Dispenser with automatic stub roll drop down
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Solution Overview
Problem
Existing tissue dispensers face issues with stub rolls being depleted unexpectedly, especially in secured environments, leading to waste and the need for manual intervention to replace rolls, which can be inconvenient or impossible.
Innovation Solution
A dispensing system with a sensor and piston mechanism that detects a threshold roll size, disengaging from the roll support to allow the stub roll to drop automatically, making space for a fresh roll, while maintaining dispensing functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual replacement of stub rolls is required, then roll replacement can be controlled, but user convenience deteriorates and manual intervention increases
Solution Approach 1:
The dispenser system performs self-service by automatically detecting when a stub roll needs replacement and executing the replacement process without human intervention. The sensor detects stub roll conditions, triggers the ejection mechanism, and prepares the dispenser for new roll installation automatically.
Solution Approach 2:
The system performs preliminary actions by ejecting the stub roll before it is completely depleted, creating space in advance for the next roll. This prevents the harmful effect of complete depletion and ensures continuous operation readiness.
2Loss of substance
If stub rolls are kept in the dispenser, then material waste is reduced, but space for fresh rolls deteriorates and manual removal is required
Solution Approach 1:
The sensor detects when a stub roll reaches a predetermined size threshold and triggers ejection before the roll is completely depleted. This preliminary action preserves remaining material for continued use while proactively creating space for the next roll.
Solution Approach 2:
The ejection mechanism extracts the stub roll from the dispenser interior and moves it to an exterior storage position. This separates the depleted roll from the active dispensing space, maintaining space availability for fresh rolls.
3Extent of automation
If automatic stub roll ejection is implemented, then manual intervention is reduced, but device complexity increases
Solution Approach 1:
A sensor acts as an intermediary between the stub roll and the control system, detecting roll conditions and triggering ejection automatically. This intermediary component enables automation while keeping the control logic simple and manageable.
Solution Approach 2:
The dispenser system is segmented into functional modules: sensor detection module, control module, and ejection mechanism. This segmentation allows each component to perform its specific function independently, simplifying the overall system design and maintenance.
4Reliability
If locked dispenser is used for security, then theft prevention is improved, but maintenance access deteriorates
Solution Approach 1:
The automatic ejection system performs preliminary action by removing stub rolls before maintenance personnel need to access the dispenser. This eliminates the need for maintenance staff to open the locked dispenser for roll replacement, maintaining both security and ease of maintenance.
Solution Approach 2:
The dispenser performs self-service maintenance by automatically managing stub roll ejection and creating space for new rolls. This eliminates the need for human intervention in routine roll replacement, allowing the locked dispenser to remain secure while still functioning properly.
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
Enables efficient use of remaining stub roll material and reduces manual intervention by automatically making space for a fresh roll, ensuring continuous operation and minimizing waste.
Implementation Method 1
The sensor moves as the roll decreases in size (e.g., the outside diameter decreases) and applies a force to the roll
Implementation Method 2
Due to an operational connection of the sensor and piston, the movement of the sensor causes the piston to move too
Implementation Method 3
the roll (now a stub roll) automatically dropping, such as at least partly by force of gravity, from a main position to a secondary position
Data Source
Figure 1
Figure 2~5
Figure 6A~6B
AI summary
Various dispensing systems with drop-down features are disclosed. In certain embodiments, the dispensing system includes a roll support with a sensor and a piston. The sensor can move as the roll decreases in size (e.g., the outside diameter decreases) and can apply a force to the roll. The piston can move to become less engaged with the roll, such as becoming less received in a roll plug or the hollow core of the roll. When the roll has decreased to a threshold size, the piston substantially or fully disengages from the roll and/or the sensor applies a force to dislodge the roll from the roll support. This results in the roll automatically dropping off the roll support. The roll support is thus available to receive a fresh roll.