End Plug Locking Geometry for Easy Roll Exchange
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Solution Overview
Problem
Existing dispensers for rolls of material, such as tissue paper, face challenges in improving the insertability, locking forces, and exchangeability of end plugs within retention mechanisms, leading to inefficient roll handling and potential misalignment or damage.
Innovation Solution
The design of an end plug with a bearing member featuring varying outer diameters and a locking portion, such as a truncated cone, ring-shaped, stepped, or chamfered structure, which interacts with an inclined locking member in the retention mechanism to provide enhanced insertion, locking, and removal properties, ensuring a secure yet easy exchange of rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a bearing member with varying outer diameters is used, then the insertability of the end plug is improved, but the device complexity increases
Solution Approach 1:
The bearing member is segmented into three distinct portions along its longitudinal axis, each with a different outer diameter. The first portion has a larger diameter for initial engagement, the second portion has a smaller diameter for passing through the retention mechanism, and the third portion has an intermediate diameter for final positioning. This segmentation allows the single bearing member to guide the end plug through different stages of insertion with appropriate clearance at each stage.
Solution Approach 2:
Different sections of the bearing member are given different local qualities in terms of diameter to suit their specific functional requirements. The first portion's larger diameter provides stability during initial insertion, the second portion's smaller diameter enables passage through tight spaces, and the third portion's intermediate diameter ensures proper final positioning. This local differentiation of geometric properties optimizes the insertion process without requiring multiple separate components.
2Force
If a locking portion with extension larger than bearing pin diameters is added, then the locking force is improved, but the device complexity increases
Solution Approach 1:
The locking portion is merged with the bearing member as an integrated structure rather than being a separate component. The locking portion extends radially outward from the bearing member's surface and incorporates locking geometry that engages with corresponding features in the retention mechanism. This merging approach provides enhanced locking force while avoiding the complexity of additional separate locking components.
Solution Approach 2:
The bearing member is designed to serve multiple functions: it provides bearing support for rotation, guides insertion through varying diameters, and provides locking through the integrated locking portion. By combining these functions into a single component, the design achieves strong locking capability without proportionally increasing overall device complexity, as the locking function is added to an existing multi-functional element.
3Ease of operation
If the locking portion is positioned closer to the end face than the second portion, then the exchangeability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The locking portion is positioned on the bearing member such that it engages with the retention mechanism before the final seating of the end plug occurs. This preliminary locking action secures the end plug in place during insertion, preventing misalignment or damage, and facilitates easy exchange by maintaining a secure connection throughout the replacement process. The positioning closer to the end face ensures this preliminary locking happens at the optimal moment in the insertion sequence.
Data Source
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AI summary
The invention relates to an end plug (5) for a roll of material to be inserted into a retention mechanism (1), the end plug comprising: a receiving portion (60) for being inserted in the roll of material, an end face (680) for contacting the retention mechanism and a bearing member (70) for being inserted into the retention mechanism. The bearing member comprises a bearing pin (80) comprising a counter surface (82) facing the end face and at least one locking portion (950) for locking the end plug in an end position (250) in the retention mechanism, the locking portion being positioned within a zone (900) defined by a first surface (90') extending towards the end face from an intersection position (910) with the bearing pin, the first surface being inclined with respect to the longitudinal axis of the bearing pin by an angle of 117 and a second surface (90'') extending towards the end face from the intersection position, the second surface being inclined with respect to the longitudinal axis of the bearing pin by an angle of 141.