A roll dispenser for supporting a roll of packaging material

Abstract

The roll dispenser is positioned to support a roll of packaging material and includes a chuck assembly including a first chuck unit having a first plug housed in a first axial end of the roll core, a first shaft secured to the first plug, a first mount engaging the first shaft, and a first brake connected to the first plug and the first mount to establish friction between the first plug and the first mount. A first handle assembly adjusts the axial compressive force applied between the first mount and the first shaft to adjust the friction between the first plug and the first mount. The chuck assembly may also include a second chuck unit housed in a second axial end of the core to provide additional support for the roll of packaging material.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to a system for converting roll stock packaging, such as paper-based roll stock or other materials, into protective packaging, and more particularly to a roll dispenser for supporting a roll of packaging material. [Background technology]

[0002] Protective packaging, or dunnage, is produced by crumpling or deforming a material. For example, dunnage can be produced by passing a generally continuous piece of material through a dunnage conversion machine, which converts the material into a less dense dunnage material. The resulting dunnage can be cut to a desired length to effectively fill voids within a container containing a product. The dunnage material can be manufactured as needed for the individual or machine performing the packaging operation. Summary of the Invention

[0003] Roll materials used in the manufacture of protective packaging include plastic- and paper-based roll materials, including heavy-duty commercial and industrial bubble rolls, void-fill paper packaging, surface protection papers, grocery and food service papers, and printing / laminating films.

[0004] Paper-based dunnage has various advantages when employed as dunnage material. In one aspect, paper-based dunnage can provide protection to prevent damage from shock and vibration. In another aspect, paper has a high biodegradability rate compared to other types of packaging materials, such as plastic. In a further aspect, paper is very easy to recycle. In a further aspect, paper is a sustainable material because it is composed of naturally occurring forest products.

[0005] Expandable paper (or "stretchable paper") is an example of a paper-based dunnage material. The base paper material is slit. As the base paper is drawn from the dispenser, tension is applied to the paper, causing the slits to open and form a lattice structure. This lattice structure can provide protective cushioning or interleaving for fragile products. Additionally, the expandable paper's lattice structure can overlap itself, reducing or eliminating the need for tape or other adhesives to hold the expandable paper in place.

[0006] However, it will be appreciated that achieving such expandable paper depends, at least in part, on the ability of the dispenser to apply tension to the dispensed paper substantially uniformly and at the appropriate target level. In one aspect, if tension is not applied substantially uniformly, with certain areas having significantly higher or lower tension than other areas, the resulting lattice structure may be non-uniform. In one aspect, applying tension significantly lower than the target level may result in a partially formed lattice structure or no formation at all. In another aspect, applying tension significantly higher than the target may damage (e.g., tear) the dispensed paper. In either case, the dispensed paper lattice may be incomplete and / or damaged, compromising its protective cushioning or interleaving function.

[0007] Therefore, there is a need for a dispenser that can apply a substantially uniform tension to an expandable / stretchable material, such as paper, while dispensing the material.

[0008] The roll dispenser may include a chuck assembly and a base. The chuck assembly preferably includes a first chuck unit and a base for accommodating the first chuck unit. The first chuck unit includes a compression train having a first side and a second side. The first side of the compression train includes at least an anti-rotation element. The second side of the compression train may include at least a first plug configured to engage a core of the roll of material. A first brake is operably associated with the first plug and the anti-rotation element to establish friction therebetween that resists rotation of the first plug relative to the anti-rotation element as the packaging material is drawn from the roll. The first handle assembly may be configured to adjust the compression force applied between the first side and the second side of the compression train. The base is configured to support the chuck assembly on the anti-rotation element. When the chuck assembly is supported by the base, the second side of the compression train is configured to rotate about the axis of rotation, and the first side of the compression train is restrained from rotating about the axis of rotation by the anti-rotation element and the base. This arrangement of the chuck assembly and base allows for the application of a substantially uniform tension to the open expandable paper, preferably provided within the roll of material. In particular, the expandable paper (also known as stretchable paper) typically has a plurality of slits formed therein that can be opened under tension, and the compression force may be adjusted by the first handle assembly.

[0009] According to the present disclosure, a roll dispenser for supporting a roll of packaging material includes a base and a chuck assembly including a first chuck unit, the first chuck unit including a first mount attached to the base such that the base limits rotation of the first mount, a first plug configured to be inserted into a first axial end of a core of the roll of packaging material and locked to rotate with the core, and a first brake operably associated with the first plug and the first mount to establish friction therebetween that resists rotation of the first plug relative to the first mount as the packaging material is drawn from the roll.

[0010] The roll dispenser may further include a first handle assembly connected to the first plug and configured to adjust a first compressive force applied axially to adjust friction between the first mount and the first plug.

[0011] The first plug may include a distal portion for insertion into a first axial end of a core of the roll of wrapping material and a proximal portion defining a first shaft.

[0012] The roll dispenser may further include a pressure cap disposed between the first mount and the first handle assembly, the pressure cap defining a cavity sized to accommodate at least a portion of the first shaft. A spring may be disposed around an outer periphery of the first shaft and between an end of the first mount and an end of the pressure cap opposite the first handle assembly.

[0013] The first plug and the first shaft may be configured to rotate together about an axis of rotation. The first handle assembly may be operably connected to the first shaft. The first handle assembly may be configured to be rotated manually by an operator or automatically by a machine.

[0014] The first plug may be configured to rotate about the axial axis of rotation, and the first mount may be configured to restrain rotation about the axis of rotation.

[0015] The roll of packaging material can include a roll of expandable paper including a plurality of slits, and the first brake can be configured to adjust friction between the first mount and the first plug sufficient to open one or more slits in the expandable paper without tearing the expandable paper.

[0016] The first mount may include a non-circular outer surface configured to contact the base to prevent axial rotation.

[0017] The chuck assembly may further include a second chuck unit. The second chuck unit may include a second plug configured to be received in a second axial end of the core of the roll of packaging material, a second shaft operably connected to the second plug, and a second mount configured to be connected to the second shaft. The second chuck unit may further include a second handle assembly configured to adjust a second compressive force applied axially between the second mount and the second shaft.

[0018] According to the present disclosure, a base of a roll dispenser configured to support a roll of packaging material includes a base support extending in a longitudinal direction and a pair of supports extending laterally from the base support, each of the supports defining a first end and a second end, the first end of each of the pair of supports being attached to a first surface of the base support, and at least one slot being formed adjacent to the second end of each of the pair of supports, the at least one slot of the first support of the pair of supports being configured to receive a first mount of a first chuck unit, and the at least one slot of the second support of the pair of supports being configured to receive a second mount of a second chuck unit, thereby supporting a chuck assembly.

[0019] The base support may be configured to be mounted to a vertical wall so as to be substantially flush with the vertical wall, or to be mounted to a horizontal surface. The at least one slot may include a stepped entrance area for receiving the first mount or the second mount and a recessed area for holding the first mount or the second mount by gravity. The at least one slot may include a first slot and a second slot, wherein the first slot extends from the second end of each of the pair of supports, and the second slot extends from a side surface of each of the pair of supports, the side surface being located between the first end and the second end of the pair of supports.

[0020] According to the present disclosure, a system for dispensing packaging material from a roll disposed on a roll dispenser includes a base and a chuck assembly including a first chuck unit, the first chuck unit including a first plug configured to be inserted into a first axial end of a core of the roll of packaging material and locked to rotate with the core, a first brake configured to brake rotation of the first plug and the core when the packaging material is drawn from the roll, and the roll of packaging material supported by the base with the first plug inserted into the core.

[0021] The system may further include a first mount attached to the base such that the base limits rotation of the first mount.

[0022] The roll of packaging material may include a roll of expandable paper including a plurality of slits, and the first brake may be configured to adjust friction between the first mount and the first plug sufficient to open one or more slits in the expandable paper without tearing the expandable paper.

[0023] The chuck assembly may further include a second chuck unit, the second chuck unit including a second plug configured to be received in a second axial end of the core of the roll of packaging material, a second shaft operably connected to the second plug, and a second mount configured to be connected to the second shaft. [Brief explanation of the drawings]

[0024] [Figure 1] 1 is a perspective view of a first embodiment of a roll dispenser including a base and a chuck assembly having a first chuck unit and a second chuck unit. FIG. [Figure 2] FIG. 2 is an exploded perspective view of the roll dispenser of FIG. 1. [Figure 3]FIG. 3 is an exploded view of the first chuck unit of the chuck assembly of FIG. 2. [Figure 4] FIG. 3 is a cross-sectional view of a first chuck unit of the chuck assembly of FIG. 2. [Figure 5] FIG. 3 is an exploded view of the second chuck unit of the chuck assembly of FIG. 2. [Figure 6] FIG. 3 is a cross-sectional view of a second chuck unit of the chuck assembly of FIG. 2. [Figure 7] FIG. 3 is a perspective view of the base of the roll dispenser of FIGS. 1 and 2. [Figure 8] 3 is a view of the roll dispenser of FIGS. 1 and 2 as viewed from a first direction. FIG. [Figure 9] 3 is a view of the roll dispenser of FIGS. 1 and 2 as viewed from a second direction. FIG. [Figure 10] FIG. 10 is an exploded perspective view of a second embodiment of a roll dispenser including a base and a single chuck unit including multiple plugs. [Figure 11] FIG. 11 is an exploded view of the chuck assembly of the roll dispenser of FIG. 10. [Figure 12] FIG. 11 is a perspective view of the base of the roll dispenser of FIG. 10. [Figure 13] FIG. 10 is a diagram of a third embodiment of a roll dispenser including a base, a chuck assembly secured to the base in a cantilever configuration, and a roll of material attached to the base. [Figure 14] FIG. 14 is an exploded view of the chuck assembly of FIG. 13. [Figure 15] 14 is an alternative embodiment of a chuck assembly for the roll dispenser of FIG. 13. DETAILED DESCRIPTION OF THE INVENTION

[0025] In the following description, conventional features of the disclosed technology that would be apparent to one skilled in the art are omitted or only briefly described. Reference to various embodiments does not limit the scope of the claims appended hereto. In addition, any examples described herein are intended to be non-limiting and merely set forth some of the many possible embodiments for the appended claims. Furthermore, specific features described herein can be used in combination with other described features, in each of a variety of possible combinations and permutations. Those skilled in the art will recognize, using routine experimentation in combination with other methods of achieving results not specifically disclosed in the examples or embodiments.

[0026] Unless otherwise defined herein, all terms are to be interpreted in the broadest possible sense, including the meaning implied by the specification, the meaning understood by those skilled in the art, and / or the meaning defined in dictionaries, specialized texts, etc. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art of the disclosed technology. It should also be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural references unless otherwise specified, and that, as used herein, the terms "includes" and / or "including" identify the presence of stated features, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Furthermore, methods, apparatuses, and materials similar or equivalent to those described herein can also be used in the practice or testing of the disclosed technology.

[0027] Throughout this disclosure, various examples of the disclosed technology are provided. The use of these examples is illustrative only and in no way limits the scope and meaning of the invention or the exemplified forms. Likewise, the invention is not limited to the specific preferred embodiments described herein. Indeed, modifications and variations of the invention will be apparent to those skilled in the art upon reading this specification and can be made without departing from its spirit and scope. Therefore, the present invention is limited only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0028] As used herein, certain relationships between suppressor features are described using the terms "substantially" or "substantially equal." As used herein, the terms "substantially" and "substantially equal" indicate that the equal relationship is not an exact relationship and does not exclude functionally similar variations. Unless the context or description indicates otherwise, when the terms "substantially" or "substantially equal" are used in connection with two or more listed dimensions, the equal relationship between the dimensions includes variations that do not change the least significant digit of the dimensions using mathematical and engineering principles recognized in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.). As used herein, the term "substantially parallel" indicates that the parallel relationship is not an exact relationship and does not exclude functionally similar variations. As used herein, the term "substantially orthogonal" indicates that the orthogonal relationship is not an exact relationship and does not exclude functionally similar variations.

[0029] A system for converting high-density material into low-density dunnage is disclosed. The material is processed by a dispenser configured to apply tension substantially uniformly across the width of the material dispensed from the dispenser. The material is stored in roll form, and the material may be continuous or perforated. If the material is an intumescent material, the applied tension causes slits to open and form a lattice structure. Dunnage containing this lattice structure can provide protective cushioning or interleaving for fragile products. In a further embodiment of the dispenser, the amount of tension applied can be easily adjusted to form a substantially complete lattice structure without damaging the dispensed dunnage.

[0030] Dispenser embodiments of the present disclosure are described herein with reference to paper stock. However, it will be understood that the disclosed embodiments can be employed with any suitable type of material. Examples can include, but are not limited to, pulp-based virgin and recycled paper, newsprint, cellulose and starch compositions, and poly or synthetic materials (e.g., thermoplastic materials such as webs of plastic material). Further examples of paper materials can have a basis weight of about 20 pounds to about 100 pounds. The material can also have any other suitable characteristics, such as thickness, weight, dimensions, etc.

[0031] FIG. 1 is a perspective view illustrating a roll dispenser 10 according to a first embodiment of the present disclosure and a chuck assembly 12 including a first chuck unit 20 and a second chuck unit 80, and FIG. 2 is an exploded perspective view of the roll dispenser 10 of FIG. 1. Referring to FIGS. 1 and 2, the first chuck unit 20 is configured to apply a substantially uniform axial tension force and an axial compression force to a roll of material 2 disposed on the roll dispenser 10.

[0032] 1 and 2, the roll dispenser 10 includes a base 30 and a first chuck unit 20 and a second chuck unit 80 configured to be attached to the base 30. According to a first embodiment, the chuck assembly 12 includes the first chuck unit 20 and the second chuck unit 80. In other embodiments, the first chuck unit 20 and the second chuck unit 80 may be replaced by a single chuck unit, as described herein.

[0033] Referring to FIG. 3 , the first chuck unit 20 can include a compression train having a first side 42 and a second side 44 and an interface 50. The interface 50 is configured to adjust the compressive force applied between the first side 42 and the second side 44 of the compression train. The base 30 can be configured to engage and support the first chuck unit 20. When the first chuck unit 20 is engaged with the base 30, the second side 44 of the compression train and the material coupled thereto can be configured to rotate about the axis of rotation of the roll 2. Furthermore, when the first chuck unit 20 is engaged with the base 30, the first side 42 of the compression train is constrained from rotating about the axis of rotation.

[0034] As described in more detail below, in certain embodiments, interface 50 may include a first threaded rod 52 coupled to a member (e.g., first handle 54) that a user (i.e., a human operator) can grasp or that a machine can engage to, for example, turn first handle 54, knob, or the like. In the following description, the terms "handle" or "knob" are used. However, it will be understood that the members included as part of interface 50 may take other forms without limitation.

[0035] The first threaded rod 52 may extend along a portion or the entire length of the compression train. For example, the first threaded rod 52 preferably terminates in a first plug 60. Configured in this manner, the interface 50 may be rotated manually by a user or automatically by a machine. Friction is generated by contact between the surfaces of the components of the first chuck unit 20. Thus, the frictional force resisting rotation of the second side 44 of the compression train, and the associated roll 2 of material, depends on the applied compression force and is adjustable by the interface 50.

[0036] In an alternative embodiment (not shown), the rotation of interface 50 may be controlled by a machine. For example, a machine may be directly coupled (e.g., by a motor and drive train) to first threaded rod 52. In such a configuration, a handle or knob may be omitted because the machine can directly control the rotation of first threaded rod 52 without having to manually grip any parts.

[0037] The compression train may optionally include one or more components to facilitate adjusting the resistance to rotation. The one or more components may be located on the first side 42 of the compression train, the second side 44 of the compression train, or both. Thus, the compressive force applied between the first side 42 and the second side 44 of the compression train is the sum of the compressive force applied by the interface 50 and the opposing tension force created by frictional forces between the components on the first side 42 and the second side 44 of the compression train. Alternatively or additionally, one or more components may include a bearing surface (not shown) for transmitting the compressive force within the compression train.

[0038] Additionally, in one embodiment, one or more components may include a spring 55 (see FIG. 3). Generally, the spring 55 may be configured to provide a more gradual change in compressive force. For example, when the spring 55 is compressed from an equilibrium position, it exerts an opposing force (tension) in a direction toward the equilibrium position. This damping of the compressive force applied by the interface 50 may provide a more gradual change in compressive force than the compressive force provided by the interface 50 alone. As a result, the resistance to rotation of the roll of material 2 relative to the base 30 may be more gradual.

[0039] In use, the core 4 of a roll 2 of packaging material (e.g., expandable material) can be mounted in the roll dispenser 10 with the core 4 axially coupled to the first plug 60. When the roll 2 of expandable material is mounted in the roll dispenser 10 and the first / outer layer of expandable material is separated from the stock roll 2, the roll 2 is urged to rotate about its axis of rotation along with the second side 44 of the compression train. This rotation is resisted by a resistance to rotation provided by a compressive force applied between the first side 42 and the second side 44 of the compression train. The resistance to rotation provided by the compressive force can be adjusted to a value that allows for substantially uniform expansion of the expandable material simultaneously with the rotation of the roll 2 and the dispensing of the expandable material. In this manner, uneven expansion and / or tearing of the expandable material can be substantially avoided.

[0040] Roll dispenser embodiments having different configurations are described in more detail below.

[0041] 2-9 are diagrams of a first embodiment of a roll dispenser. For example, referring to FIGS. 2-6, the roll dispenser 10 includes a base 30 and a chuck assembly 12 including a first chuck unit 20 and a second chuck unit 80. The base 30 includes a base support 32 extending in a longitudinal (or axial) direction and a pair of supports 34, 36 extending perpendicularly from a first end 31 and a second end 33 of the base support 32, respectively (see FIG. 7). Each of the pair of supports 34, 36 can be attached to the base support 32 such that the pair of supports 34, 36 are offset from each other via a longitudinal offset 35. At least one slot (e.g., a first slot 38 and a second slot 39) may be formed adjacent to a free end 37 of each of the pair of supports 34, 36. As will be described in more detail below, at least one slot 38 , 39 is configured to receive a first chuck unit 20 and a second chuck unit 80 for attaching a roll of material 2 to the roll dispenser 10 .

[0042] The first chuck unit 20 is illustrated in more detail in FIGS. 3-4. FIG. 3 is an exploded view of the chuck unit 20, and FIG. 4 is a cross-sectional view of the assembled first chuck unit 20. As illustrated, the first chuck unit 20 corresponds to the first and second sides 42, 44 of the compression train and the interface 50. The first side 42 of the compression train preferably includes a generally planar first pad 70 and a first mount 72 coupled to the first side of the first pad 70, where the first mount 72 functions as an anti-rotation element. The second side 44 of the compression train preferably includes a generally planar second pad 74. The first shaft 62 is coupled to the first side of the second pad 74, and the first plug 60 is coupled to the second side of the first pad 70.

[0043] As provided herein, the first pad 70 and the second pad 74 may be configured to form an area or region of surface contact (e.g., flat surfaces) to constitute a first brake and establish frictional contact, and the first pad 70 and the second pad 74 are preferably formed to approximately the same size and shape. The frictional force generated by contact between the first pad 70 and the second pad 74 can be adjusted by adjusting the compression force via the interface (e.g., first handle assembly) 50. Preferably, when the roll of packaging material 2 is made of expandable paper, the first brake is operable to adjust the friction between the first mount 72 and the first plug 60 (e.g., between the first pad 70 connected to the first mount 72 and the second pad 74 connected to the first plug 60) to be sufficient to open one or more slits in the expandable paper without tearing the expandable paper.

[0044] The first chuck unit 20 includes at least an interface (e.g., a first handle assembly) 50 operably connected to the first plug 60, and further includes a first mount 72 configured to engage the first plug 60, for example, by surrounding or encircling the first plug 60 so that the first plug 60 can rotate within the first rotation mount 72. The base 30 is configured to support the first chuck unit 20 via fixed contact with the first mount 72, and the first plug 60 is configured to rotate about an axis of rotation, and the first mount 72 is fixed to the base 30 to be restrained from rotating about the axis of rotation.

[0045] 3, first mount 72 preferably includes a non-circular outer surface 73 (e.g., a square or hexagonal surface with straight edges) such that rotation of outer surface 73 may be limited when attached to base 30. In particular, when first mount 72 is attached to base 30, first mount 72 includes non-circular outer surface 73, which substantially limits or prevents its rotation within base 30.

[0046] The first plug 60 includes a distal portion for insertion into a first axial end of the core 4 of the roll of expandable material 2 and a proximal portion defining a first shaft 62. In particular, the first plug 60 forms an interference fit or is otherwise received in the core 4 of the roll of expandable material 2, thereby locking it for rotation therewith. Furthermore, the first plug 60 and the first shaft 62 are configured to rotate together about an axis of rotation, and the first shaft 62 is configured to be operably connected to the interface (first handle assembly) 50. The first shaft 62 may be coaxially received within the first mount 72, but preferably has minimal contact with the first mount 72, which is received in the base 30, thereby allowing the first plug 60 connected to the first shaft 62 to rotate freely axially.

[0047] The interface 50 includes a first handle 54, a first threaded rod 52 extending from the first handle 54, and a channel 63 formed in the first shaft 62. The first threaded rod 52 passes through the channel 63 and is secured to the first shaft 62. In one embodiment, the first shaft 62 may be hollow, and a nut 64 (e.g., a lock nut) may be disposed thereon. The nut 64 may threadably engage the first threaded rod 52 to secure the first threaded rod 52 (and the first handle 54) to the first shaft 62. The interface 50 adjusts the compression force by rotating the first handle 54 to move the first pad 70 and the second pad 74 closer or farther apart.

[0048] Optionally, a friction layer 66 may be provided on at least one of the first pad 70 and the second pad 74. The friction layer 66 is formed of a material that increases the friction generated by the rotation of the second pad 74 relative to the first pad 70 when the first and second pads 70 and 74 are in contact with each other. In certain embodiments, the friction layer 66 may be formed of vinyl. However, other materials that increase friction between the two contacting surfaces may also be employed. In embodiments in which two friction layers are employed, i.e., a first friction layer on the first pad 70 and a second friction layer on the second pad 74, the first and second friction layers may be formed of the same material or different materials.

[0049] As shown in FIGS. 3 and 4 , the first side 42 of the compression train can further include a pressure cap 58 and a spring 55. The pressure cap 58 is disposed between the first mount 72 and the first handle 54 and can further define a cavity sized to accommodate a portion of the first shaft 62. The spring 55 is disposed around the outer periphery of the first shaft 62 and between the mount 72 opposite the first end and pad 70 and the pressure cap end 58 opposite the first handle 54. As described above, when the first handle 54 is rotated, the spring 55 is compressed, urging the first pad 70 and the second pad 74 into contact (e.g., between the first mount 72 and the compression cap 58). A compressed spring exerts tension when compressed, reducing the compressive force applied to the first side 42 and the second side 44 of the compression train in response to rotation of the first handle 54. Thus, when the spring 55 is present, rotating the first handle 54 causes a more gradual increase in compression force than when the spring 55 is not present.

[0050] It is understood that in alternative embodiments, the spring 55 is positioned elsewhere within the first side 42 of the compression train or the second side 44 of the compression train.

[0051] The second chuck unit 80 is shown in more detail in Figures 5 and 6. Figure 5 is an exploded view, and Figure 6 is an assembled cross-sectional view. The second chuck unit 80 includes a generally planar pad 82, a second plug 84 coupled to a first side of a third base 82, a second shaft 86 coupled to a second side of the third base 82, a second mount 88, and a second handle 90.

[0052] The second handle 90 and the second plug 84 may be rigidly coupled. As an example, a second threaded rod 92 may be coupled to the second handle 90 and configured to engage with the second shaft 86 and the second plug 84. For example, a channel 83 may be formed in the second mount 88. The second threaded rod 92 may be configured to extend through the channel 83 and secured to the second shaft 86 via corresponding threads (e.g., a channel) in the second shaft 86. In one example, the second shaft 86 is hollow, and a nut 94 (e.g., a lock nut) may be disposed therein. The nut 94 may threadably engage the second threaded rod 92 to secure the second threaded rod 92 (and the second handle 90) to the second shaft 86.

[0053] 5 and 6, a second threaded rod 92 can be tightened through the second handle 90 to secure the handle 90 to the second plug 84. As a result, the second chuck unit 80 is locked to rotate with the core 4 of the roll of packaging material 2. The second mount 88 can be housed in the base 30, and the second mount 88 can have a circular or non-circular outer surface to be housed in the base 30.

[0054] 1 and 2, the first chuck unit 20 and the second chuck unit 80 may be received in at least one of the slots 38, 39 on the base 30. In particular, once assembled, the first chuck unit 20 and the second chuck unit 80 are arranged such that the first plug 60 and the second plug 84 are configured to engage opposite ends of the core 4 of the roll of material 2. As shown in FIG. 3, the first plug 60 may include a plurality of first ribs 61 circumferentially mounted around the internal shaft of the first plug 60. As shown in FIG. 5, the second plug 84 may include a plurality of second ribs 85 circumferentially mounted around the internal shaft of the second plug 84. Each of the plurality of first ribs 61 and the plurality of second ribs 85 may extend radially outward from the axis of rotation when the first chuck unit 20 and the second chuck unit 80 are mounted on the base 30.

[0055] The plurality of first ribs 61 and the plurality of second ribs 85 are dimensioned such that radially facing surfaces of the plurality of first ribs 61 and the plurality of second ribs 85 contact the inner circumference of the core 4 of the roll of material 2. In this manner, the first chuck unit 20 and the second chuck unit 80 may be coupled to the roll of material 2 by an interference fit between the core 4 and the first plug 60 and the second plug 84, respectively.

[0056] As provided herein, first chuck units 20 and second chuck units 80 may be provided at opposite ends of a roll of material 2 in accordance with one or more embodiments of the present disclosure. For example, in one embodiment, two of the first chuck units 20 may be provided at opposite ends of the roll 2. Alternatively, in another embodiment, two of the second chuck units 80 may be provided at opposite ends of the roll 2. In certain embodiments, the opposite ends of the roll 2 include one of the first chuck units 20 and one of the second chuck units 80.

[0057] Figure 7 is a perspective view of the base 30 of the roll dispenser 10 of Figures 1 and 2. As shown, the base 30 includes a longitudinally extending base support 32 and a pair of supports 34, 36. The supports 34, 36 extend from first and second ends 31, 33 of the base support 32, respectively, to respective free ends 37. The pair of supports 34, 36 are generally planar and may be mounted substantially parallel to each other while being disposed substantially perpendicular to the base support 32. Furthermore, the pair of supports 34, 36 are longitudinally offset from each other by a longitudinal offset 35.

[0058] At least one slot (e.g., first and second slots 38, 39) is further formed in the free ends 37 of the pair of supports 34, 36, i.e., at a position away from the intersection between the supports 34, 36 and the base support 32. In one embodiment, the at least one slot includes a first slot 38 extending from the free end 37 of each of the pair of supports 34, 36. In another embodiment, the at least one slot may further include a second slot 39 extending from a side of each of the pair of supports 34, 36. In certain embodiments, only the first slot 38 or the second slot 39 is provided. In other embodiments, both the first and second slots 38, 39 are provided.

[0059] At least one slot in the first support 34 is configured to receive the first mount 72 of the first chuck unit 20 (see FIGS. 3 and 4), and at least one slot is configured to receive the second mount 88 of the second chuck unit 80 (see FIGS. 5 and 6). In this manner, the chuck assembly 12, along with the roll of material 2 coupled to the chuck assembly 12, may be supported by the base 30. For example, because the first mount 72 is received in at least one slot in the base 30, the base 30 itself does not need to be adjustable. Instead, the resistance is provided by the chuck assembly 12 itself. For a first mount 72 that may be fixed to the base 30 during use, adjustment of the compression force is achieved via an interface (e.g., a first handle assembly) 50.

[0060] 8 and 9, the first and second slots 38, 39 are configured to facilitate mounting the roll of material 2 in different orientations relative to the base support 32 of the base 30. For example, the supports 34, 36 may each include a substantially similar or identical arrangement of the first and second slots 38, 39, with both the first and second slots 38, 39 present in both the supports 34, 36.

[0061] 1 and 2 in a first orientation, e.g., with the first chuck unit 20 and the second chuck unit 80 housed in the first slot 38. When the roll dispenser 10 is placed on a horizontal surface (i.e., with the base layer 30 placed in contact with the horizontal surface), the first slot 38 extends from the free ends 37 of the supports 34, 36 toward the base support 32. Thus, a gravitational force acts on the roll 2, holding the first chuck unit 20 and the second chuck unit 80 in the first slot 38.

[0062] 9 shows the roll dispenser 10 of FIGS. 1 and 2 in a second orientation, with the first chuck unit 20 and the second chuck unit 80 housed in the second slot 39. When the roll dispenser 10 is attached to a vertical wall, for example, when the base support 32 is placed in contact with the vertical wall, the second slot 39 is oriented vertically. Thus, a gravitational force is applied to the roll 2, holding the first chuck unit 20 and the second chuck unit 80 in the second slot 39.

[0063] 10 to 12 show a second embodiment of a roll dispenser according to the present disclosure. In the second embodiment, the roll dispenser preferably includes a chuck assembly including a single chuck unit 120, as opposed to the multiple chuck units described in the first embodiment.

[0064] 10 is an exploded perspective view of a roll dispenser 110 including a base 130 and a single chuck unit 120 having multiple plugs. The single chuck unit 120 is described in more detail below with reference to FIG. 11. The base 130 is described in more detail below with reference to FIG. 12.

[0065] FIG. 11 is an exploded perspective view of the single chuck unit 120 depicted in FIG. 10. As shown, the compression train may include a first side 142 having an interface 150 for adjusting the compression force acting on the roll dispenser 110 and a second side 144 including a shaft 162 configured to be received by at least one slot provided in the base 130 (see FIG. 12). The shaft 162 preferably extends between a first end 163 and a second end 165. The shaft 162 is configured to receive a generally planar second pad 174. Additionally, the first portion 164 of the shaft 162 may function as an anti-rotation element, and the first portion 164 is preferably provided adjacent the first end 163 of the shaft 162.

[0066] Compression train 142 includes a generally planar first pad 170, a first plug 160 coupled to first pad 170, a second plug 184, a first mount 172 interposed between first plug 160 and second plug 184, and a second mount 188 located on a side of second plug 184 opposite first mount 172. First pad 170, first plug 160, second plug 184, first mount 172, and second mount 188 each include a respective channel extending therethrough that is sized to accommodate shaft 162.

[0067] The interface 150 may include a knob 154 (or handle), a threaded rod 152 extending from the knob 154, and a threaded channel 167 formed in the second end 165 of the shaft 162. In use, the shaft 162 is preferably inserted into the channels of the second pad 174, the first plug 160, the second plug 184, the first mount 172, and the second mount 188, and the threaded rod 152 is preferably engaged with the threaded channel 167 formed within the shaft 162. This configuration positions the first pad 170 and the second pad 174 in opposition. The compression force between the first side 142 and the second side 144 is adjusted by rotating the knob 154 of the compression trains 142, 144, thereby moving the biased first pad 170 and second pad 174 closer or farther apart.

[0068] Optionally, the single chuck unit 120 may include one or more springs, as described above, to allow for more gradual adjustment of the compression force than would be possible without the springs. The springs may be provided on the first side 142 of the compression train, on the second side 144 of the compression train, or on both the first side 142 and the second side 144 of the compression train. For example, as shown in FIG. 11 , a spring 155 may be disposed between the second plug 184 and the second mount 188, and an additional spring 157 may be disposed between the first plug 160 and the first mount 172.

[0069] Optionally, a friction layer 166 may be provided on at least one of the first pad 170 and the second pad 174. The friction layer 166 is preferably formed from a material that increases the friction resulting from the rotation of the second pad 174 relative to the first pad 160 when the first pad 160 and the second pad 174 are placed in contact with each other. In certain embodiments, the friction layer 166 may be formed from vinyl. However, other materials that increase friction between the two contacting surfaces may also be employed. In embodiments in which two friction layers are employed, for example, an embodiment in which a first friction layer is placed on the first pad 160 and a second friction layer is placed on the second pad 174, the first and second friction layers may be formed from the same material or different materials.

[0070] The first plug 160 and the second plug 184 are configured to engage the core 4 of the roll of material 2. In one embodiment, the first plug 160 may include an internal mount (not numbered) and a plurality of first ribs 161 circumferentially attached thereto. The second plug 184 may include an internal mount (not numbered) and a plurality of second ribs 186 attached thereto. Each of the plurality of first ribs 161 and the plurality of second ribs 186 may extend radially outward from the axis of rotation when the single chuck unit 120 is attached to the base 130.

[0071] The plurality of first ribs 161 and the plurality of second ribs 186 are dimensioned such that radially facing surfaces of the plurality of first ribs 161 and the plurality of second ribs 186 contact the inner circumference of the core 4 of the roll of material 2. In this manner, the single chuck unit 120 may be coupled to the roll of material 2 by an interference fit between the core 2 and the first plug 160 and second plug 184, respectively.

[0072] Figure 12 is a perspective view of an embodiment of a base 130 configured for use with the roll dispenser 110 of Figure 10. As shown, the base 130 includes a longitudinally extending base support 132 and a pair of supports 134, 136 extending from first and second ends 131, 133 of the base support 132 to respective free ends 137. The pair of supports 134, 136 are generally planar and may be mounted substantially parallel to each other while being disposed substantially perpendicular to the base support 132. Additionally, the pair of supports 134, 136 are longitudinally offset from each other by an offset 135.

[0073] The first slot 175 and the second slot 177 may be formed in the opposite free ends 137 of the pair of supports 134, 136, respectively, with the first slot 175 and the second slot 177 located away from the intersection of the supports 134, 136 and the base support 132. The first slot 175 is preferably configured to accommodate the first portion 164 of the shaft 162. The second slot 177 is preferably configured to accommodate the second mount 188. Thus, when the first portion 164 of the shaft 162 is accommodated in the first slot 175 and the second mount 188 is accommodated in the second slot 177, the single chuck unit 120 and the roll of material 2 attached thereto are supported by the base 130.

[0074] In one embodiment, first portion 164 of shaft 162 has a cross-sectional shape with two substantially parallel sides, and first slot 175 has a locking portion 179 with two substantially parallel sides that is sized to receive first portion 164 of shaft 162. Locking portion 179 of first slot 175 is configured to restrain compression train first side 142 from rotating about the axis of rotation when first portion 164 of shaft 162 is received therein.

[0075] 11 and 12, the second mount 188 preferably has a generally curved cross-sectional shape, and the second slot 177 includes a support 181 having a curved surface. The support 181 of the second slot 177 is configured to allow the second side 144 of the compression train to rotate about an axis of rotation when the second mount 188 is received therein.

[0076] The locking portion 179 and / or the support 181 form recesses in the pair of supports 134, 136 and are therefore configured to receive and support the first mount 172 and the second mount 188 by gravity.

[0077] Optionally, in FIG. 12 , the first slot 175 and the second slot 177 each further have mouth portions 183, 185 with stepped entrance regions. The mouth portion 183 of the first slot 175, if present, is interposed between the locking portion 179 and the free end 137 of the first support 134 and has a width greater than that of the locking portion 179. The mouth portion 185 of the second slot 177, if present, is interposed between the support 181 and the free end 137 of the second support 136 and preferably has a width greater than that of the support 181. The larger widths of the mouth portions 183, 185 of the first slot 175 and the second slot 177 compared to the widths of the locking portion 179 and the support 181 facilitate insertion of a single chuck unit 120 (e.g., the first portion 164 of the shaft 162 and the second mount 188) into the first slot 175 and the second slot 177.

[0078] In further embodiments, the lengths of the first slot 175 and the second slot 177 may extend at a non-zero angle relative to a reference line (e.g., a vertical axis) perpendicular to the base support. In combination with the mouths 183, 185 of the first slot 175 and the second slot 177, the angle of the first slot 175 and the second slot 177 relative to the reference line can facilitate insertion of a single chuck unit 120 into the first slot 175 and the second slot 177.

[0079] As shown in FIG. 12 , the first slot 175 and the second slot 177 extend from the free ends 137 of the first support 134 and the second support 136. However, in an alternative embodiment (not shown), the first slot 175 may extend from a side of the first support 134 extending along at least a portion of the length of the first support 134, and the second slot 177 may extend from a side of the first support 136 extending along at least a portion of the length of the first support 136. As mentioned above, the above-described arrangement of the first slot 175 and the second slot 177 can facilitate mounting the base 130 in different orientations (e.g., table mount and wall mount). In certain embodiments, the base 130 may include pairs of the first slot 175 and the second slot 177 extending from the ends and / or sides of the first support 134 and the second support 136.

[0080] 13-15 illustrate a third embodiment of a roll dispenser 210 according to the present disclosure. In the third embodiment, the roll dispenser preferably comprises a chuck assembly including a single chuck unit 220, with FIG. 15 being an alternative variation of the single chuck unit 220 depicted in FIGS. 13-14.

[0081] 13, a single chuck unit 220 is configured to be secured to a base 230 in a cantilever configuration with a roll of material 2 attached thereto. An exploded view of the chuck assembly of FIG. 13 is shown in FIG.

[0082] 13, the base 230 includes a longitudinally extending base support 232 and a single, generally planar support 234 attached to a first surface of the base support 232. In contrast to the above-described embodiment, the end of the single chuck unit 220 is configured to be coupled to the support 234 rather than being received in a slot.

[0083] The chuck assembly of Figure 13 is similar to the embodiment depicted in Figure 11. However, a first end 263 of a shaft 262 is configured to be rigidly coupled to a support 234. As a result, the second side 244 of the compression train includes the support 234 of the base 230, and the first end 263 of the first end shaft 262 is rigidly coupled to the support 234 of the base 230, acting as an anti-rotation element.

[0084] 11 , the first side 242 of the compression train includes a generally planar pad 270, a first plug 260 coupled to the base 270, a second plug 284, a first mount 272 interposed between the first plug 260 and the second plug 284, and a mount 288 located on a side of the second plug 284 opposite the first mount 272. Each of the base 270, the first plug 260, the second plug 284, the first mount 272, and the second mount 288 includes a respective channel extending therethrough that is sized to accommodate the shaft 262.

[0085] 11 , interface 250 includes a knob (or handle) 254, a threaded rod 252 extending from knob 254, and a threaded channel 267 formed in a second end 265 of shaft 262. Interface 250 is configured such that rotation of knob 254 adjusts the compressive force to move base 270 closer to or farther from support 234.

[0086] Optionally, as described above, a friction layer 266 may be provided on the surface of the support 234 opposite the base 270, on the surface of the base 270, or both.

[0087] Optionally, one or more springs (e.g., spring 255) may be provided on the first side 242 of the compression train, the second side 244 of the compression train, or both the first side 242 and the second side 244 of the compression train.

[0088] The first plug 260 and the second plug 284 may be configured to engage the core 4 of the roll of material 2, as described above. In one embodiment, the first plug 260 may include an internal mount (not numbered) with a plurality of first ribs 261 circumferentially attached thereto. The second plug 284 includes an internal mount (not numbered) and a plurality of second ribs 286 circumferentially attached thereto. Each of the plurality of first ribs 261 and the plurality of second ribs 286 may extend radially outward from the axis of rotation.

[0089] The roll of material 2 can be attached to the roll dispenser 210 by horizontally moving the roll 2 while the core 4 and the single chuck unit 220 are axially aligned. The plurality of first ribs 261 and the plurality of second ribs 286 are dimensioned such that the radially facing surfaces of the plurality of first ribs 261 and the plurality of second ribs 286 contact the inner circumference of the core 4 of the roll of material 2. In this manner, the single chuck unit 220 can be coupled to the roll of material 2 by an interference fit between the core 4 and the first plug 260 and second plug 284, respectively.

[0090] FIG. 15 illustrates a variation of the chuck assembly, including a single chuck unit 330, as an alternative to the single chuck unit 230 in the roll dispenser 210 of FIG. 13. The single chuck unit 330 of FIG. 15 is configured and operates in a manner similar to the single chuck unit 230 of FIG. 12, except that the first plug 260 and the second plug 284 are replaced with a single plug 360 operably connected to a shaft 363. The single plug 360 comprises a plurality of radial fins 361 attached to the outer surface of a first mount 372, which may be arranged circumferentially around the first mount 372. Thus configured, the radial fins 361 may extend along at least a portion of the length of the first mount 372. The second mount 388 has a structure and function similar to the second mount 288 depicted in FIG. 12. Notably, the longitudinal / axial compression force can be adjusted using a knob 354 or handle.

[0091] While the present disclosure has been described above with reference to exemplary embodiments and accompanying drawings, the present disclosure is not limited thereto and can be variously modified and changed by those skilled in the art to which the present disclosure pertains without departing from the spirit and scope of the present disclosure as set forth in the following claims.

[0092] [CROSS-REFERENCE TO RELATED APPLICATIONS]

[0093] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63 / 374,236, filed August 31, 2022, the entire contents of which are incorporated herein by reference.

Claims

1. 1. A roll dispenser for supporting a roll of packaging material, comprising: The roll dispenser includes: With the base, a chuck assembly including a first chuck unit; The first chuck unit includes: a first mount attached to a base such that the base limits rotation of the first mount; a first plug configured to be inserted into a first axial end of a core of the roll of wrapping material and locked for rotation with the core; a first brake operably associated with the first plug and the first mount to establish friction therebetween that resists rotation of the first plug relative to the first mount as the wrapping material is unwound from the roll; Roll dispenser.

2. 2. The roll dispenser of claim 1, further comprising a first handle assembly connected to the first plug and configured to adjust a first axially applied compressive force to adjust friction between the first mount and the first plug.

3. 3. The roll dispenser of claim 2, wherein the first plug includes a distal portion for insertion into a first axial end of a core of the roll of packaging material and a proximal portion defining a first shaft.

4. 4. The roll dispenser of claim 3, further comprising a pressure cap disposed between the first mount and the first handle assembly, the pressure cap defining a cavity dimensioned to accommodate at least a portion of the first shaft.

5. 5. The roll dispenser of claim 4, further comprising a spring disposed around the outer periphery of the first shaft and between the end of the first mount and the end of the pressure cap opposite the first handle assembly.

6. The roll dispenser of claim 3 , wherein the first plug and the first shaft are configured to rotate together about an axis of rotation.

7. The roll dispenser of claim 3 , wherein the first handle assembly is operably connected to the first shaft.

8. The roll dispenser of claim 1 , wherein the first handle assembly is configured to be rotated manually by an operator or automatically by a machine.

9. 2. The roll dispenser of claim 1, wherein the first plug is configured to rotate about the axial axis of rotation and the first mount is configured to restrain the first plug from rotating about the axis of rotation.

10. The roll dispenser of claim 1 , wherein the roll of wrapping material comprises a roll of expandable paper containing a plurality of slits.

11. 11. The roll dispenser of claim 10, wherein the first brake is configured to adjust friction between the first mount and the first plug sufficient to open one or more slits in the expandable paper without tearing the expandable paper.

12. The roll dispenser of claim 1 , wherein the first mount includes a non-circular outer surface configured to contact the base to prevent axial rotation.

13. the chuck assembly further includes a second chuck unit; The second chuck unit includes: a second plug configured to be received in a second axial end of the core of the roll of wrapping material; a second shaft operably connected to the second plug; a second mount configured to be connected to the second shaft.

14. A roll dispenser base configured to support a roll of packaging material, comprising: The base is a longitudinally extending base support; a pair of supports extending laterally from the base support, each support defining a first end and a second end; the first end of each of the pair of supports is attached to a first surface of the base support; At least one slot is formed adjacent the second end of each of the pair of supports; the at least one slot of a first support of the pair of supports is configured to receive a first mount of a first chuck unit, and the at least one slot of a second support of the pair of supports is configured to receive a second mount of a second chuck unit, thereby supporting a chuck assembly; base.

15. The base of claim 14 , wherein the base support is configured to be mounted to a vertical wall so as to be substantially flush with the vertical wall, or to be mounted to a horizontal surface.

16. 15. The base of claim 14, wherein the at least one slot includes a stepped entrance area for receiving the first mount or the second mount and a recessed area for retaining the first mount or the second mount by gravity.

17. the at least one slot includes a first slot and a second slot; the first slot extends from the second end of each of the pair of supports; The base of claim 14 , wherein the second slot extends from a side surface of each of the pair of supports, the side surfaces being located between the first end and the second end of the pair of supports.

18. 1. A system for dispensing packaging material from a roll disposed on a roll dispenser, comprising: The system comprises: With the base, a chuck assembly including a first chuck unit; The first chuck unit includes: a first plug configured to be inserted into a first axial end of a core of the roll of wrapping material and locked for rotation with the core; a first brake configured to brake rotation of the first plug and the core as the wrapping material is drawn from the roll; the roll of packaging material supported by the base with the first plug inserted into the core; system.

19. 20. The system of claim 18, further comprising the first mount attached to the base such that the base limits rotation of the first mount.

20. 20. The system of claim 19, wherein the roll of packaging material comprises a roll of expandable paper including a plurality of slits, and the first brake is configured to adjust friction between the first mount and the first plug sufficient to open one or more slits in the expandable paper without tearing the expandable paper.

Images