Soap bar dispenser

Abstract

A dispenser for dispensing soap bars provided in a stack is disclosed. The stack may include a plurality of soap bars, including an uppermost bar and a lowermost bar. The stack further includes a leading edge, a trailing edge, and an aperture through the stack adjacent to the trailing edge from the lowermost strip to the uppermost strip. The dispenser comprises: a housing having compartments for receiving a stack and having a dispensing opening through which each strip can be dispensed to a user; a post positioned within the housing, the post sized and arranged to be received within the stack aperture; an engagement element movably mounted relative to the housing to engage the lowermost strip and move the strip to and through the dispensing opening; and a biasing element for biasing the stack toward the bonding element.

Description

Technical Field

[0001] The present disclosure relates to dispensers for soap, particularly for soap in the form of bars, flakes, sheets, etc. The present disclosure also relates to a method of refilling a soap bar dispenser and a soap bar refill. Background Art

[0002] Various types of soap dispensers are known. Liquid soap dispensers are particularly common in public spaces such as restaurants, offices, and travel terminals. An example of such a dispenser is known from WO 2009 / 104992. While such dispensers generally function optimally, they can only be refilled by replacing the entire container. If the next service visit is expected to occur after the container has been emptied, the attendant may choose to replace a partially empty container with a full one. Clearly, attendants cannot accurately predict expected usage in public spaces and tend to err on the side of caution, resulting in wasted unused soap.

[0003] It would be desirable to provide a dispenser for soap that alleviates at least some of the disadvantages of known dispensers. In particular, it would be desirable to provide a soap dispenser that allows refilling even before the dispenser is completely empty. Summary of the Invention

[0004] The invention relates in particular to a dispenser according to the appended claim 1 and to a method of refilling such a dispenser according to claim 18. Embodiments are set forth in the appended dependent claims, the following description and the accompanying drawings.

[0005] Thus, a dispenser for dispensing soap bars provided in a stack is disclosed. The stack may include a plurality of soap bars, including an uppermost bar and a lowermost bar. The stack may also include a leading edge and a trailing edge. The dispenser includes a housing having a compartment for receiving the stack and having a dispensing opening, and a biasing element through which a single bar can be dispensed to a user, the biasing element being configured to bias the stack toward the dispensing opening.

[0006] In contrast to liquid soap, the use of soap bars facilitates refilling the dispenser. Depending on its fill level, additional soap bars can be provided to the dispenser. These additional bars can be inserted into the compartments, which are preferably aligned and hold them for proper dispensing. A full stack of bars can be added on top of the existing topmost bar. Alternatively, maintenance personnel can add only a partial stack to ensure the dispenser is full.

[0007] Besides being easier to refill, soap bars made from solid soap are more concentrated. It's important to understand that liquid soap contains a significant amount of water that must be transported and stored. In fact, liquid soap is typically around 85% water. This high water content also makes it susceptible to bacterial contamination. Furthermore, refill containers must be much larger than equivalent solid soap bar packaging. Furthermore, stacks of soap bars can be packaged in a more environmentally friendly manner than the plastic bottles typically required for liquid soap. This can include paper or card-based packaging, but thin plastic film, which may or may not be made from biodegradable materials, can also be used.

[0008] In certain markets, particularly in outdoor and camping environments, soap bars have gained considerable acceptance. Such soap bars are typically very thin and dissolve completely during hand washing. It will be appreciated that the size of an individual bar can be adapted for the intended purpose, and a bar used for a single hand wash may be smaller than a bar used for a bath or shower.

[0009] The soap bar involved in the present disclosure can be any soap bar or sheet suitable for dispensing from the dispenser involved. Typical bars are based on soap combined with a water-soluble carrier or adhesive, such as water-soluble paper or a water-soluble polymer (such as polyvinyl alcohol). The carrier or adhesive should be able to dissolve quickly in water. Preferably, even in cold water, this dissolution should be completed in 60 seconds or less. Examples of soap sheets with a polymer carrier are available as, for example, Coleman Camp soap sheets. In this context, reference to soap is intended to include all forms of soap, including natural soaps, surfactants, and combinations thereof. Natural soaps are typically prepared by combining a strong alkaline substance (such as sodium hydroxide or potassium hydroxide) with oils and fats (such as lauric acid, palmitic acid, palmitoleic acid, stearic acid, and oleic acid). Surfactants such as synthetic surfactants are typically used in hand soaps, shampoos, and soap formulations. Such surfactants may include anionic surfactants, cationic surfactants, amphoteric surfactants, nonionic surfactants, or combinations thereof.

[0010] Currently available sheets and strips may typically have dimensions of approximately 6 cm x 4 cm and a thickness between 50 and 100 microns. However, the present disclosure is intended to encompass strips of all suitable sizes that may be suitable for use in a dispenser. Such strips may have a thickness of less than 50 microns or up to 500 or even 1000 microns. They may have any suitable shape, although a rectangular shape is preferred.

[0011] Dispensers for soap bars or soap flakes have been proposed, such as that shown in US20210289995. Although this disclosure recognizes the possibility of filling and refilling the dispenser box, it requires maintenance personnel to insert additional sheets through a window of the dispenser box to fill the box. The option of inserting additional sheets from the top of the box is also discussed, but this disclosure fails to provide a convenient way for service personnel to easily refill the box. In addition, the dispenser requires the sheet to include multiple panels that are folded over each other, thereby defining a series of interwoven adjacent sheets. Adding additional sheets requires interwoven connections to ensure that the dispenser continues without interruption.

[0012] In the above and below, references to lowermost, uppermost, upward, and downward are with respect to a dispenser positioned in a stacked, vertical orientation with the lowermost strip and dispensing opening located at or near the bottom of the housing. However, it should be understood that other alternative orientations are possible and that the terminology is not intended to limit the configuration of the dispenser.

[0013] The biasing element may take the form of any suitable device that can apply a force to the stack. In a simple form, the biasing element may comprise one or more springs, including coil springs, leaf springs, extension springs or leaf springs. The biasing element may alternatively be other than a mechanical spring, including an electromechanical actuator, a motor, a gas spring, etc. In one embodiment, the biasing element comprises a pressure plate for engaging the uppermost strip. The pressure plate may have a flat lower surface that roughly corresponds to the dimensions of the stack. More preferably, it has a wavy lower surface that pushes the leading edge of the stack towards the dispensing opening. In one embodiment, the pressure plate may extend to the trailing edge of the stack and may include a hole through which a post or the like may pass, as discussed further below. In this context, the hole may comprise a complete hole or slot, such as an opening towards the rear. For a vertically oriented stack, the biasing element may be used to bias the stack downwardly and may comprise a weight acting under gravity. However, it is not excluded that the stack may have a different orientation.

[0014] In one embodiment, the biasing element can be retracted to refill the dispenser. In this context, the retraction of the biasing element is intended to mean that the biasing element no longer biases the stack downward and creates space above the stack so that another stack or another strip can be inserted. The retraction can be performed manually by the user lifting the biasing element off the stack. A stop can be provided to lock the biasing element in the raised position. Alternatively, this can occur automatically, for example, by an actuator that acts on the biasing element or a portion of the biasing element (such as a pressure plate) to raise it.

[0015] The retracted biasing element may be manually released upon completion of the refill operation, and may involve manually releasing a detent mechanism or otherwise manually actuating the biasing element.

[0016] In one embodiment, the biasing element can be retracted to refill the dispenser and automatically released when the refilling operation is complete. Automatic release can involve releasing a detent mechanism or otherwise actuating the biasing element. This can occur automatically, for example, when the lid is closed to the housing, or can be a suitable switch that can interlock with the lid. Once released, the biasing element can descend, and the pressure plate can engage the uppermost bar.

[0017] In normal use, it is contemplated that the dispenser can be refilled by placing a new stack of soap bars into the compartment. This can preferably be done even before the last, or uppermost, bar is dispensed. Preferably, the compartment is of sufficient height to allow the new stack to be introduced above the existing stack and to allow the biasing element to be sufficiently raised. The compartment can be an enclosed space within the housing, or it can simply be a designated area defined between guides, plates, or vanes into which the stack can be placed for movement, such as, for example, a lift in an elevator car.

[0018] In some embodiments, the compartment can be movable relative to the rest of the housing. In another embodiment, the compartment can be tilted forward from an operating position to a filling position for refilling the dispenser. The compartment can be pivotally mounted within the compartment. This can provide more space for maintenance personnel to insert a new stack. It can also ensure that the biasing element and / or pressure plate do not need to be retracted too far. The compartment can automatically tilt forward, for example, when a refilling operation is initiated or when the lid is opened.

[0019] In one embodiment, the dispenser includes a retaining element positioned within the housing that is sized and arranged to engage a portion of the stack to retain the remaining strips and prevent them from leaving with the lowermost strip. Various forms of retaining elements can be envisioned that act on one or more remaining strips in the stack. The retaining element can include a form-fitting device whereby the stack has a cross-sectional shape that is retained by a corresponding shape of the housing. It will be appreciated that with such a retaining element, insertion of a new stack into a compartment may need to be performed in the vertical or axial direction of the compartment. In this case, sufficient raising of the biasing element and / or pivoting of the compartment away from the biasing element can facilitate such access.

[0020] In one embodiment, the retaining element is a post positioned within the housing, and a new soap bar stack can be placed on the post, where the post can be received within a hole that passes through the stack from the lowest bar to the highest bar. The post ensures that the stack is aligned with the existing stack and the engaging element. Additionally, the post ensures that only the lowest bar is dispensed outward through the dispensing opening. During dispensing, the lowest bar can be removed from the post and moved to the dispensing opening. The immediately adjacent bar is retained by the post and, after the dispensing operation is complete, becomes the next lowest bar.

[0021] Before the lowermost bar can be removed, it should be removed or detached from the post. In a preferred embodiment, this is achieved by tearing a hole at the trailing edge of the bar. The post and hole can be adapted to ensure easy separation. A weakening line can be provided in the bar, or the hole and / or post can be shaped accordingly. In one embodiment, the engaging element is arranged to exert a force on the bar in a direction parallel to the plane of the bar, which force is sufficient to rupture the trailing edge of the bar and remove it from the post. In this document, reference to a hole refers to a closed hole as well as an open hole that communicates with the edge of the soap bar.

[0022] Preferably, the length of the column is greater than the height of a single stack, preferably greater than the height of two stacks. This ensures that maintenance personnel will always be able to insert a new stack onto the column, even if only a few strips have been used. Once the bottom strip or strips of a new stack are inserted onto the column, the biasing element can effectively guide the new stack further down as the strips are dispensed. Regardless of the size of each stack, the column can have a length greater than 4 cm, greater than 6 cm, greater than 10 cm, or even greater than 15 cm, depending on, for example, the height of each stack.

[0023] The bar can be removed from the dispenser in any suitable manner. The user can directly engage the bar by hand and extract it through the dispensing opening. In a preferred embodiment, the dispenser can include an engaging element that is movably mounted relative to the housing and arranged to engage the bar and move it into and through the dispensing opening. This avoids the need for a user with wet hands to touch the soap bar during the dispensing operation.

[0024] Various alternatives can be provided for the engaging element, including the use of suction, adhesives, and electrostatic forces to engage the bar and move it to the dispensing opening. In one embodiment, the engaging element includes a friction surface for frictionally engaging and moving the bar. The precise nature of the friction surface will depend on the soap bar selected. This can be a hard surface, such as a knurled or serrated metal surface that deforms the soap bar to apply lateral force. Alternatively, it can be a soft or elastic material, such as rubber or an elastomer. Thermoplastic elastomers (TPEs) have been found to be particularly convenient because they can be easily applied to the functional component during the injection molding process.

[0025] Those skilled in the art will be aware of various mechanisms that can provide such movement of the strips toward the dispensing opening. These can include translation mechanisms, rack and pinion arrangements, cams, drive belts, actuators, and the like. In one embodiment, the engaging element comprises one or more rollers rotatably mounted relative to the housing. In one embodiment, a single roller can be provided. The roller can have the aforementioned friction surface at its outer circumference. The roller can engage the stack at any position between the leading edge and the aperture. In one embodiment, the roller engages the stack approximately midway between the leading edge and the aperture. The roller can also have a diameter that is appropriate for the size of the strips. In one embodiment, the circumference of the roller is equal to or greater than the length of the strips. The roller can be a right circular cylinder, but can also be a concave or convex cylinder. The curvature of the cylinder can be used to help guide the lowermost strip after it leaves the roller.

[0026] The engaging element can also be arranged to move the strip over a predetermined distance during the dispensing stroke. For an engaging element that moves linearly, the stroke can correspond to the distance moved. For rollers, it should be understood that the rollers simply rotate, while the outer surface rotates a distance representing the stroke. This stroke should be sufficient to move the strip to the dispensing opening. The strip can then continue to move under its own inertia or through gravity. In one embodiment, the stroke can correspond to, for example, at least one-quarter or at least half the length of the strip.

[0027] The operation of the dispenser can be manual or automatic. In one embodiment, the dispenser includes a manual actuator that can be engaged by the user's hand to move the engaging element to dispense the soap bar. Preferably, the actuator includes a button or lever that is pushed by the user for an actuator stroke sufficient to complete the dispensing stroke of the engaging element. A gear transmission can be provided so that the dispensing stroke is different from the actuator stroke. A single actuator stroke can dispense a single bar. Alternatively, multiple actuations may be required to dispense a single bar, or multiple bars can be dispensed in a single actuation stroke. In one embodiment, manual actuation is performed with the heel of the hand. The user is familiar with this action and can apply significant force to the actuator to move it a short distance, thereby producing a larger dispensing stroke.

[0028] Alternatively, the dispenser includes an automatic actuator that is operable to cause movement of the engagement element in response to an actuation signal to dispense one or more bars. The automatic actuator may include a motor or solenoid or other form of actuator to move the engagement element. The actuation signal may be provided by a sensor, a switch, or a button. Those skilled in the art are well-versed in possible sensors that may be used for this purpose, and preferably, the automatic actuation is caused in a manner similar to that of existing liquid soap dispensers.

[0029] The dispensing opening can be located in any suitable position for the user to receive the soap bar in their hand. However, it is most desirable for it to be received in the palm of the hand in response to single-handed operation of a manual or automatic actuator. The bar can be dispensed forward from the dispensing opening in the front side of the housing. In one embodiment, the dispensing opening is located on the underside of the housing below the stack, and the bar is dispensed downward. In this embodiment, the lowermost bar is initially horizontal and can be lowered downward in its horizontal position. Alternatively, the bar can be moved around a curved path that changes the bar's orientation from horizontal to vertical, dispensing the bar vertically downward into the user's hand.

[0030] For manual actuators, the dispensing opening can be placed behind the actuator, which is pushed by the heel of the hand. In this case, the strip can fall onto the fingers. Alternatively, the dispensing opening can be placed in front of the actuator, which is pulled by the fingers. In this case, the strip can fall into the palm of the hand.

[0031] The lid can be opened by sliding or pivoting, etc. Preferably, it is hinged to the open position and can be locked in the closed position by a suitable lock. In the closed position, access to the stack should be prevented except through the dispensing opening to dispense the strips. The movement of the lid between the open and closed positions can also perform other functions. These can include the release or engagement of biasing elements or the movement of the compartments to facilitate refilling. In one embodiment, the lid is preferably pivotally connected to the housing about a transversely extending horizontal axis. The pivot axis is preferably located in the lower section of the housing and can be located below the dispensing opening. This allows the lid to be fully pivoted away from the housing during refilling and maintenance operations. The lid, compartments and actuator can all be mounted to pivot or rotate about mutually parallel transverse axes.

[0032] The present disclosure also provides a method for refilling a soap bar dispenser including a housing having a compartment for receiving a stack of soap bars and a lid that is openable to provide access to the compartment. The method may include: opening the lid to provide access to the compartment; moving a biasing element to a detent position; inserting the stack of soap bars into the compartment; releasing the biasing element from the detent position to bias the stack toward a dispensing opening; and closing the lid.

[0033] The method may be performed by allowing release of the biasing element to occur by closing of the lid. This may be achieved by providing a suitable interlock to ensure that the biasing element is automatically released.

[0034] The method may also be facilitated by tilting the compartment forwardly into the filling position.The compartment may be tilted sufficiently away from the biasing element so that the stack may be inserted axially into the compartment.

[0035] In one embodiment, the compartment comprises a post, and the stack comprises a hole through all of the soap bars in the stack. The method can then include inserting the post into the hole and sliding the stack down over the post. The post or compartment can be long enough so that two stacks can be inserted together.

[0036] Due to the somewhat slippery nature of the soap bars, it is desirable that they remain securely together in the package before and during refilling of the dispenser. Preferably, the package is removed only after the stack of soap bars has been inserted into the compartment. The package may be partially opened before the stack is inserted into the dispenser. Alternatively, it may be opened upon insertion, for example by interacting with a portion of the housing or compartment.

[0037] According to the present invention, a refill for a soap bar dispenser is also provided, comprising a stack of soap bars. The stack may have a height extending from a lowermost bar to an uppermost bar and a length defined between a leading edge and a trailing edge of the stack. If the dispenser includes a retaining element in the form of a post, the stack may include a hole extending through each bar in the stack from the lowermost bar to the uppermost bar. The hole may be located at a distance near the trailing edge such that, when the post is inserted through the hole, the bar can be easily removed from the post by tearing at the hole.

[0038] The refill can include any number of strips, preferably between 200 and 1000 strips or between 300 and 600 strips. The height of the stack can vary accordingly, but it will be appreciated that in order to refill the dispenser, it may be desirable to include as many strips as possible in a single refill. In some embodiments, the stack can be taller than the width. In other words, for a typical strip thickness of 50 to 100 microns, there may be a large number of strips in the stack. In some embodiments, the stack can be taller than 3 cm or taller than 4 cm.

[0039] The refill may include packaging for protecting the soap bars prior to use and for facilitating insertion of the stack into the dispenser. The packaging may be of any suitable material, including (biodegradable) polymer foils and paper and card-based materials. It may take any form, including a sleeve, wrapper, ribbon, box, or envelope. In a preferred embodiment, the packaging completely seals the stack for hygienic purposes.

[0040] In one embodiment, the package has a lower web that at least partially covers the lowermost strip and an upper web that at least partially covers the uppermost strip. For stacks with holes for mating with posts, each web can have a penetration location aligned with the hole, whereby the refill can be placed over the post. The penetration location itself can be a hole or a designated area intended to be ruptured or penetrated by the post. Thus, the refill can be placed over the post with the package still at least partially in place. It will be appreciated that this is important if the individual strips in the stack are to be prevented from becoming misaligned or misplaced during or prior to refilling.

[0041] Once the refill has been placed on the post, the package can be removed. To this end, the package can be provided with a tab that the user can grasp to remove the package. Thus, the package can be removed from the dispenser. The package can also be provided with one or more lines of weakness to facilitate its separation and removal from the stack. These lines of weakness can extend from a penetration point to the rear of the stack, facilitating the tearing of the upper and lower webs from the post. Alternatively, the rear side of the package can have a line of weakness extending in the height direction of the stack. Alternatively, the rear side of the package can be at least partially opened before it is placed in the compartment. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The features and advantages of the present disclosure will be understood by referring to the following drawings of several exemplary embodiments, in which:

[0043] Figure 1 shows a schematic perspective view of a stack of soap bars;

[0044] Figure 2 shows a perspective view of a soap bar dispenser;

[0045] Figure 3 Shown Figure 2 An exploded perspective view of a dispenser;

[0046] Figure 4 Shown Figure 3 A perspective view of a housing of a dispenser;

[0047] Figure 5 Shown Figure 3 A perspective view of a base of the dispenser;

[0048] Figure 6 Shown Figure 3 A perspective view of a compartment of a dispenser;

[0049] Figure 7 Shown Figure 3 A perspective view of a pressure plate of a dispenser;

[0050] Figure 8 Shown Figure 3a perspective view of an actuator of a dispenser;

[0051] Figure 9 Shown Figure 3 An exploded perspective view of a roller of a dispenser;

[0052] Figures 10A to 10C Shown with Figure 8 The actuator and Figure 9 The rollers are assembled together Figure 5 Perspective views of the base from different directions;

[0053] Figure 11A The components of Figure 10 are Figure 6 The front view of the compartments together;

[0054] Figure 11B It is along Figure 11A A section taken along line XI-XI;

[0055] Figure 11C corresponds to Figure 11B a cross section in which the compartments are inclined;

[0056] Figure 12A and 12B yes Figure 3 A perspective view of the compartment and pressure plate;

[0057] Figure 12C is in Figure 12B A front view of the compartment and pressure plate in position together with the base;

[0058] Figure 12D shows a front view of the dispenser with the lid closed;

[0059] 13A to 13F It is along Figure 12D a cross-sectional view taken along the direction XIII-XIII;

[0060] Figure 13G yes Figure 13F an enlarged view of a portion of , showing the roller and the doctor blade;

[0061] Figure 13H yes Figure 13G A schematic front view of a roller and a scraper;

[0062] Figure 14 It is along Figure 12D A cross-sectional view taken along the XIV-XIV direction,

[0063] Figure 15A and 15B The operation of the second embodiment of the dispenser is schematically illustrated;

[0064] Figure 16A second embodiment of the retaining element and the stack is schematically shown;

[0065] Figure 17 A third embodiment of the retaining element and stack is schematically shown;

[0066] Figure 18 A fourth embodiment of the dispenser is shown having a horizontal orientation;

[0067] Figure 19 A fifth embodiment of a dispenser having a pair of rollers is shown;

[0068] Figure 20A and 20B corresponds to Figure 13G and 13H a view of a sixth embodiment of the view of FIG; and

[0069] Figure 21 shows an alternative soap bar and its holes. DETAILED DESCRIPTION

[0070] Figure 1 A perspective view of a stack 1 of soap bars 2 is shown. The stack 1 includes an uppermost bar 2z and a lowermost bar 2a that has been removed from the stack 1. The stack 1 has a leading edge 4 and a trailing edge 6, and includes a hole 8 that passes through the stack 1 from the uppermost bar 2z to the lowermost bar 2a. The hole 8 is shown as circular, but alternative shapes, including a teardrop shape, are preferred. Hereinafter, references to the leading edge 4, trailing edge 6, and hole 8 will apply to the relevant portions of the stack 1 and the individual bars 2. The stack 1 has a height h, a length l, and a width w. Each individual bar also has the same length and width, but is considerably thinner. In the illustrated embodiment, the width w is 4 cm, the length l is 6 cm, and the thickness of each bar 2 is approximately 100 microns. The stack 1 has a height h of 4 cm, and approximately 400 bars are present in the stack 1 before first use.

[0071] As will be described further below, the user has removed the lowermost strip 2a from the stack 1. The hole 8 has been torn open at the tear 9 to the rear edge 6. The stack 1 is shown with a wrapper 7 that holds the strips 2 together before use. The wrapper 7 shown simply surrounds the stack on four sides, but it will be appreciated that alternative or additional wrappers may be provided, such as wrappers that completely enclose the stack before use.

[0072] Figure 2 A dispenser 10 for dispensing bars of soap is shown in perspective. The dispenser 10 comprises a housing 12 having a lid 13 which is closable and secured with a lock 14.

[0073] Figure 3 The exploded view shows Figure 21 , illustrating the various components that form the dispenser 10. Within the housing 12, the dispenser 10 includes a base 20, a compartment 30, a pressure plate 40, an actuator 50, and a roller 60, which are interconnected by additional components described in further detail below, including torsion springs 39A, 39B and a ribbon spring 48. Figure 3 Also shown are directions that will be further used to describe the dispenser 10 and its operation, namely a longitudinal direction X, a transverse direction Y, and a sagittal direction Z.

[0074] Figure 4 The housing 12 and the lid 13 are shown pivotally connected together at a hinge 16. The hinge 16 is located on the housing guard portion 74 and the lid guard portion 75. The hinge 16 is aligned with the transverse direction Y and allows the lid 13 to pivot away from the housing 12 to expose the access opening 11 that provides access to the interior of the housing 12. The housing 12 and the lid 13 close together in the manner of a clam shell, forming an overlapping joint 17 that extends in the XY plane. Figure 2 In the closed position of the lid 13 shown, the lid 13 and the housing 12 are joined together around most of their periphery, thereby preventing access to the interior of the housing 12. Only on the underside is a dispensing opening 15 provided between the lid 13 and the housing 12. Also on the underside, inside the housing 12, there is an attachment point 19 located centrally between guide flanges 72, which extend over the entire height of the housing 12.

[0075] Figure 4 Also shown is a pair of release flanges 18 within the cover 13, the function of which will be explained further below. The housing 12 and cover 13 are shown as being injection molded from ABS plastic material. However, it will be appreciated that other materials (e.g., polycarbonate) and other manufacturing processes may be employed. In particular, the cover 13 may be partially or completely made of a transparent material, thereby allowing viewing of the interior of the housing 12.

[0076] Figure 5 The base 20 is shown in a perspective view. In the illustrated embodiment, the base 20 is formed from a mating left base portion 20A and a right base portion 20B. Those skilled in the art will recognize that the base 20 can also be formed as a single piece. It is also possible to integrate the functionality of the base 20 into the housing 12 and form the two components as a single, unitary element. However, this is generally less preferred for manufacturing and assembly reasons, as will become clear below. The base 20 is also shown as an injection-molded plastic component, but it should be understood that other materials, such as sintered metal, can also be used.

[0077] The elements and functions of the right base portion 20B will be further described, but it should be understood that the left base portion 20A is otherwise identical. Hereinafter, reference to an element of the dispenser with the letter A will generally refer to the left element of the matching pair, while the same reference numeral with a B will refer to the right element. The same reference numeral without a designation (A or B) will generally refer to either or both elements.

[0078] The right base portion 20B includes a hollow right wall 21B extending generally parallel to the XZ plane. The right wall 21B has an inner surface 22B provided with an open slot 23B and a closed slot 24B. Both the open slot 23B and the closed slot 24B extend in an arcuate direction relative to a pivot opening 25B at the lower front corner of the right wall 21B. A stopper 26B is provided at the upper front corner of the right wall 21B. Furthermore, a right pinion mounting member 27B with a bearing opening 28B is provided at the lowermost edge of the right wall 21B.

[0079] Figure 6 The compartment 30 is shown in perspective view. The compartment 30 has left and right guide panels 31A, 31B and a rear panel 32 which together define a housing for receiving the compartment. Figure 1 A generally rectangular space for stacking 1 of cells 1 is formed. A post 34 extends generally vertically upward from a base plate 35 in the longitudinal direction X within the compartment 30 . Behind the post 34 , a guide slot 33 in the rear plate 32 also extends vertically from the base plate 35 in the longitudinal direction X.

[0080] Referring to the left guide plate 31A, there is a pivot pin 36A located at the lower front corner and an outwardly angled guide lug 37A located at the uppermost edge. Furthermore, a lug 38A extends in the transverse direction Y from a position midway between the base plate 35 and the guide lug 37A. The right guide plate 31B is otherwise substantially identical to the left guide plate 31A and will not be described further. The compartment 30 may also be made of injection-molded plastic material, but the guide plates 31A and 31B may alternatively be made of sheet metal. The post 34 in the disclosed embodiment is metal.

[0081] Figure 7 A perspective view of a pressure plate 40 is shown, viewed from the rear quarter. The pressure plate 40 has a body 41 with a slider 42 on the rear side and a handle 43 on the front side. The lower surface of the body 41 is contoured with a downwardly curved nose 44. Resiliently mounted latches 46A, 46B are located on the left and right sides of the body 41, respectively. A cylindrical hole 47 extends through the body 41.

[0082] Also shown is a biasing element in the form of a strip spring 48 attached to the rear of the slider 42. The strip spring 48 is a conventional constant force device of the type found in tape measures and the like. It will be appreciated that other forms of springs and other attachment locations can provide the same functionality, as will be described in further detail below. The pressure plate 40 is shown as being made of an injection-molded plastic material, but it will be appreciated that other materials, including metal, may also be employed.

[0083] Figure 8 Actuator 50 is shown in perspective view. The illustrated actuator 50 is an injection-molded component comprising a push plate 52 integrally formed with a left wing 54A and a right wing 54B extending rearwardly therefrom. Push plate 52 and the left and right wings 54A, 54B also function as a drip shield, as will be described further below. With reference to right wing 54B, an outwardly projecting trunnion pin 55B is located at the uppermost corner. A toothed rack 56B is formed along the lower edge of right wing 54B. Rack 56B curves in an arc centered on trunnion pin 55B. Left wing 54A is otherwise identical. Figure 8 Also shown are respective left and right actuator springs 58A, 58B mounted about trunnion pins 55A, 55B, respectively.

[0084] Figure 9 The roller 60 is shown in an exploded perspective view. The roller 60 shown has a generally cylindrical body 62 formed of injection-molded plastic, having a friction surface 64 of thermoplastic elastomer (TPE) and a left short shaft 65A and a right short shaft 65B extending on both sides in the transverse direction Y. The friction surface 64 has a molded shape with a circumferential groove 68. The left short shaft 65A and the right short shaft 65B carry a left pinion 66A and a right pinion 66B mounted around a left ratchet bearing 67A and a right ratchet bearing 67B. The ratchet bearings 67A and 67B allow the roller 60 to rotate in one direction relative to the pinions 66A and 66B, but not in the opposite direction. Although two ratchet bearings 67A and 67B are shown, it should be understood that the dispenser will operate with only a single ratchet bearing and conventional bearings.

[0085] Will refer to Figures 2 to 9 Based on Figure 10 to Figure 14 The interaction and assembly of the components forming the dispenser 10 is further described.

[0086] Figures 10A-10C The base 20 assembled with the actuator 50 and the roller 60 is shown in perspective views from different angles. Figure 10B The underside of the base 20 is shown so that the interior of the hollow left wall 21A can be seen. The left wing 54A of the actuator 50 is inserted from below into the left wall 21A, whereby the left trunnion pin 55A engages the trunnion mount 29A (see FIG. Figure 11B). It can also be seen that the toothed rack 56B on the right wing 54B engages with the right pinion 66B of the roller 60.

[0087] Figure 10C is a partially cutaway view of the base 20 as viewed from the rear. In this view, the left pinion 66A can be seen within the left pinion mount 27A. The left stub shaft 65A passes through the left bearing opening 28A (not shown), whereby the roller 60 is captured between the left and right pinion mounts 27A, 27B and supported for rotation by the bearing openings 28A, 28B (see FIG. 2 ). Figure 5 ).

[0088] Figures 11A-11C It is shown how the compartment 30 is mounted relative to the base 20 .

[0089] Figure 11A is a front view of the base 20 and compartment 30. It should be understood that the base 20 will be mounted within the housing 12, but this has been omitted for clarity. The left and right base portions 20A, 20B are spaced apart by a distance corresponding to the compartment 30, such that the inner surfaces 22A, 22B of the left and right walls 21A, 21B are adjacent to the left and right guide plates 31A, 31B. The compartment 30 is pivotally coupled to the base 20 via pivot pins 36A, 36B located within corresponding pivot openings 25A, 25B.

[0090] In this view, the open slots 23A, 23B are also visible, in which the guide ears 37A, 37B of the compartment 30 are located. Also visible are the lugs 38A, 38B that extend outwardly from the left and right guide plates 31A, 31B and insert into the corresponding closed slots 24A, 24B.

[0091] Figure 11B is Figure 11A A cross-section in the XZ plane, taken in the direction XIB-XIB, is shown. This shows the interior of the hollow left wall 21A, including the left torsion spring 39A. In this position, the compartment 30 is in its in-use position, with the column 34 essentially vertical. The compartment 30 is fully pivoted clockwise about the pivot pin 36A, with the lug 38A located at the right-hand end of the closed slot 24A. The guide lug 37A is also located at the right-hand end of the open slot 23A. The torsion spring 39A is held between the left base portion 20A and the lug 38A and exerts a force F on the lug 38A toward the left. Also visible in this cross-sectional view is the trunnion mounting 29A, in which the aforementioned trunnion pin 55A is located.

[0092] Figure 11C Shown with Figure 11BThe same cross section shows compartment 30 in the filled position, as will be explained further below. In this position, compartment 30 is rotated counterclockwise about pivot pin 36A. Lug 38A travels around arcuate closed slot 24A until it reaches and abuts the left-hand end. This movement is facilitated by torsion spring 39A acting on lug 38A. In this position, guide lug 37A has rotated out of open slot 23A, and post 34, as well as rear plate 32, have rotated away from side walls 21A, 21B of base 20.

[0093] Figures 12A-12C It shows how the pressure plate 40 is arranged relative to the compartment 30 and the base 20 .

[0094] exist Figure 12A In the figure, the pressure plate 40 is in a use position, in which it is centered relative to the compartment 30. The slider 42 engages within the guide slot 33, and the body 41 of the pressure plate 40 is positioned between the left guide plate 31A and the right guide plate 31B. It can be seen that the post 34 extends through the cylindrical hole 47. The pressure plate 40 is biased downward by a strip spring 48, which is attached to the attachment point 19 of the housing 12. For clarity, the remainder of the housing 12 has been omitted.

[0095] Figure 12B Shown Figure 12A 30 , wherein the pressure plate 40 is raised to the refill position. The user can engage the handle 43 at the front side of the pressure plate 40 and lift the pressure plate 40 upward relative to the compartment 30. The slider 42 slides in the guide slot 33 against the force of the deployed strip spring 48. The upward movement can continue until the slider 42 leaves the guide slot 33 and the body 41 leaves the compartment 30. Although not shown in this view, the slider 42 is also partially guided within the housing 12 by the guide flange 72, as shown in FIG. Figure 4 shown.

[0096] Figure 12C A front view of the compartment 30 within the base 20 is shown, corresponding to Figure 11A , but including Figure 12B 3. As can be seen in this view, once the pressure plate 40 is lifted out of the compartment 30, it is no longer guided by the guide slots 33, the left and right guide plates 31A, 31B, or the posts 34. However, it is still guided by the guide flanges 72 (not shown) of the housing 12 and is constrained by the inner surfaces 22A, 22B of the left and right walls 21A, 21B of the base 20. At this point, the resiliently mounted latches 46A, 46B on the body 41 of the pressure plate 40 engage the left and right stops 26A, 26B of the base 20. The pressure plate 40 is thus held in this refill position against the force of the strip spring 48.

[0097] Figure 12DThe dispenser 10 is shown in a front view with the lid 13 closed, ready for use.

[0098] Now refer to Figures 13A to 13F and 14 depict the operation of the dispenser 10 to dispense soap bars 2 from the stack 1 .

[0099] exist Figure 13A In the middle, along Figure 12D The cross-section along line XIII-XIII shows a partially filled soap dispenser 10. Lid 13 is closed, and stack 1 is present in compartment 30 beneath platen 40. Stack 1 rests on rollers 60, with posts 34 extending through holes 8. The soap bars 2 are generally flexible, and the downwardly curved nose 44 of the contoured lower surface of platen 40 causes the leading edge 4 of stack 1 to bend downward. Strip springs 48 maintain constant pressure on stack 1. The lowermost bar 2a is unsupported at its leading edge 4 and overhangs rollers 60.

[0100] Figure 13A Also shown is how the housing guard portion 74, the lid guard portion 75, the push plate 52, and the wings 54 together form a generally tubular shroud 76 surrounding the dispensing opening 15. The shroud 76 extends approximately 4 cm downwardly below the roller 60 and helps prevent water from splashing into the dispensing opening 15 and wetting the soap bar 2 or the friction surface 64 of the roller 60. The shroud 76 also obscures the roller 60 from view and prevents a user from inserting their fingers into the dispensing opening 15 to remove the soap bar 2.

[0101] exist Figure 13B In the embodiment of the present invention, the user operates dispenser 10 by applying pressure P on push plate 52 to dispense soap bar 2a. Pressure P causes actuator 50 to rotate counterclockwise about trunnion pin 55, thereby rotating rack 56, which is engaged with pinion 66, counterclockwise. Pinion 66 drives roller 60 to rotate R. Friction surface 64 of roller 60 engages the lowermost bar 2a and extracts it from post 34 by tearing trailing edge 6 at slit 9.

[0102] exist Figure 13C In the process, the movement of the push plate 52 is completed, and the rotation R of the roller 60 causes the lowermost strip 2a to move through the dispensing opening 15. At this time, the roller 60 contacts the penultimate strip 2b, while the lowermost strip 2a remains temporarily engaged with the friction surface 64.

[0103] exist Figure 13D, the user has released the pressure on the push plate 52. The dispenser 10 and the push plate 52 are designed to be operated by the heel of the user's hand H. It should be understood that other ways of moving the push plate 52 will result in the same movement, but operation with the heel of the hand H will allow the fingers and palm to be positioned below the dispensing opening 15. After releasing the push plate 52, the hand H can remain below the dispensing opening 15, allowing the lowermost strip 2a to fall onto the palm of the hand H. The actuator 50 now rotates in a clockwise direction under the bias of the left and right actuator springs 58A, 58B. The operation of the ratchet bearings 67A, 67B ensures that the roller 60 does not rotate when the rack 56 rotates the pinion 66 in a clockwise direction.

[0104] When a user or maintenance personnel wishes to maintain the dispenser 10 , the cover 13 can be opened by releasing the lock 14 . Figure 13E Shown as 13A to 13D , wherein the cover 13 is open. If it is determined that additional soap bars should be added to the compartment 30, the platen 40 can be manually raised by lifting the platen 40 with the handle 43 against the action of the strip spring 48. Figure 13F 12C , whereby the latches 46A, 46B on the pressure plate 40 engage the left and right stops 26A, 26B of the base 20 .

[0105] Once the pressure plate 40 is lifted away from the compartment 30 and the column 34, the compartment 30 can be tilted forward to the position indicated by the torsion springs 39A, 39B. Figure 13F The illustrated position. In this position, access to the compartment is not blocked by the pressure plate 40 or the housing 12. A new stack 1 can be placed on the post 34, with the left and right guide ears 37A, 37B helping to guide the stack 1 into the space between the left and right guide plates 31A, 31B. It will be appreciated that a new stack 1 can be introduced even if there are still bars of soap remaining in the compartment. In the illustrated embodiment, the height of the compartment 30 is 18 cm, and three complete stacks 1 can be inserted.

[0106] As in Figure 13F As can be seen in FIG, a new stack 1 is inserted into the compartment 30 while the package 7 is still intact and around the stack to ensure that the strips 2 remain together and aligned. Once the new stack 1 is within the compartment 30 and retained by the posts 34, the package 7 can be removed. A tear strip, line of weakness or perforation may be provided to ensure that the package 7 opens at the desired location.

[0107] When refilling is complete, the lid 13 is closed. Closing of the lid serves to push the compartment 30 vertically back into the housing 12, against the force of the torsion springs 39A, 39B, to its initial position between the left and right base parts 20A, 20B. Figure 14 is Figure 12D 1-14. A plan view of a section taken in the direction XIV-XIV of the housing 12 and the cover 13 is shown. In this view, the operation of the release flange 18 can be seen. When the cover 13 is closed, the release flange 18 extends inwardly between the side walls 21A, 21B of the left and right base parts 20A, 20B and on both sides of the pressure plate 40. In doing so, they engage and bend the latches 46A, 46B inwardly. The latches 46A, 46B disengage from the left and right stops 26A, 26B of the base 20, and the pressure plate 40 is free to move downward under the force of the strip spring 48. It can also be seen in this view that the slider 42 is guided toward the guide slot 33 by the guide flange 72 of the housing.

[0108] Figure 13G Shown from Figure 13F An enlarged cross-sectional view of the lower region of the housing 12 is shown. It shows an additional protective element of the housing 12 in the form of a scraper 77 extending below the roller 60. The roller 60 and the scraper 77 are Figure 13H 60. The scraper 77 has a profiled edge 78 including ridges 79 that align with the grooves 68 in the roller 60. The scraper 77 not only protects the underside of the roller 60 from dripping and contact by the user, but also ensures that soap bars or soap residue do not remain on the roller 60. As the roller 60 rotates during use, its friction surface 64 moves past the scraper 77, whereby any soap residue that is stuck or otherwise attached to the roller 60 can be released by the ridges 79. In this embodiment, the profiled edge 78 itself is spaced apart from the friction surface 64, but those skilled in the art will appreciate that it can engage the roller 60 more closely to actually scrape the friction surface 64 if desired. It should also be appreciated that more or fewer ridges 79 or other forms of protrusions can be provided at any location along the profiled edge 78.

[0109] Those skilled in the art will understand that Figures 1 to 14 The embodiments shown and described above are merely exemplary and many variations are possible. Figure 15A and 15B A second embodiment of a dispenser 110 is shown having a housing 112 and a cover 113. In this embodiment, the cover 113 is pivotally connected to the housing 112 for rotation about a pivot 116 at the upper side of the cover 113. In this embodiment, the cover 113 also serves as an actuator and carries a toothed rack (not shown) that engages with the roller 160 as in the first embodiment. A spring (not shown) within the housing 112 biases the cover 113 to Figure 15A Position shown.

[0110] Operation of the dispenser 110 occurs by applying a force P to the lower portion 152 of the cover 113. This causes the cover 112 to rotate in a counterclockwise direction about the pivot 116, as shown in FIG. Figure 15BAs the lid 112 rotates, the movement is transmitted to the roller 160, which rotates in a counterclockwise direction R to dispense the soap bar 2 through the dispensing opening 115. When the force P on the lid 113 is released, the lid 113 returns to its initial position. Many other alternative actuator mechanisms can be provided, including actuator levers for two-handed or elbow operation. In addition, automated operation can be provided, such as using a proximity sensor in combination with a motor to separate the bar from the stack and dispense the bar through the dispensing opening.

[0111] Furthermore, while posts have been shown for retaining the soap bars within the stack, a variety of different retaining elements are contemplated that will also accomplish the same function of retaining the stack in place while dispensing a single soap bar. Such retaining elements may be positioned within the housing and sized and arranged to engage a portion of the stack to retain the remaining bars and prevent them from dislodging with the lowermost bar.

[0112] exist Figure 16 , a second embodiment is disclosed in which a pair of posts 134A, 134B are provided within the compartment 130. The stack 101 and each soap bar 102 are provided with a pair of holes 108A, 108B that fit over the posts 134A, 134B. The operation may otherwise be the same, but it will be appreciated that the soap bar 102 must be torn at two locations, rather than a single location as is the case with the first embodiment.

[0113] exist Figure 17 , a third embodiment is disclosed in which the compartment 230 has a pair of retaining elements 234A, 234B that engage within the slots 208A, 208B at either side of the stack 201. The retaining elements 234A, 234B may have any suitable shape and may be angled to better retain the stack 201. In this case, removal of the soap bar 202 may be without tearing or with limited tearing.

[0114] exist Figure 18 , a fourth embodiment of a dispenser 310 is schematically disclosed in which compartments 330 are arranged with horizontally oriented posts 334. A stack 301 of soap bars 302 is suspended downwardly from the posts 334. The next soap bar 302a to be dispensed is removed from the stack 301 by an engaging element 360, which moves toward the stack 301 and downwardly to tear the next soap bar 302a from the posts 334. Those skilled in the art will recognize that there are any number of possible engaging elements 360 that can be used to engage the bars 302a to exert force thereon. These may include the use of suction, friction, adhesion, electrostatic, or mechanical engagement.

[0115] Figure 19A fifth embodiment of a dispenser 410 is schematically shown, having a pair of rollers 60A, 60B disposed within a housing 412. A stack 401 is supported on two posts 434A, 434B located at opposite ends of the housing 412. A pressure plate 440 is urged downward by a biasing spring 448 to bias the stack 401 downward toward a dispensing opening 415 centrally located between the rollers 60A, 60B. The rollers 60A, 60B are provided with an actuator (not shown) that rotates them in opposite directions to dispense the lowermost soap bar 402a from the stack 401. In doing so, the lowermost bar 402a is torn from both posts 434A, 434B. In this embodiment, it should be understood that the stack and bars do not have leading and trailing edges in the sense of the first embodiment, as the bars are withdrawn and dispensed in a state where the center portion of the bar is dispensed first. However, to the extent relevant, the center fold of the bar 402a can be considered a leading edge relative to the user.

[0116] Figure 20 corresponds to Figure 13G The figure shows a schematic side view of a portion of a sixth embodiment of a dispenser. An alternative scraper 577 is provided that extends further around roller 560 to also cover a portion of the front side of roller 560, providing additional splash protection. In this embodiment, grooves 568 are provided at the left and right edges of roller 560. In addition, contoured edges 578 and ridges 579 have chamfered surfaces facing roller 560.

[0117] In Figure 21 an alternative soap bar is shown having holes of a different form. Figure 21A In the embodiment, the soap bar 2' has a closed teardrop-shaped hole 8'. Figure 21B In the soap bar 2″ there is a closed circular hole 8″ with a weakening line 9″ extending to the trailing edge 6″. Figure 21C In the embodiment shown, the soap bar 2'" has an open hole 8'" joined to the rear edge 6'" by a cutout 9'". Those skilled in the art will appreciate that many other alternative shapes are possible.

[0118] It will be appreciated that many modifications other than those described above may be made to the structures and techniques described herein without departing from the scope of the invention. Thus, although specific embodiments have been described, these are merely examples and are not intended to limit the scope of the invention.

Claims

1. A dispenser for dispensing soap bars provided in a stack, the stack having an uppermost bar and a lowermost bar, the dispenser comprising: a housing having compartments for receiving the stack, an access opening providing access to the compartments, and a dispensing opening through which the lowermost strip can be dispensed to a user; a cover that cooperates with the housing to close the access opening and is capable of being opened to provide access to the compartment; as well as A biasing element is provided for biasing the stack toward the dispensing opening.

2. The dispenser according to claim 1, wherein The biasing element is retractable for refilling of the dispenser and is latched in the retracted position.

3. The dispenser according to claim 2, wherein The biasing element is capable of automatically releasing when the refilling operation is complete.

4. The dispenser according to claim 3, wherein The biasing element is automatically releasable by movement of the cover to close the access opening.

5. A dispenser according to any one of the preceding claims, wherein The biasing element includes a pressure plate for engaging the uppermost strip.

6. A dispenser according to any one of the preceding claims, wherein The compartment is tiltable forwardly from an operative position to a fill position for refilling the dispenser.

7. The dispenser of any one of the preceding claims, further comprising a retaining element positioned within the housing, the retaining element being sized and arranged to engage a portion of the stack to retain remaining strips and prevent them from exiting with the lowermost strip.

8. The dispenser according to claim 7, wherein The retaining element includes a post receivable within a hole through the stack from the lowermost bar to the uppermost bar.

9. The dispenser according to claim 8, wherein The stack and corresponding soap bar have a leading edge and a trailing edge, and the aperture is located adjacent the trailing edge.

10. The dispenser of any preceding claim, further comprising an engagement element movably mounted relative to the housing to engage a lowermost strip and move the strip to and through the dispensing opening.

11. The dispenser according to claim 10, wherein The engagement element includes a friction surface for frictionally engaging and moving the strip.

12. A dispenser according to claim 10 or claim 11, wherein The engagement element comprises a roller rotatably mounted relative to the housing.

13. The dispenser according to any one of claims 10 to 12, wherein: The engagement element is arranged to move the strip over a dispensing stroke, which preferably corresponds to at least 25% of the length of the strip.

14. The dispenser of any preceding claim, further comprising a manual actuator engageable by a user's hand to cause dispensing of the soap bar.

15. The dispenser of any one of claims 1-13, further comprising an automatic actuator operable to dispense one or more strips in response to an actuation signal.

16. A dispenser according to any one of the preceding claims, wherein The dispensing opening is located on the underside of the housing below the stack.

17. A dispenser according to any one of the preceding claims, wherein The cover is pivotably connected to the housing, preferably about a laterally extending horizontal axis located below the dispensing opening.

18. A method of refilling a soap bar dispenser comprising a housing having a compartment for receiving a stack of soap bars and a lid that can be opened to provide access to the compartment, the method comprising: opening the lid to provide access to the compartment; moving the biasing element to a stop position; inserting a stack of soap bars into the compartment; releasing the biasing element from the detent position to bias the stack toward a dispensing opening; as well as Close the cover.

19. The method according to claim 18, wherein Release of the biasing element occurs by closing the cover.

20. The method of claim 18 or claim 19, further comprising tilting the compartment forwardly to a filling position.

21. The method according to any one of claims 18 to 20, wherein The compartment comprises a post, and the stack comprises a hole through all of the soap bars in the stack, and the method comprises inserting the post into the hole.

22. The method according to any one of claims 18 to 21, wherein: The stack is enclosed in a package, and the package is removed after the stack of soap bars is inserted into the compartment.

23. A soap bar refill comprising a plurality of soap bars provided in a stack for use with the dispenser of any one of claims 1-17 or the method of claims 18-2.

24. The soap bar refill of claim 23, comprising a removable wrapper surrounding the stack.

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