Dispenser and methods of manufacturing and loading dispenser

Abstract

A dispenser for expanding material includes a support frame having a base, an upright portion, a top portion, and a hanging portion, wherein the upright portion connects the base to the top portion, and the top portion connects the upright portion to the hanging portion. The dispenser also includes a rotatable member supported by the support frame and a tension adjustment device configured to apply resistive force from the support frame to the rotatable member.

Description

PA102906W002DISPENSER AND METHODS OF MANUFACTURING AND EOADING DISPENSERTechnical Field

[0001] The present disclosure relates to a dispenser for expanding material. The present disclosure further relates to a method of manufacturing the dispenser and loading the dispenser.Background

[0002] Typically, many logistics and courier services industries use substantially complex dispensers to dispense package cushioning material used for safeguarding goods during shipping from any external forces which may damage the goods. These dispensers may include complex design which may require accurate dimensions to function properly. Further, these dispensers may be prone to damage during shipment, which may increase maintenance costs. As the dispensers may have complex design, they may not be cost effective to manufacture. Further, such dispensers may be bulky, leading to higher shipping costs and inconvenience for the end-user.

[0003] Therefore, there is a need for an improved solution for addressing the abovementioned shortcomings to develop a dispenser that may be cheaper, stronger, and easier to assemble and use.Summary

[0004] In one embodiment, a dispenser for expanding material includes a support frame having a base, an upright portion, a top portion, and a hanging portion, wherein the upright portion connects the base to the top portion, and the top portion connects the upright portion to the hanging portion. The dispenser also includes a rotatable member supported by the support frame and atension adjustment device configured to apply resistive force from the support frame to the rotatable member.

[0005] In another embodiment, a method of manufacturing a dispenser for expanding material includes forming a support frame from a single piece of material by cutting and bending the material to create a base, an upright portion, a top portion, and a hanging portion, wherein the upright portion connects the base to the top portion, and the top portion connects the upright portion to the hanging portion. The method also includes forming at least two openings in the support frame and mounting at least one bearing element in at least one of the openings.

[0006] In yet another embodiment, a method of loading a dispenser for expanding material includes sliding a roll laterally onto a rotatable member such that inner surfaces of the roll engage barbed or wedge-shaped features of at least one barbed or wedge-shaped support plate or a barbed or wedge-shaped support member. The method also includes retaining the roll on the rotatable member through frictional engagement between the barbed or wedge-shaped features and an inner diameter of the roll.

[0007] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.Brief Description of the Drawings

[0008] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0009] FIG. 1A shows a schematic perspective view of a dispenser for expanding material, according to an embodiment of the present disclosure;

[0010] FIG. IB shows a schematic view of a view of a roll of material;

[0011] FIG. 2A shows a schematic perspective view of a support frame of the dispenser, according to an embodiment of the present disclosure;

[0012] FIG. 2B shows a schematic perspective view of a support frame of the dispenser, according to another embodiment of the present disclosure;

[0013] FIG. 3A shows a schematic top view of a barbed or wedge-shaped support plate, according to an embodiment of the present disclosure;

[0014] FIG. 3B shows a schematic top view of a barbed or wedge-shaped support plate, according to another embodiment of the present disclosure;

[0015] FIG. 4 shows a schematic cross-sectional view of the roll of material and the barbed or wedge-shaped support plate clamped onto a rotatable member, according to an embodiment of the present disclosure;

[0016] FIG. 5 shows a partial front perspective view of the dispenser, according to an embodiment of the present disclosure;

[0017] FIGS. 6A-6G show cross-sectional views of rotatable members having different sectional shapes, according to an embodiment of the present disclosure;

[0018] FIGS. 7A-7G show schematic views of different tension adjustment devices, according to an embodiment of the present disclosure;

[0019] FIG. 8 shows a schematic perspective view of a dispenser for expanding material, according to another embodiment of the present disclosure;

[0020] FIG. 9 shows a flow chart of a method of manufacturing a dispenser for expanding material, according to an embodiment of the present disclosure; and

[0021] FIG. 10 shows a flow chart of a method of loading a dispenser for expanding material, according to an embodiment of the present disclosure.Detailed Description

[0022] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0023] In the following disclosure, the following definitions are adopted.

[0024] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

[0025] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / - 20 % for quantifiable properties).

[0026] The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 10% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0027] The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0028] As used herein, the terms “first” and “second” are used as identifiers. Therefore, such terms should not be constmed as limiting of this disclosure. The terms “first” and “second” when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

[0029] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0030] Typically, many logistics and courier services industries use substantially complex dispensers to dispense package cushioning material used for safeguarding goods during shipping from any external forces which may damage the goods. These dispensers may include complex design which may require accurate dimensions to function properly. Further, these dispensers may be prone to damage during shipment, which may increase maintenance costs. As the dispensers may have complex design, they may not be cost effective to manufacture. Further, such dispensers may be bulky, leading to higher shipping costs and inconvenience for the end-user.

[0031] Therefore, there is a need for an improved solution for addressing the abovementioned shortcomings to develop a dispenser that may be cheaper, stronger, and easier to assemble and use.

[0032] The present disclosure relates to a dispenser for expanding material. The dispenser includes a support frame having a base, an upright portion, a top portion, and a hanging portion. The upright portion connects the base to the top portion. The top portion connects the upright portionto the hanging portion. The dispenser further includes a rotatable member supported by the support frame. The dispenser further includes a tension adjustment device configured to apply resistive force from the support frame to the rotatable member.

[0033] The support frame may create a cantilevered support for the rotatable member, which may allow a roll of material to be loaded laterally onto the dispenser. This may simplify the loading process compared to systems that require a roll to be lifted over a support or that have supports on both ends. The tension adjustment device may allow the user to control the resistance force, which may be critical for expanding materials that require a specific tension to be properly unfurled and applied. Further, the dispenser may use fewer components, may have fewer assembly steps, and may be robust and less likely to be damaged (e.g., in shipping or handling). In addition, the dispenser may have a smaller footprint which may lead to cheaper shipping and may be convenient for the end-user.

[0034] Referring now to figures, FIG. 1A shows a schematic perspective view of a dispenser 100 for expanding a material 302, according to an embodiment of the present disclosure. FIG. IB shows a schematic view of a view of a roll of material 300. The roll of material 300 may be interchangeably referred to as “the roll 300” herein.

[0035] Referring to FIGS. 1A and IB, the material 302 may be a Scotch™ Cushion Lock™ which is an eco-friendly solution that protects goods from external forces during shipping. The material 302 may also be any other expandable wrap material. By way of non-limiting example, the material 302 may be “honeycomb paper” available commercially under trade names by various companies across the industry. Other embodiments of the material 302 may utilize any tension-activated kirigami pattern rolls of any suitable material. Some embodiments may be found in 3M™ patents and published patent applications such as, by way of non-limiting examples, US12434464B2, WO2025078892A1, US20250I878I0AI, USD1110171, CA207635S, USD1016497, USD946907, USD971019, USD1004290, US20220379576A1, US20220379575A1, US20230020226A1, WO2021130628A1, US20230022987A1, and US12202226B2. The material 302 may be a recyclable paper or a virgin paper or some combinations. It may be extensible or non-extensible. The material may require less space when not expanded. This may make shipping of goods cheaper and convenient for a user. The material 302 may include any material as per desired application attributes. In the illustrated embodiment of FIG. 1A, the material 302 is coiled in the form of the roll of material 300. In some embodiments, the roll of material 300 is coreless. In such embodiments, the roll of material 300 has an inner diameter 310.

[0036] A coordinate system including mutually perpendicular x-, y-, and z-axes is also illustrated in FIG. 1A. The x- and y-axes show a length and a width of the dispenser 100, respectively. The z-axis shows a height of the dispenser 100.

[0037] As shown in FIG. 1A, the dispenser 100 for expanding the material 302 includes a support frame 110. The support frame 110 includes abase 112, an upright portion 114, atop portion116, and a hanging portion 118. The upright portion 114 connects the base 112 to the top portion 116. The top portion 116 connects the upright portion 114 to the hanging portion 118. In some embodiments, the support frame 110 is formed from a single piece of material bent to define the base 112, the upright portion 114, the top portion 116, and the hanging portion 118. In some embodiments, the support frame 110 is formed from a single piece of material formed from cutting, molding, casting, etc. In some embodiments, the single piece of material is a single bent metal bar or sheet. Forming the support frame 110 from a single piece of material may create a monolithic, unitary structure which may reduce a component count by eliminating a need for separate plates, brackets, fasteners, or welds. This may simplify both manufacturing and final assembly, thereby lowering costs. Further, a unitary frame may inherently be more robust and durable than a multipart assembly, making it less prone to damage during shipping, handling, and use. Moreover, it may eliminate tolerance issues that may arise when multiple components are joined together, resulting in a more precise and fault-tolerant final product.

[0038] The dispenser 100 further includes a rotatable member 120 supported by the support frame 110. The rotatable member 120 extends along a rotatable member axis 128. The rotatable member axis 128 extends substantially along the x-axis. The dispenser 100 further includes atension adjustment device 130 configured to apply resistive force 150 from the support frame 110 to the rotatable member 120.

[0039] FIG. 2A shows a schematic perspective view of the support frame 110 of the dispenser 100 of FIG. 1A, according to an embodiment of the present disclosure.

[0040] Referring to FIGS. 1A and 2A, in some embodiments, the support frame 110 includes two openings 122, 124. Specifically, in some embodiments, the hanging portion 118 of the support frame 110 includes the opening 122 and the upright portion 114 of the support frame 110 includes the opening 124. The two openings 122, 124 may provide defined, stable mounting points for bearings or bushings, ensuring a smooth and reliable axis of rotation for the rotatable member 120. In some embodiments, a bearing 180 is removably coupled in the opening 122 and a bearing 182 is removably coupled in the opening 124. The bearings 180, 182 may be interchangeably referred to as “the bearing elements 180, 182” herein. In some embodiments, the support frame 110 further includes an opening 132 in the top portion 116.

[0041] In some embodiments, the support frame 110 includes at least one bend 170, 172 that creates a spacing region 174. In the illustrated embodiment of FIG. 2A, the support frame 110 includes two bends 170, 172 that create the spacing region 174. In some embodiments, the support frame 110 includes the at least one bend 170, 172 that creates the spacing region 174 for the two openings 122, 124. In some embodiments, the bend 170 separates the top portion 116 and the hanging portion 118 and the bend 172 separates the top portion 116 and the upright portion 114 of the support frame 110. In some embodiments, the top portion 116 of the support frame 110 may becurved. In other words, the top portion 116 may have an arch shape. The support frame 110 further includes a bend which separates the base 112 and the upright portion 114.

[0042] In the illustrated embodiment of FIG. 2A, the spacing region 174 does not face the base 112 of the support frame 110. Specifically, the top portion 116 does not face the base 112 of the support frame 110. Moreover, in the illustrated embodiment of FIG. 2A, the base 112 includes two flat portions 113 with a separation 119 between them to stabilize the dispenser 100 (shown in FIG.1A). The two flat portions 113 with the separation 119 may provide a wider stance for the base 112 of the dispenser 100 which may improve stability and prevent the dispenser 100 from tipping or rocking during use, especially when a user is pulling on the material 302. The separation 119 may also allow for more efficient nesting of parts when cutting multiple support frames from a single sheet of material, reducing manufacturing waste.

[0043] FIG. 2B shows a schematic perspective view of a support frame 110’, according to another embodiment of the present disclosure. The support frame 110’ is substantially similar to the support frame 110 shown in FIG. 2A, with like elements designated by like reference characters.

[0044] In the illustrated embodiment of FIG. 2B, the support frame 110’ includes a base 112’ instead of the base 112. The base 112’ of the support frame 110’ includes a single flat portion. In other words, the support frame 110’ includes the base 112’ which is devoid of the two flat portions 113 (shown in FIG. 2A) with the separation 119 (shown in FIG. 2A) between them. Further, in the illustrated embodiment of FIG. 2B, the spacing region 174 faces the base 112’ of the support frame 110’. Specifically, the top portion 116 faces the base 112’ of the support frame 110’.

[0045] In some embodiments, the rotatable member 120 occupies the opening 124, 122 in each of the upright portion 114 and the hanging portion 118. Specifically, the rotatable member 120 occupies the opening 122 in the hanging portion 118 and the opening 124 in the upright portion 114. Thus, the support frame 110 supports the rotatable member 120 at two distinct points along the rotatable member axis 128. This may enhance stability and alignment for the rotatable member 120 and may prevent wobbling, binding, or misalignment during rotation, which in turn may ensure that the roll of material 300 dispenses smoothly and that the resistive force 150 from the tension adjustment device 130 is applied consistently and evenly.

[0046] In some embodiments, the tension adjustment device 130 applies the resistive force 150 through the opening 132 in the top portion 116 directly onto the rotatable member 120. In some embodiments, the tension adjustment device 130 includes a bolt 134 configured to interact in a straight line path with the rotatable member 120. The straight line path may be substantially along the z-axis. In other words, the bolt 134 which passes through the opening 132 in the top portion 116 may apply a direct linear resistance to the rotatable member 120. In some embodiments, the bolt 134 has a thread count sufficient to permit fine control of the resistive force 150. The bolt 134 may include thread count configuration such as !4-100 thread which may be desirable to permit fine control of the resistive force 150. The bolt 134 with a high thread count (e.g., many threads perinch) may produce a small linear displacement for each full rotation and may provide the user with fine, gradual, and precise control. This may allow the user to easily and accurately dial in the optimal resistive force 150 required for a specific material, without the resistive force 150 increasing too abruptly, which may enhance the functionality and user experience of the dispenser 100.

[0047] The bolt 134 may provide a simple, low-cost, and reliable mechanism for applying the resistive force 150. The bolt 134 may be easily available and integrated. Further, the straight line path may be the most direct and efficient way to translate the rotational input of the bolt 134 into a linear force, further contributing to the mechanical simplicity and cost-effectiveness of the dispenser 100. Moreover, by applying the resistive force 150 directly, the dispenser 100 may eliminate a need for complex, multi -part lever arms, linkages, or friction pads, which are common in prior art systems. The dispenser 100 may reduce an overall number of components, lower manufacturing costs, decrease footprint of the dispenser 100, and improve reliability by removing potential points of mechanical failure.

[0048] In some embodiments, the tension adjustment device 130 further includes a compressive element 138 interacting with a bearing element 136 to provide gradually increasing resistive force (i.e., the resistive force 150). In some embodiments, the compressive element 138 may be a rubber sleeve disposed between the bolt 134 and the bearing element 136. In some other embodiments, the compressive element 138 may be a spring and may be interchangeably referred to as “the spring element 138” herein. The compressive element 138 may provide a more progressive and dampened application of the resistive force 150 and allow the resistive force 150 to increase smoothly and gradually as the bolt 134 is tightened. This may further enhance the user’s ability to achieve fine control over the resistive force 150.

[0049] In some embodiments, the bearing element 136 is a spacer and may be interchangeably referred to as “the spacer 136” herein. In some embodiments, the bearing element 136 is a force distribution sleeve and may be interchangeably referred to as “the force distribution sleeve 136” herein. In some embodiments, the tension adjustment device 130 further includes the at least one spring element 138 positioned to apply loading force (e.g., the resistive force 150) to the spacer 136 contacting the rotatable member 120. The at least one spring element 138 may provide a consistent and repeatable application of force and normalize the resistive force 150 applied to the rotatable member 120, absorbing minor variations and providing a smooth, predictable increase in resistance as the tension adjustment device 130 is tightened. This may contribute to the overall precision and reliability of the tension adjustment device 130.

[0050] In some embodiments, the dispenser 100 further includes at least one barbed or wedge-shaped support plate 160 fixed to the rotatable member 120 and configured to engage the inner diameter 310 of the roll of material 300. In some embodiments, the at least one barbed or wedge-shaped support plate 160 includes two barbed or wedge-shaped support plates 160 that are clamped to the rotatable member 120 to define a gripping interface 162 for the roll 300. The grippinginterface 162 may be interchangeably referred to as “the barbed or wedge surfaces 162” herein. In some embodiments, the barbed or wedge-shaped support plate 160 is inserted in the inner diameter 310 of the roll of material 300 by using lateral movement 312.

[0051] FIG. 3 A shows a schematic top view of the barbed or wedge-shaped support plate 160, according to an embodiment of the present disclosure.

[0052] In some embodiments, the at least one barbed or wedge-shaped support plate 160 is laser cut or stamped from sheet metal. The barbed or wedge-shaped support plate 160 may be laser cut or stamped from sheet metal which may enable low volume and high-volume manufacturing in sheet metal shops. Further, in some embodiments, the barbed or wedge-shaped support plate 160 may be made from sheet metal and not from plastic as plastic molded designs may require expensive molds and high-volume production, or expensive 3D printing of few parts. In the illustrated embodiment of FIG. 3 A, the barbed or wedge-shaped support plate 160 includes a barbed support plate including a plurality of barbed surfaces as the gripping interface 162 throughout a length (i.e., substantially along the x-axis) of the barbed support plate. In such embodiments, the barbed or wedge-shaped support plate 160 may be interchangeably referred to as “the barbed support plate 160” herein.

[0053] FIG. 3B shows a schematic top view of a barbed or wedge-shaped support plate 163, according to another embodiment of the present disclosure. In the illustrated embodiment of FIG.3B, the barbed or wedge-shaped support plate 163 includes a wedge-shaped support plate including wedge surfaces as the gripping interface 162 proximal to ends of the wedge-shaped support plate. In such embodiments, the barbed or wedge-shaped support plate 163 may be interchangeably referred to as “the wedge-shaped support plate 163” herein.

[0054] FIG. 4 shows a schematic cross-sectional view of the roll of material 300 and the barbed or wedge-shaped support plate 160 clamped onto the rotatable member 120 and inserted in the inner diameter 310 of the roll of material 300, according to an embodiment of the present disclosure. The roll of material 300 may have no inner core such that the barbs of the barbed or wedge-shaped support plate 160 directly connect with the roll of material 300. A coreless design may have the advantage of less waste material for the end user, in addition, when all of the material 302 on the roll 300 has been used the barbed or wedge-shaped support plate 160 is empty and ready for the next roll. If a core is present, then it must be removed before the next roll is loaded onto the dispenser 100 (shown in FIG. 1).

[0055] Referring to FIGS. 1, 3A, and 4, as discussed above, the barbed or wedge-shaped support plate 160 is removably clamped to the rotatable member 120 and inserted in the inner diameter 310 of the roll of material 300 by using the lateral movement 312. Further, the gripping interface 162 retains the roll 300 on the rotatable member 120 without requiring tightening knobs or fasteners.

[0056] FIG. 5 shows a partial front perspective view of the dispenser 100, according to an embodiment of the present disclosure.

[0057] Referring to FIGS. 1 to 5, in some embodiments, the rotatable member 120 includes a flat portion 126 configured to allow torque transmission to the at least one barbed or wedge-shaped support plate 160 while allowing free axial movement.

[0058] FIG. 6A shows a schematic cross-sectional view of the rotatable member 120 having a circular shape 123-1, according to an embodiment of the present disclosure. FIG. 6B shows a schematic cross-sectional view of the rotatable member 120 having a D-shape 123-2, according to an embodiment of the present disclosure. FIG. 6C shows a schematic cross-sectional view of the rotatable member 120 having a rounded rectangular shape 123-3, according to an embodiment of the present disclosure. FIG. 6D shows a schematic cross-sectional view of the rotatable member 120 having a pentagonal shape 123-4, according to an embodiment of the present disclosure. FIG.6E shows a schematic cross-sectional view of the rotatable member 120 having a hexagonal shape 123-5, according to an embodiment of the present disclosure. FIG. 6F shows a schematic cross-sectional view of the rotatable member 120 having a dodecagonal shape 123-6, according to an embodiment of the present disclosure. FIG. 6G shows a schematic cross-sectional view of the rotatable member 120 having a rectangular shape 123-7, according to an embodiment of the present disclosure.

[0059] Referring to FIGS. 6A to 6G, in some embodiments, the rotatable member 120 may not be limited to the circular shape 123-1, the D-shape 123-2, the rounded rectangular shape 123-3, the pentagonal shape 123-4, the hexagonal shape 123-5, the dodecagonal shape 123-6, and the rectangular shape 123-7 but may include any other suitable shapes according to desired application attributes.

[0060] FIG. 7A shows a schematic view of a tension adjustment device 130-1, according to an embodiment of the present disclosure. The tension adjustment device 130-1 is substantially similar to the tension adjustment device 130 shown in FIG. 1A, with like elements designated by like reference characters. Specifically, the tension adjustment device 130-1 includes the bolt 134 configured to press against the force distribution sleeve 136 to apply the resistive force 150 from the support frame 110 to the rotatable member 120 (partially shown). In other words, the bolt 134 pushes directly on the force distribution sleeve 136 to increase the resistance. However, the tension adjustment device 130-1 does not include the compressive element 138. In some embodiments, a compressive sleeve may be added around the force distribution sleeve 136 to act like a spring and slowly increase the resistive force 150 as the bolt 134 pushes into it.

[0061] FIG. 7B shows a schematic view of atension adjustment device 130-2, according to an embodiment of the present disclosure. The tension adjustment device 130-2 is substantially similar to the tension adjustment device 130 shown in FIG. 1A, with like elements designated by like reference characters. Specifically, the tension adjustment device 130-2 further includes a cap 139configured to directly press against the force distribution sleeve 136 to apply the resistive force 150 from the support frame 110 to the rotatable member 120. In some embodiments, the cap 139 may be configured to directly press against the rotatable member 120 to apply the resistive force 150. In some embodiments, the cap 139 may be made of rubber or soft plastic material which may help to maintain set resistance on the rotatable member 120. In such embodiments where the cap 139 is made of a resilient, compressive material such as rubber, the cap 139 may serve a dual function, acting as both the force distribution sleeve 136 and as the compressive element 138, providing a progressive increase in resistive force 150 as the bolt 134 is advanced.

[0062] FIG. 7C shows a schematic view of atension adjustment device 130-3, according to an embodiment of the present disclosure. The tension adjustment device 130-3 is substantially similar to the tension adjustment device 130 shown in FIG. 1A, with like elements designated by like reference characters. Specifically, the tension adjustment device 130-3 further includes an internal threaded sleeve 142 with a collar facing the force distribution sleeve 136. The internal threaded sleeve 142 passes through the top portion 116 via the opening 132 (best shown in FIGS. 2A and 2B). The internal threaded sleeve 142 is configured to not rotate with the bolt 134. The tension adjustment device 130-3 further includes the compressive element 138 including a spring 138-1. In the illustrated embodiment of FIG. 7C, one end of the spring 138-1 presses against the support frame 110 and the other end of the spring 138-1 presses against the collar of the internal threaded sleeve 142 to prevent any disturbance to set resistance on the rotatable member 120.

[0063] FIGS. 7D-7E show schematic perspective views of atension adjustment device 130-4, according to an embodiment of the present disclosure. The tension adjustment device 130-4 is substantially similar to the tension adjustment device 130 shown in FIG. 1A, with like elements designated by like reference characters. Specifically, the tension adjustment device 130-4 includes the compressive element 138 including a plurality of conical washers 138-2. In some embodiments, the plurality of conical washers 138-2 includes Belleville washers.

[0064] In the illustrated embodiment of FIG. 7D, at least one conical washer 138-2 of the plurality of conical washers 138-2 presses against the force distribution sleeve 136 to prevent any disturbance of set resistance on the rotatable member 120. In the illustrated embodiment of FIG.7E, at least one conical washer 138-2 of the plurality of conical washers 138-2 presses against the support frame 110 to prevent any disturbance of set resistance on the rotatable member 120.

[0065] FIG. 7F shows a schematic perspective view of a tension adjustment device 130-5, according to an embodiment of the present disclosure. The tension adjustment device 130-5 is substantially similar to the tension adjustment device 130-3 shown in FIG. 7C or FIG. 7E, with like elements designated by like reference characters. Specifically, the tension adjustment device 130-5 includes an internal threaded sleeve 143 having a hexagonal cross-section and passing through a hexagonal opening 132-1. The internal threaded sleeve 143 having the hexagonal cross-section and passing through the hexagonal opening 132-1 may resist rotation with the bolt 134, but includesufficient clearance so it can translate along the z-axis. Further, the tension adjustment device 130-5 may include a plurality of wave spring washers 138-3 which presses against at least one of the support frame 110 and the force distribution sleeve 136 to prevent any disturbance of set resistance on the rotatable member 120.

[0066] FIG. 7G shows a schematic cross-sectional view of a tension adjustment device 130-6, according to an embodiment of the present disclosure. The tension adjustment device 130-6 is substantially similar to the tension adjustment device 130 shown in FIG. 1A, with like elements designated by like reference characters. Specifically, the tension adjustment device 130-6 further includes a jam nut 144, a flat washer 140, and the plurality conical washers 138-2, configured to directly press against a tube spacer 136-1 to apply the resistive force 150 from the support frame 110 to the rotatable member 120. The jam nut 144 may be used to provide a pushing surface on the bolt 134. The jam nut 144 is configured to lock a tightening nut 145 that presses against the flat washer 140 to lock set resistance on the rotatable member 120.

[0067] FIG. 8 shows a schematic perspective view of a dispenser 200 for expanding the material 302 shown in FIGS. 1A-1B, according to another embodiment of the present disclosure. The dispenser 200 is substantially similar to the dispenser 100 shown in FIG. 1A, with like elements designated by like reference characters. However, the dispenser 200 includes barbed or wedge-shaped support members 165 instead of the barbed or wedge-shaped support plate 160 shown in FIG. 1A.

[0068] In the illustrated embodiment of FIG. 8, at least one barbed or wedge-shaped support member 165 of the barbed or wedge-shaped support members 165 is disposed on one end of the rotatable member 120 proximal to the hanging portion 118 of the support frame 110’ and at least one barbed or wedge-shaped support member 165 of the barbed or wedge-shaped support members 165 is disposed on the other end of the rotatable member 120, i.e., distal to the hanging portion 118 of the support frame 110’. In some embodiments, the at least one barbed or wedge-shaped support member 165 disposed proximal to the hanging portion 118 of the support frame 110’ maybe fixedly attached.

[0069] In some embodiments, the barbed or wedge-shaped support members 165 include barbed or wedge-shaped features 167 configured to grip on to the inner diameter 310 of the roll of material 300. In some embodiments, the barbed or wedge-shaped support members 165 may retain the roll 300 on the rotatable member 120 without requiring tightening knobs or fasteners.

[0070] FIG. 9 shows a flow chart of a method 900 of manufacturing a dispenser (e.g., the dispenser 100, 200 shown in FIGS. 1 A and 8, respectively) for expanding material (e.g., the material 302 shown in FIGS. 1A-1B), according to an embodiment of the present disclosure.

[0071] Referring to FIGS. 1A-1B and 9, at step 902, the method 900 includes forming a support frame (e.g., the support frame 110, 110’) from a single piece of material by cutting and bending the material to create a base (e.g., the base 112, 112’), an upright portion (e.g., the uprightportion 114), atop portion (e.g., the top portion 116), and ahanging portion (e.g., the hanging portion 118). The upright portion connects the base to the top portion, and the top portion connects the upright portion to the hanging portion.

[0072] The forming the support frame from the single piece of material through cutting and bending may simplify the manufacturing process and consolidate multiple fabrication and assembly steps (e.g., welding, fastening multiple parts) into a few simple, repeatable operations. This may reduce labor time, tooling costs, and the potential for assembly errors, resulting in a dispenser that is cheaper and faster to produce.

[0073] At step 904, the method 900 further includes forming at least two openings (e.g., the openings 122, 124) in the support frame.

[0074] At step 906, the method 900 further includes mounting at least one bearing element (e.g., the bearing element 180, 182) in at least one of the openings. In some embodiments, the method 900 further includes mounting two bearing elements in the openings. Mounting bearings in the openings may provide a low-friction, durable interface for the rotatable member. Further, installing bearing elements may ensure that the rotatable member can rotate freely with minimal wear, which may be essential for smooth dispensing and for proper functioning of the tension adjustment device over the lifetime of the dispenser.

[0075] In some embodiments, the method 900 further includes forming at least one barbed or wedge-shaped support plate (e.g., the barbed or wedge-shaped support plate 160) from sheet material. In some embodiments, the method 900 further includes attaching the at least one barbed or wedge-shaped support plate to a rotatable member (e.g., the rotatable member 120) and installing the rotatable member into the at least one bearing element to form a cantilevered support assembly. Further, in some embodiments, the at least one barbed or wedge-shaped support plate includes two barbed or wedge-shaped support plates and attaching the at least one barbed or wedge-shaped support plate to the rotatable member includes attaching the two barbed or wedge-shaped support plates to the rotatable member.

[0076] In some embodiments, the method 900 further includes forming a flat portion (e.g., the flat portion 126) on the rotatable member to permit torque transmission to the at least one barbed or wedge-shaped support plate.

[0077] Furthermore, in some embodiments, the method 900 includes installing a tension adjustment device (e.g., the tension adjustment device 130) aligned to apply resistive force (e.g., the resistive force 150) directly along a rotatable member axis (e.g., the rotatable member axis 128) of the rotatable member.

[0078] FIG. 10 shows a flow chart of a method 1000 of loading a dispenser (e.g., the dispenser 100, shown in FIGS. 1A and 8, respectively) for expanding material (e.g., the material 302 shown in FIGS. 1A-1B), according to an embodiment of the present disclosure.

[0079] Referring to FIGS. 1 and 10, at step 1002, the method 1000 includes sliding a roll (e.g., the roll 300) laterally onto a rotatable member (e.g., the rotatable member 120) such that inner surfaces of the roll engage barbed or wedge-shaped features (e.g., the barbed or wedge-surfaces 162 and the barbed or wedge-shaped features 167) of at least one barbed or wedge-shaped support plate (e.g., the barbed or wedge-shaped support plate 160) or a barbed or wedge-shaped support member (e.g., the barbed or wedge-shaped support member 165).

[0080] At step 1004, the method 1000 further includes retaining the roll on the rotatable member through frictional engagement between the barbed or wedge-shaped features and an inner diameter (e.g., the inner diameter 310) of the roll . In some embodiments, the retaining force prevents the roll from coming off the at least one barbed or wedge-shaped support plate or the barbed or wedge-shaped support member during use without requiring tightening knobs or separate fastening components.

[0081] In some embodiments, the method 1000 further includes loading the roll onto the rotatable member by tilting the dispenser. In some embodiments, after titling the dispenser, the method 1000 includes sliding the roll laterally onto the at least one barbed or wedge-shaped support plate or the barbed or wedge-shaped support member without lifting the roll. Therefore, the roll may be loaded to the dispenser without lifting its full weight. In some cases, the dispenser may be lighter in weight than the roll, as a result the loading of the roll on to the dispenser may be easy and convenient for the user. In some cases, the dispenser may have small footprint and may have good fault tolerance in which the dispenser may tolerate errors in angles, dimensions, sloppy holes, etc. The method 1000 may provide user convenience and safety and make the loading process faster, easier, and ergonomically superior to conventional methods.

[0082] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0083] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Claims

CLAIMS1. A dispenser for expanding material includes:a support frame having a base, an upright portion, a top portion, and a hanging portion, wherein the upright portion connects the base to the top portion, and the top portion connects the upright portion to the hanging portion;a rotatable member supported by the support frame; anda tension adjustment device configured to apply resistive force from the support frame to the rotatable member.

2. The dispenser of claim 1, wherein the rotatable member occupies an opening in each of the upright portion and the hanging portion.

3. The dispenser of claim 1, wherein the tension adjustment device applies resistive force through an opening in the top portion directly onto the rotatable member.

4. The dispenser of claim 1, wherein the support frame is formed from a single piece of material bent to define the base, upright portion, top portion, and hanging portion.

5. The dispenser of claim 1, wherein the support frame includes two openings.

6. The dispenser of claim 1, wherein the tension adjustment device includes a bolt configured to interact in a straight line path with the rotatable member.

7. The dispenser of claim 6, wherein the bolt has a thread count sufficient to permit fine control of resistive force.

8. The dispenser of claim 1, wherein at least one barbed or wedge-shaped support plate is fixed to the rotatable member and configured to engage an inner diameter of a roll of material.

9. The dispenser of claim 8, wherein the roll of material is coreless.

10. The dispenser of claim 8, wherein the at least one barbed or wedge-shaped support plate is laser cut or stamped from sheet metal.

11. The dispenser of claim 8, wherein the at least one barbed or wedge-shaped support plate comprises two barbed or wedge-shaped support plates that are clamped to the rotatable member to define a gripping interface for the roll.

12. The dispenser of claim 8, wherein barbed or wedge surfaces of the at least one barbed or wedge-shaped support plate retain the roll on the rotatable member without requiring tightening knobs or fasteners.

13. The dispenser of claim 1, wherein the tension adjustment device includes a compressive element interacting with a bearing element to provide gradually increasing resistive force.

14. The dispenser of claim 1, wherein the tension adjustment device includes at least one spring element positioned to apply loading force to a spacer contacting the rotatable member.

15. The dispenser of claim 1, wherein the rotatable member includes a flat portion configured to allow torque transmission to the at least one barbed or wedge-shaped support plate while allowing free axial movement.

16. The dispenser of claim 1, wherein the base includes two flat portions with a separation between them to stabilize the dispenser.

17. The dispenser of claim 1, wherein the support frame includes at least one bend that creates a spacing region for the two openings.

18. A method of manufacturing a dispenser for expanding material includes:forming a support frame from a single piece of material by cutting and bending the material to create a base, an upright portion, a top portion, and a hanging portion, wherein the upright portion connects the base to the top portion, and the top portion connects the upright portion to the hanging portion;forming at least two openings in the support frame; andmounting at least one bearing element in at least one of the openings.

19. The method of claim 18, further including mounting two bearing elements in the openings.

20. The method of claim 18, further including:forming at least one barbed or wedge-shaped support plate from sheet material; and attaching the at least one barbed or wedge-shaped support plate to a rotatable member and installing the rotatable member into the at least one bearing element to form a cantilevered support assembly.

21. The method of claim 20, wherein the at least one barbed or wedge-shaped support plate includes two barbed or wedge-shaped support plates and attaching the at least one barbed or wedge-shaped support plate to the rotatable member includes attaching the two barbed or wedge-shaped support plates to the rotatable member.

22. The method of claim 20, further including forming a flat portion on the rotatable member to permit torque transmission to the at least one barbed or wedge-shaped support plate.

23. The method of claim 20, further including installing a tension adjustment device aligned to apply resistive force directly along a rotatable member axis of the rotatable member.

24. A method of loading a dispenser for expanding material includes:sliding a roll laterally onto a rotatable member such that inner surfaces of the roll engage barbed or wedge-shaped features of at least one barbed or wedge-shaped support plate or a barbed or wedge-shaped support member; andretaining the roll on the rotatable member through frictional engagement between the barbed or wedge-shaped features and an inner diameter of the roll.

25. The method of claim 24, wherein the retaining force prevents the roll from coming off the at least one barbed or wedge-shaped support plate or the barbed or wedge-shaped support member during use without requiring tightening knobs or separate fastening components.

26. The method of claim 24, further includes loading the roll onto the rotatable member by:tilting the dispenser; andafter titling the dispenser, sliding the roll laterally onto the at least one barbed or wedge-shaped support plate or the barbed or wedge-shaped support member without lifting the roll.

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