341] 5. A molded fiber end plug as described in Clause 3 or Clause 4, wherein the dome has the same structure.

[0342] 6. The molded fiber end plug as described in any one of Clauses 3 to 5, wherein each dome stands upright from a base on the roll-facing side of the end plug, optionally wherein the end plug includes a flange surrounding the periphery of the end plug, and the base on the roll-facing side of the end plug includes a roll-facing surface of the peripheral flange.

[0343] 7. The molded fiber end plug as described in any one of Clauses 3 to 6, wherein the dome surrounds the central portion of the end plug on the roll-facing side.

[0344] 8. The molded fiber end plug as described in Clause 7, wherein the central portion defines a planar surface facing the roll.

[0345] 9. A molded fiber end plug as described in Clause 7 or Clause 8, wherein the central portion is located at a horizontal plane between the base and the top of the dome on the roll-facing side of the end plug.

[0346] 10. The molded fiber end plug as described in any one of Clauses 7 to 9, wherein each dome extends between the central portion on the roll-facing side and the roll-facing surface of the peripheral flange of the end plug.

[0347] 11. A molded fiber end plug as described in any one of Clauses 7 to 10, wherein the dispenser-facing side of the end plug includes an annular structure defining a central hole for receiving a protrusion defined by a roll retainer portion of the dispenser, wherein the central hole is a closed end hole, wherein the closed end of the hole is provided by a roll-facing surface of a portion of the end plug, and an opposing surface of the portion provides the central portion of the roll-facing side of the end plug.

[0348] 12. The molded fiber end plug as described in Clause 11, wherein the dispenser-facing side of the end plug includes a plurality of reinforcing ribs extending on the dispenser-facing side between the annular structure and the peripheral region of the end plug, optionally wherein each rib extends across a recess in the dispenser-facing side of the end plug, the recess corresponding to the dispenser-facing side of the dome.

[0349] 13. The molded fiber end plug as described in any one of Clauses 3 to 12, wherein each dome includes a base portion and an upper portion, wherein the outer wall of the dome includes a first portion of the base portion of the dome erected from the base on the roll-facing side of the end plug and a second inclined portion of the upper portion of the dome, the second inclined portion being inclined relative to the first portion, optionally wherein the angle between the first portion and the second portion of the outer wall is in the range of 20 degrees to 40 degrees, such as 30 degrees.

[0350] 14. The molded fiber end plug as described in any one of Clauses 3 to 13, wherein the domes are spaced apart from each other by connecting portions, each connecting portion extending between a central portion of the end plug on the roll-facing side and a base of the end plug on the roll-facing side, wherein each connecting portion includes one or more inclined portions; optionally, wherein the connecting portion includes an opening.

[0351] 15. The molded fiber end plug as described in Clause 14, wherein the dispenser-facing side of the end plug includes a plurality of inclined surfaces configured to cooperate with the surface of the ramp structure of the roll retainer portion of the dispenser so that the end plug can be mounted to the roll retainer portion, wherein the inclined surfaces on the dispenser-facing side are provided by the dispenser-facing side of the inclined portion of the connecting portion.

[0352] 16. A molded fiber end plug as described in any of the preceding clauses, wherein the dispenser-facing side of the end plug includes a plurality of reinforcing ribs, and optionally, wherein the configuration of the roll-facing side includes a plurality of domes, and each rib extends across a recess in the dispenser-facing side of the end plug, the recess corresponding to the dispenser-facing side of the dome.

[0353] 17. The molded fiber end plug as described in any one of Clauses 1 to 16, wherein the dispenser-facing side of the end plug further includes one or more inclined surfaces configured to cooperate with the ramp structure of the roll retainer portion, wherein the inclined surfaces are provided by the opposite side of a configuration on the roll-facing side of the end plug.

[0354] 18. The molded fiber end plug as described in any of the preceding clauses, wherein the configuration for securing the end plug to the roll-facing side of the sheet roll includes a configuration configured to provide an interference fit for securing the end plug to the roll.

[0355] 19. The molded fiber end plug as described in Clause 18, which is subordinate to Clause 3, wherein the construction for providing the interference fit includes convex angles, wherein each convex angle projects outward from a corresponding dome among the domes.

[0356] 20. A molded fiber end plug as described in any of the preceding clauses, wherein the end plug is formed of a material comprising a mixture of fibers and an adhesive.

[0357] 21. The molded fiber end plug as described in Clause 20, wherein the adhesive comprises one or more biodegradable biopolymers.

[0358] 22. A molded fiber end plug as described in Clause 20 or Clause 21, wherein the adhesive comprises starch, such as potato starch or tapioca starch.

[0359] 23. The molded fiber end plug as described in any one of Clauses 20 to 22, wherein the adhesive provides a matrix for holding the fibers of the molded fiber end plug in place.

[0360] 24. A molded fiber end plug as described in any of the preceding clauses, wherein the fiber is a cellulose fiber.

[0361] 25. A molded fiber end plug as described in any of the preceding clauses, wherein the end plug comprises 10% to 40% fiber based on the total solids content, and / or wherein the end plug comprises at least 50% adhesive based on the total solids content.

[0362] 26. The molded fiber end plug as described in any of the preceding clauses, wherein the end plug is biodegradable.

[0363] 27. A molded fiber end plug as described in any of the preceding clauses, wherein the end plug is injection molded.

[0364] 28. A roll product comprising: a sheet roll having an opening at its end; and a molded fiber end plug according to any one of Clauses 1 to 27, the molded fiber end plug being fastened to the end of the roll, the end plug being configured to be insertable into the opening at the end of the sheet roll, the roll-facing side of the end plug being inserted into the opening at the end of the roll.

[0365] 29. A dispenser system, the dispenser system comprising;

[0366] The molded fiber end plug according to any one of Clauses 1 to 27 and the dispenser including a roll retainer portion, the roll retainer portion including a configuration configured to cooperate with the dispenser-facing side of the end plug in use for mounting the end plug to the dispenser.

[0367] 30. A dispenser system, the dispenser system comprising;

[0368] A distributor for sheet rolls, the distributor including a roll retainer portion;

[0369] A sheet roll having an opening at its end;

[0370] And a molded fiber end plug according to any one of Clauses 1 to 27, the molded fiber end plug being fastened to the end of the sheet roll;

[0371] The end plug, configured to be able to be inserted into an opening at the end of the sheet roll, is inserted into the opening at the end of the sheet roll.

[0372] Furthermore, the configuration associated with the dispenser-facing side of the end plug cooperates with the configuration of the dispenser's roll retainer position to mount the end plug to the dispenser.

[0373] 31. The dispenser system as described in Clause 30, wherein the dispenser-facing side of the end plug cooperates with the roll retainer portion to rotatably mount the end plug to the roll retainer portion of the dispenser.

[0374] 32. A method of using an end plug according to any one of Clauses 1 to 27, the method comprising using the end plug to mount a sheet roll to a roll retainer portion of a dispenser.

[0375] 33. The method or dispenser system of any one of Clauses 29 to 32, wherein the configuration of the dispenser-facing side of the end plug and the configuration of the roll retainer portion that cooperate with each other comprise a respective set of one or more configurations that are complementary to each other.

[0376] 34. A method of manufacturing a molded fiber end plug according to any one of Clauses 1 to 27, the method comprising providing the molded fiber end plug using a molding process, optionally wherein the molding process is an injection molding process.

[0377] 35. A method for manufacturing a molded fiber end plug according to any one of Clauses 1 to 27, the method comprising:

[0378] Provides slurries containing fibers, adhesives, and liquids;

[0379] The slurry is introduced into the mold;

[0380] And heating the slurry in the mold to provide molded fiber end plugs.

[0381] 36. The method of Clause 35, wherein the adhesive comprises a polymeric adhesive, and the heating step causes the polymeric adhesive material to gel and / or crosslink to provide a matrix for holding the fibers in place.

[0382] 37. The method as described in Clause 35 or Clause 36, wherein the method comprises heating the mixture to a temperature of at least 150 degrees Celsius or at least 180 degrees Celsius.

[0383] 38. The method of any one of Clauses 35 to 37, wherein the step of introducing the slurry into the mold comprises injecting the slurry into the mold.

[0384] 39. The method of any one of Clauses 34 to 38, wherein the mold is a metal mold, such as an aluminum mold.

Claims

1. A molded fiber end plug for mounting a sheet roll to a distributor, The end plug has a roll-facing side, the roll-facing side including a configuration that allows it to be inserted into an opening in the end of the sheet roll during use, the roll-facing side including a configuration for securing the end plug to the sheet roll. And the opposite dispenser-facing side, which includes a configuration that cooperates with the roll retainer portion of the dispenser in use for mounting the end plug to the dispenser. The configuration, wherein the roll-facing side of the sheet roll is configured to be inserted into the opening at the end of the sheet roll, includes a plurality of domes; The domes are spaced apart from each other by connecting portions, each connecting portion extending between a central portion of the end plug on the roll-facing side and a base on the roll-facing side of the end plug, wherein each connecting portion includes one or more inclined portions; wherein the connecting portion includes an opening.

2. The molded fiber end plug of claim 1, wherein at least some of the configurations of the dispenser-facing side of the end plug are provided on the opposite side of the configuration of the roll-facing side of the end plug.

3. The molded fiber end plug as claimed in any of the preceding claims, wherein the configuration for securing the end plug to the roll-facing side of the sheet roll includes a configuration configured to provide an interference fit for securing the end plug to the roll.

4. The molded fiber end plug of claim 3, wherein the construction for providing the interference fit includes a convex angle.

5. The molded fiber end plug of claim 1 or claim 2, wherein the side of the end plug facing the dispenser includes an annular structure defining a central hole for receiving a protrusion defined by a roll retainer portion of the dispenser.

6. The molded fiber end plug as claimed in claim 1 or claim 2, wherein the side of the end plug facing the dispenser includes a plurality of reinforcing ribs.

7. The molded fiber end plug as claimed in claim 1, wherein two to six domes are provided.

8. The molded fiber end plug as claimed in claim 1 or claim 7, wherein the dome has the same structure.

9. The molded fiber end plug of claim 8, wherein each dome stands upright from a base on the roll-facing side of the end plug, wherein the end plug includes a flange surrounding the periphery of the end plug, and the base on the roll-facing side of the end plug includes a roll-facing surface of the peripheral flange.

10. The molded fiber end plug of claim 9, wherein each dome includes a base portion and an upper portion, wherein the outer wall of the dome includes a first portion of the base portion of the dome erected from the base on the roll-facing side of the end plug and a second inclined portion of the upper portion of the dome, the second inclined portion being inclined relative to the first portion, wherein the angle between the first portion and the second inclined portion of the outer wall is in the range of 20 degrees to 40 degrees.

11. The molded fiber end plug of claim 1, wherein the dispenser-facing side of the end plug includes a plurality of inclined surfaces configured to cooperate with the surface of a ramp structure of the roll retainer portion of the dispenser to allow the end plug to be mounted to the roll retainer portion, wherein the inclined surfaces on the dispenser-facing side are provided by the dispenser-facing side of an inclined portion of the connecting portion.

12. The molded fiber end plug as claimed in any one of claims 9 to 11, wherein the dome surrounds the central portion of the end plug on the roll-facing side.

13. The molded fiber end plug of claim 12, wherein the central portion defines a planar surface facing the roll.

14. The molded fiber end plug of claim 13, wherein the central portion is located at a horizontal plane between the base and the top of the dome on the roll-facing side of the end plug.

15. The molded fiber end plug of claim 12, wherein each dome extends between the central portion on the roll-facing side and the roll-facing surface of the peripheral flange of the end plug.

16. The molded fiber end plug of claim 12, wherein the dispenser-facing side of the end plug includes an annular structure defining a central hole for receiving a protrusion defined by a roll retainer portion of the dispenser, wherein the central hole is a closed end hole, wherein the closed end of the hole is provided by a roll-facing surface of a portion of the end plug, and an opposing surface of the portion provides the central portion of the roll-facing side of the end plug.

17. The molded fiber end plug of claim 16, wherein the dispenser-facing side of the end plug includes a plurality of reinforcing ribs extending on the dispenser-facing side between the annular structure and the peripheral region of the end plug, wherein each rib extends across a recess in the dispenser-facing side of the end plug, the recess corresponding to the dispenser-facing side of the dome.

18. The molded fiber end plug of claim 7, wherein the configuration for securing the end plug to the roll-facing side of the sheet roll includes a configuration configured to provide an interference fit for securing the end plug to the roll, wherein the configuration for providing the interference fit includes protrusions, and wherein each protrusion protrudes outward from a corresponding dome among the domes.

19. The molded fiber end plug of claim 18, wherein the convex corner is associated with each dome.

20. The molded fiber end plug of claim 18 or claim 19, wherein each dome includes a base portion and an upper portion, wherein the outer wall of the dome includes a first portion of the base portion of the dome erected from the base on the roll-facing side of the end plug and a second inclined portion of the upper portion of the dome, the second inclined portion being inclined relative to the first portion, wherein the height of the convex angle is at least as large as the height of the base portion of the dome.

21. The molded fiber end plug of claim 1 or claim 2, wherein the dispenser-facing side of the end plug further includes one or more inclined surfaces configured to cooperate with the ramp structure of the roll retainer portion, wherein the inclined surfaces are provided by the opposite side of a configuration on the roll-facing side of the end plug.

22. The molded fiber end plug as claimed in claim 1 or claim 2, wherein the end plug is formed of a material comprising a mixture of fibers and an adhesive.

23. The molded fiber end plug of claim 22, wherein the adhesive comprises one or more biodegradable biopolymers.

24. The molded fiber end plug of claim 22, wherein the adhesive comprises starch.

25. The molded fiber end plug of claim 22, wherein the adhesive provides a matrix for holding the fibers of the molded fiber end plug in place.

26. The molded fiber end plug of claim 22, wherein the fiber is a cellulose fiber.

27. The molded fiber end plug of claim 1 or claim 2, wherein the end plug comprises 10% to 40% fiber based on the total solids content, and / or wherein the end plug comprises at least 50% adhesive based on the total solids content.

28. The molded fiber end plug as claimed in claim 1 or claim 2, wherein the end plug is biodegradable.

29. The molded fiber end plug as claimed in claim 1 or claim 2, wherein the end plug is injection molded.

30. A roll product comprising: A sheet roll having an opening at its end; And a molded fiber end plug according to any one of claims 1 to 29, the molded fiber end plug being fastened to the end of the roll, the end plug being configured to be insertable into an opening in the end of the sheet roll, the roll-facing side of the end plug being inserted into the opening in the end of the roll.

31. A dispenser system, the dispenser system comprising: The molded fiber end plug according to any one of claims 1 to 29 and the dispenser including a roll retainer portion, the roll retainer portion including a configuration configured to cooperate with the dispenser-facing side of the end plug in use for mounting the end plug to the dispenser.

32. A dispenser system, the dispenser system comprising: A distributor for sheet rolls, the distributor including a roll retainer portion; A sheet roll having an opening at its end; And a molded fiber end plug according to any one of claims 1 to 29, the molded fiber end plug being fastened to the end of the sheet roll; The end plug, configured to be able to be inserted into an opening at the end of the sheet roll, is inserted into the opening at the end of the sheet roll. Furthermore, the configuration associated with the dispenser-facing side of the end plug cooperates with the configuration of the roll retainer portion of the dispenser to mount the end plug to the dispenser.

33. The dispenser system of claim 32, wherein the dispenser-facing side of the end plug cooperates with the roll retainer portion to rotatably mount the end plug to the roll retainer portion of the dispenser.

34. The dispenser system of claim 32, wherein the dispenser-facing side of the end plug cooperates with the roll retainer portion to securely mount the end plug to the roll retainer portion, thereby preventing relative rotation between the roll retainer portion of the dispenser and the end plug, wherein the roll retainer portion is rotatable relative to the cooperating portion of the dispenser to allow the roll to rotate relative to at least a portion of the dispenser once the roll is mounted for dispensing sheet, wherein the cooperating portion of the dispenser is an arm of the dispenser, and the roll retainer portion is mounted to the arm of the dispenser via a mounting portion rotatable relative to the arm.

35. The dispenser system of claim 34, wherein the dispenser-facing side of the end plug includes one or more recesses for receiving a corresponding protrusion of one or more protrusions of the roll retainer portion, the edges of the recesses cooperating with the corresponding protrusions of the one or more protrusions of the roll retainer portion to provide a key connection between the roll retainer portion and the end plug.

36. The dispenser system of claim 34 or 35, wherein the roll-facing side of the end plug includes a plurality of domes, and the dispenser-facing side of the end plug includes a plurality of recesses, each recess corresponding to the dispenser-facing side of one of the domes, wherein one of the recesses corresponding to the dome-facing side of the end plug, defined on the dispenser-facing side of the end plug, receives a protrusion of the roll retainer portion to provide a key connection between the end plug and the roll retainer portion; wherein the protrusion of the roll retainer portion is a sensor component.

37. The dispenser system of any one of claims 32 to 35, wherein the configuration of the dispenser-facing side of the end plug and the configuration of the roll retainer portion, which cooperate with each other, comprise a respective set of one or more complementary configurations.

38. A method of using an end plug according to any one of claims 1 to 29, the method comprising using the end plug to mount a sheet roll to a roll retainer portion of a dispenser.

39. A method of manufacturing a molded fiber end plug according to any one of claims 1 to 29, the method comprising providing the molded fiber end plug using a molding process, wherein the molding process is an injection molding process.

40. A method for manufacturing a molded fiber end plug according to any one of claims 1 to 29, the method comprising: Provides slurries containing fibers, adhesives, and liquids; The slurry is introduced into the mold; And heating the slurry in the mold to provide the molded fiber end plugs.

41. The method of claim 40, wherein the adhesive comprises a polymeric adhesive, and the heating step causes the polymeric adhesive to gel and / or crosslink to provide a matrix for holding the fibers in place.

42. The method of claim 40 or claim 41, wherein the method comprises heating the slurry to a temperature of at least 150 degrees Celsius or at least 180 degrees Celsius.

43. The method of claim 40 or claim 41, wherein the step of introducing the slurry into the mold comprises injecting the slurry into the mold.

44. The method of claim 40 or claim 41, wherein the mold is a metal mold.

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