Dispenser with Drop Down Feature and Method
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Solution Overview
Problem
Existing dispensers for sheet materials require manual intervention for replacing empty rolls and loading new ones, leading to waste and inefficiency in maintenance, especially in large facilities.
Innovation Solution
A dispenser mechanism with a cradle device, abutment devices, and a transfer assembly that allows rolls to drop automatically as they deplete, enabling continuous dispensing and easy loading of new rolls without manual manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual servicing is used to replace empty rolls and load new ones, then maintenance personnel can service the dispensers, but time and effort are wasted and product is discarded before complete exhaustion
Solution Approach 1:
The dispenser mechanism automatically performs the function of replacing empty rolls and loading new ones without human intervention. The system uses gravity and mechanical components (cradle device, abutment devices, transfer assembly) to self-service the roll replacement function, eliminating the need for manual servicing and significantly improving maintenance efficiency while reducing time loss
Solution Approach 2:
The cradle device is pre-configured with abutment devices positioned to support the roll at specific locations. The transfer assembly is pre-positioned to automatically engage and transfer rolls when they become empty. This preliminary arrangement of components enables automatic roll replacement without requiring manual intervention or complex real-time control
2Ease of operation
If manual roll replacement is performed, then empty cores can be removed and new rolls loaded, but threading the leading edge is complex and prone to user error
Solution Approach 1:
The transfer assembly automatically performs the threading function by engaging the leading edge of the new roll and guiding it through the dispensing mechanism. The system self-services the complex threading operation that would otherwise require manual user intervention, making the loading process simple and error-proof while maintaining the necessary mechanical complexity internally
3Reliability
If janitors change products before dispensers are empty, then they avoid running out of products, but significant product waste occurs
Solution Approach 1:
The automatic roll replacement system continuously monitors and maintains product availability by automatically transferring rolls when they become empty. This eliminates the need for conservative early replacement strategies, allowing the system to reliably dispense products until the very last moment while preventing any waste from premature replacement
Solution Approach 2:
The system provides continuous feedback through the mechanical interaction between the cradle device, abutment devices, and transfer assembly. When a roll becomes empty, the change in weight distribution and mechanical engagement automatically triggers the transfer mechanism, creating a feedback loop that ensures product availability without waste
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates quick and efficient replacement of empty rolls and loading of new ones, reducing waste and maintenance time, ensuring uninterrupted dispensing.
Implementation Method 1
the diameter of the roll of sheet material reduces until the roll has a size that permits the roll to drop between the cradle device and the abutment devices and onto the collection device
Data Source
AI summary
A dispenser is disclosed that facilitates loading of new rolls of material and the removal of empty cores. The dispenser includes a cradle roller spaced from a pair of abutment rollers. As a roll of material is dispensed, the diameter of the roll reduces causing the roll to drop from the cradle roller to a collection device. A transfer assembly pivots with the roll so that the sheet material continues to be dispensed from the dispenser without interruption. Once the roll of material drops to the collection device, a new roll of material can be loaded into the dispenser for automatic transfer to the new roll once the first roll of material has been completely depleted.