U.S. patent application number 13/537344 was filed with the patent office on 2014-01-02 for electronic towel dispenser with additional power saving mode.
The applicant listed for this patent is Geoffrey Engelstein, John O'Connor, Paul F. Tramontina. Invention is credited to Geoffrey Engelstein, John O'Connor, Paul F. Tramontina.
Application Number | 20140001303 13/537344 |
Document ID | / |
Family ID | 49123874 |
Filed Date | 2014-01-02 |
United States Patent
Application |
20140001303 |
Kind Code |
A1 |
Tramontina; Paul F. ; et
al. |
January 2, 2014 |
Electronic Towel Dispenser With Additional Power Saving Mode
Abstract
A hands-free towel dispenser includes a housing having an
internal volume that may contain at least one roll of towel
material. Within the dispenser a dispensing mechanism is in
communication with a sensor system which scans for the presence of
a user at a first pulse rate and initiates a dispense cycle upon
sensing a user. The sensor system is in electrical communication
with a control circuit which determines the time that has elapsed
from the last dispense cycle and compare the elapsed time with a
preset value. If the elapsed time is greater than the preset value,
the control circuit configures the sensor system to scan for the
presence of a user at a second pulse rate. Upon detecting a user,
the control circuit initiates a dispense cycle and sets the sensor
system to scan for the presence of a user at the first pulse
rate.
Inventors: |
Tramontina; Paul F.;
(Harleysville, PA) ; Engelstein; Geoffrey;
(Bridgewater, NJ) ; O'Connor; John; (Roselle Park,
NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tramontina; Paul F.
Engelstein; Geoffrey
O'Connor; John |
Harleysville
Bridgewater
Roselle Park |
PA
NJ
NJ |
US
US
US |
|
|
Family ID: |
49123874 |
Appl. No.: |
13/537344 |
Filed: |
June 29, 2012 |
Current U.S.
Class: |
242/563.2 |
Current CPC
Class: |
A47K 10/36 20130101;
A47K 2010/3668 20130101 |
Class at
Publication: |
242/563.2 |
International
Class: |
B65H 26/06 20060101
B65H026/06 |
Claims
1. A hands-free towel dispenser for dispensing a measured sheet
from a roll of web material, the dispenser comprising: a housing
having an internal volume so as to retain at least one roll of web
material therein; an electronically powered dispensing mechanism
contained within the housing for dispensing a measured sheet from
the roll of web material in a dispense cycle upon actuation of the
dispensing mechanism; and a sensor system in communication with the
dispensing mechanism, the sensor system adapted to scan for the
presence of a user at a first pulse rate and to initiate a dispense
cycle upon sensing the presence of a user, the sensor system having
at least one sensor in electrical communication with a control
circuit, wherein the control circuit is configured to determine the
time that has elapsed from the last dispense cycle and compare such
elapsed time with a preset value, wherein if the elapsed time is
greater than the preset value, the control circuit is configured to
scan for the presence of a user at a second pulse rate and, upon
detecting the presence of a user, the control circuit initiates a
dispense cycle and sets the sensor system to scan for the presence
of a user at the first pulse rate.
2. The dispenser of claim 1, wherein the sensor system includes an
infrared emitter and detector which is capable of emitting at a
first pulse rate and a second pulse rate.
3. The dispenser of claim 1 wherein the first pulse rate is higher
than the second pulse rate.
4. The dispenser of claim 1, wherein the first pulse rate is lower
than the second pulse rate.
5. The dispenser of claim 1, wherein the first pulse rate is six
times per second.
6. The dispenser of claim 1, wherein the second pulse rate is three
times per second.
7. The dispenser of claim 1, wherein the preset value is one
hour.
8. A method of operation for an electronic hands-free paper towel
dispenser to dispense a sheet of web material, comprising
initiating a dispense cycle upon detection of a user and scanning
for the presence of a user with a sensor at a first pulse rate;
determining the time that has elapsed from the last dispense cycle
and comparing the elapsed time with a preset value; and setting the
sensor to scan at a second pulse rate if the elapsed time is
greater than the preset value.
9. The method of claim 8 wherein the sensor is an infrared sensor
having an emitter and detector.
10. The method of claim 8 wherein the preset value is one hour.
11. The method of claim 8 wherein the first pulse rate is higher
than the second pulse rate.
12. The method of claim 8, wherein the first pulse rate is six
times per second.
13. The method of claim 8, wherein the second pulse rate is three
times per second.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
"hands-free" electronic dispensers that automatically dispense a
measured length of towel material.
BACKGROUND OF THE INVENTION
[0002] Electronic towel dispensers are well known in the art,
including dispensers that automatically dispense a metered length
of towel material upon sensing the presence of a user. This type of
dispenser has become known in the art as a "hands-free" dispenser
in that it is not necessary for the user to manually actuate or
otherwise handle the dispenser to initiate a dispense cycle. The
control systems and mechanical aspects of conventional hands-free
dispensers are wide and varied.
[0003] Electronic dispensers are known that use an active detection
systems, and generally include an active transmitter and receiver
combination to detect the presence of a user within an active
detection zone. Typical systems may include radio frequency (RF),
infrared (IR) sensors, or the like. For example, U.S. Pat. No.
6,695,246 describes an electronic dispenser utilizing an active IR
sensing system. Additionally, U.S. Pat. No. 7,523,885 describes the
use of active and passive detectors, and is hereby incorporated in
its entirety for all purposes.
[0004] Many electronic towel dispensers rely on battery power as a
primary power source. Accordingly, conservation of battery power is
an important concern. While efforts have been made to reduce the
consumption of battery power in dispensers utilizing active sensing
systems, there remains an opportunity to reduce power consumption
in dispensers. The present invention relates to an improvement in
dispensers that may be used to improve battery life.
SUMMARY OF THE INVENTION
[0005] An electronic hands-free towel dispenser is provided for
automatically dispensing a measured sheet of web material upon
detection of an object placed within a defined detection zone. The
dispenser may be battery powered, AC powered (with an appropriate
transformer and adapter), or capable of being switched between
battery power and AC power.
[0006] The dispenser includes a housing having an internal volume
so as to retain at least one roll of towel material therein, and
may include a main roll and a stub roll. The housing may take on
any desirable configuration, and may include a back member and
removable cover member. The cover member may be hinged relative to
the back member to provide access to the interior volume and
components of the dispenser.
[0007] The dispenser includes an electronically powered dispensing
mechanism contained within the housing for automatically dispensing
the measured sheet from the roll of towel material upon a valid
detection of an object in the detection zone. Numerous
configurations of electrically driven dispensing mechanisms are
known in the art and may be configured for use with the present
dispenser. The mechanism may include a drive roller and associated
components, a pressure roll assembly, and a tear bar. The pressure
roll assembly includes a pressure roll biased against the drive
roller, the towel material passing between the pressure roll and
drive roller. An opening for the towel material is defined in the
module and aligns with a dispensing opening in the housing.
[0008] The dispensing mechanism dispenses a measured length or
sheet of the web material, which may be accomplished by various
means, such as a timing circuit that stops the drive roller after a
predetermined time.
[0009] The drive mechanism may include a drive motor and gear
assembly mounted in the module, the gear assembly transmitting
motive force from the motor to the drive roller. The web material
passes through the nip defined by the drive roller and pressure
roller such that rotation of the drive roller causes the material
to be advanced out through the dispensing throat of the housing. A
tear bar is disposed in the throat so that a user can separate a
sheet of the material by grasping and pulling the sheet across the
tear bar. In an alternative embodiment, an automatic cutting device
may be provided to automatically cut the sheet of material.
[0010] The sensor may be any one or combination of well-known
active sensing systems, such as an IR or RF system that actively
transmits a signal into a detection zone and receives a return
signal that indicates that an object is within the detection
zone.
[0011] The dispenser housing may include a dispensing throat in a
bottom portion thereof through which the web material is dispensed,
with the sensor comprising at least one transmitter and a receiver
oriented within the housing adjacent to the dispensing throat to
transmit a signal in a transmission zone that defines the detection
zone below the housing. The transmitter and receiver may be
oriented with respect to the throat such that a sheet of the web
material hanging out of the dispensing throat disrupts detection of
an object within the detection zone. Thus, a sheet that is
dispensed for one user but left hanging from the dispenser must be
removed by a subsequent user before the system is enabled for a
subsequent dispense sequence.
[0012] It should be appreciated that the dispenser is not limited
to any particular style, configuration, or intended type of web
material. For example, the dispenser may be a towel dispenser,
toilet tissue dispenser, or any other sheet material dispenser.
[0013] Various methods for operation of an electronic dispenser
incorporating such a sensor are also within the scope and spirit of
the invention. The invention will be described in greater detail
below by reference to particular embodiments illustrated in the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of an embodiment of an
electronic dispenser according to the invention;
[0015] FIG. 2 is a perspective view of the dispenser of FIG. 1 with
the front cover in its open position;
[0016] FIG. 3 is a perspective view of a removable module unit that
may be utilized with the dispenser of FIG. 1;
[0017] FIG. 4 is a side view of the dispenser of FIG. 1; and
[0018] FIG. 5 is a side diagrammatic view illustrating aspects of a
sensor and associated detection zone under the dispenser
housing.
DETAILED DESCRIPTION
[0019] Reference will now be made in detail to embodiments of the
invention, one or more examples of which are illustrated in the
drawings. Each example is provided by way of explanation of the
invention, and not meant as a limitation of the invention. For
example, features illustrated or described as part of one
embodiment, may be used with another embodiment, to yield still a
further embodiment. It is intended that the present invention
include modifications and variations to the embodiments described
herein.
[0020] Referring to FIGS. 1 through 5, an embodiment of a dispenser
10 according to the invention is illustrated. The dispenser 10
includes a housing 16 of any desired shape and configuration. The
housing 16 shown in FIG. 1 includes a base 18 and a cover 22
pivotally mounted on the base 18 so as to be movable from the
closed position illustrated in FIG. 1 to the open position
illustrated in FIG. 2. The cover 22 includes a front wall 23 and
sidewalls 27 that align with sidewalls 20 of the base 18 to define
an interior volume for housing the operational components of the
dispenser 10. A roll or rolls of web material such as a main roll
12 and a stub roll 14 that are to be dispensed are also included in
the interior volume of the housing. Any conventional locking
mechanism 21 (FIG. 2) may be provided to secure the cover 22 to the
base 18. The housing 16 includes a bottom underside portion 25 with
a throat 24 from which the material is dispensed.
[0021] The dispenser configuration 10 illustrated in FIGS. 1 and 2
is merely exemplary of any number of electronic dispenser
configurations known to those skilled in the art that may
incorporate the power saving features and method in accordance with
the invention. As such, a detailed explanation of the structural
and control features of the dispenser 10 are not necessary for
purposes of explanation of the invention, and will only be
discussed briefly below.
[0022] The operational components of the dispenser 10 may be
mounted directly onto the base 18 within the interior volume of the
housing 16. In an alternative embodiment, a dispensing module 28
(FIG. 3) is received in the housing 16, as seen in FIG. 2, and the
operational components are mounted within the module 28. The module
28 may be readily removable from the base 18 for servicing and/or
replacing components without the necessity of having to remove the
entire dispenser 10 from its support surface (i.e., wall). The
housing 16 may be considered as a shell into which the module 28 of
FIG. 3 is inserted and removed. The module 28 includes a frame or
chassis 32 having left and right side plates 34. Within the module
28 between the side plates 34 are mounted the components of the
dispensing mechanism 30, which may include, for example, a pressure
roller assembly with a pressure roller 46, a transfer mechanism
that may include a transfer bar 52, a throat assembly 50 that
defines the throat 24 and includes a tear bar 44, a drive motor and
gear assembly (not visible) that rotates drive roller 38, and
control circuitry housed within a circuit housing 68.
[0023] Left and right main roll holders 60 are attached to the
module side plates 34, as seen in FIG. 3, and hold the main roll 12
of sheet material. Stub roll holders 62 are provided for rotatably
supporting the stub roll 14 in the position within the module below
and rearward of the main roll 12. It should be understood that a
dispenser according to the invention need not be configured to
dispense from a stub roll, and thus would not need a transfer
mechanism. The dispenser may be configured for dispensing from a
single roll of web material.
[0024] The pressure roller assembly with pressure roller 46 may be
housed in the throat assembly 50 that is, in turn, mounted within
the module 28. The throat assembly 50 includes a frame that may be
fixed in position within the module, or pivotally mounted to the
module 28 to facilitate loading of new rolls of web material. The
cutting or "tear" bar 44 within the throat assembly 50 is disposed
along the dispensing path of the web material upstream of the
dispensing opening 24 and downstream of the nip between a drive
roller 38 and pressure roller 46. To separate a sheet of the web
material that has been dispensed from the dispenser 10, a user
grasps the sheet hanging from beneath the bottom portion 25 of the
housing 16 and pulls the sheet against the tear bar 44 such that
the sheet tears and separates along the line defined by the tear
bar 44.
[0025] The pressure roller 46 is spring biased against the drive
roller 38 such that the web material passing between the nip of the
rollers is advanced along the dispensing path upon rotation of the
drive roller 38. The throat assembly 50 defines a portion of the
dispensing path and the forward portion of the dispensing throat
24.
[0026] The module 28 may include an automatic transfer mechanism to
transfer dispensing of the web material from the stub roll 14 to a
main roll 12 when the web material on the stub roll 14 is nearly
fully depleted. From an operational standpoint, this transfer
mechanism can operate substantially as described in U.S. Pat. No.
6,079,305 issued on Jun. 27, 2000, with the '305 patent
incorporated herein in its entirety for all purposes. Referring to
FIGS. 2 and 3, the transfer mechanism may include a transfer bar 52
with arms pivotally mounted to the module side plates 34 through
gearing 56. The transfer bar 52 includes a "roller" section that
may be defined by a central curved ribbed section 54. The section
54 includes a securing mechanism, such as a barb, so that the
leading end of the web material from the main roll 12 passes over
the roller section 54 and is held by the barb while material is
feed from the stub roll 14. A stub roll sensing bar 58 is pivotally
mounted to the module side plates 34 below stub roll holders 62,
and is biased towards the axis of the stub roll holders 62 so as to
track the decreasing diameter of the stub roll as it is depleted.
The stub roll sensing bar 58 is configured with the gearing 56 that
rotates upon pivotal movement of the sensing bar 58. As the stub
roll is depleted, motion of the sensing bar 58 is transferred to
the transfer bar 52 via the gearing 56. At a certain decreased
diameter of the stub roll 14, the transfer bar 52 rotates to a
position such that the leading end of the web material held by the
bar 52 is brought by the roller section 54 into contact with the
web material being dispensed from the stub roll causing the leading
edge of the material from the main roll to be pulled from the bar
52 and conveyed with the material from the stub roll between the
nip of the drive roller 38 and pressure roller 46. The "new" web
material from the main roll 12 is dispensed simultaneously with the
stub roll material until the stub roll is completely depleted. If
no stub roll is present in the dispenser, the transfer bar 52 and
roller section 54 contact against the web material dispensed from
the main roll 12.
[0027] A spring biased "fuel gauge" bar 64 may be pivotally affixed
to the side plates 34 and biased towards the center of the main
roll 12 such that it tracks with the decreasing diameter of the
main roll 12 as the web material is depleted. This bar 64 may be
biased against the front side (as depicted in the figures) or the
rear side of the main roll 12. When the main roll 12 reaches a
diameter suitable for moving the roll to the stub roll position, a
pawl (not visible) on the end of one of the arms of the bar 64
causes a switch in the control circuitry to close and activate an
LED on the indicator plate 70. In this way, maintenance personnel
are alerted that the main roll 12 is depleted and should be
replaced.
[0028] A drive motor and gear assembly includes components mounted
in the module 28, for example in a space under and behind the drive
roller 38. The motor includes a drive shaft and a drive gear
attached thereto that engages the shaft of the drive roller 38.
Thus, upon energizing the motor, the drive roller 38 is caused to
rotate, which results in conveyance of the web material disposed in
the nip between the pressure roller 46 and drive roller 38 along
the conveying path and out of the dispensing throat 24.
[0029] The dispensing mechanism may be powered by batteries
contained in battery compartment 66 that is rearward of the stub
roll holders 62 (see FIG. 3). Any suitable battery storage device
or location may be used for this purpose. A conductor may be
disposed below the battery compartment that mates with contacts on
the underside of the battery compartment 66 for delivering power
from the batteries to the circuitry and the drive motor.
Alternatively, or in addition to battery power, the dispenser may
also be powered by a building's AC distribution system. The control
circuitry may include a mechanical or electrical switch that
isolates the battery circuit upon connecting the AC adapter in
order to protect and preserve the batteries.
[0030] The control circuitry also controls the length of web
material dispensed. Any number of optical or mechanical devices may
be used in this regard. In the illustrated embodiment of the
dispenser 10, an optical encoder may be used to count the
revolutions of the drive roller 38. The number of revolutions may
be used used by the control circuitry to meter the desired length
of the sheet dispensed. Other systems may track the running time of
the motor as the control variable, or detect perforations in the
web material, and so forth.
[0031] A variety of sensor systems may be utilized with the present
invention. Each such system must have at least one sensor which
causes the control circuitry to dispense a length of web material
when the sensor detects the presence of a user.
[0032] The sensor 80 is depicted in the illustrated embodiments as
one or more transmitters and associated receiver that define a
detection zone A. This active system may be any one or combination
of well-known active sensing systems, such as an RF or IR sensing
system. The transmitters emit an IR beam into the detection zone A,
and the receiver detects IR light reflected from an object in the
detection zone A. If the amount of reflected light is sufficient
(above a detection threshold value), the circuitry controller
initiates a dispense cycle wherein the motor drives the drive
roller 38 until the correct length of material has been dispensed.
The user then grasps the dispensed sheet and pulls it forward to
tear the sheet against the tear bar 44.
[0033] The IR transmitters and receivers may be mounted on a sensor
board (not shown) within the housing. Openings defined in the
housing through which the transmitters may actively transmit. The
transmitters and receiver are in electrical communication with the
control circuitry within the housing, and the transmitters
continuously transmit at a pulse rate that is dictated by the
control circuitry. Preferably, the control circuitry is a
microprocessor.
[0034] The dispenser of the present invention includes a sensor
system that can scan for the presence of a user at varying rates.
During times when usage of the dispenser is high, the sensor system
may actively scan at a high rate to enable delivery of a towel
without any perceived delay on the part of the user. During times
when the dispenser usage is low, such as during night or other
off-peak hours, the sensor system may actively scan at a lower rate
to conserve power while still enabling a towel to be delivered in a
timely manner to the user.
[0035] The control circuitry can be configured to enable the
dispenser to vary the rate at which the sensor system scans for the
presence of a user. Specifically, the control circuitry may be
configured to determine the time that has elapsed from the last
dispense cycle and compare that elapsed time with a preset value.
If the elapsed time is greater than the preset value, the control
circuit may cause the sensor system to scan for the presence of a
user at a second pulse rate. In some embodiments, the second pulse
rate will be lower than the first pulse rate which will reduce the
power consumed by the dispenser. In instances where the dispenser
is used only during normal business hours, the power consumed could
be reduced by 50%. In other embodiments, it may be desirable to set
the second pulse rate higher than the first pulse rate. While
scanning using the second pulse rate, the dispenser will initiate a
dispense cycle when a user is detected. Additionally, the control
circuit will reset the sensor system to scan for the presence of a
user at the first pulse rate once a dispense cycle has been
initiated.
[0036] While many sensor systems are suitable for use with the
present invention, sensor systems which use infrared emitters and
detectors are well-suited for use in the present invention. The
rate at which the emitters emit can be adjusted by control
circuitry to reduce the power consumed by the dispenser during
times of low usage. For example, the sensor system may be
configured so that the first pulse rate is set at six IR pulses per
second, and the second pulse rate is three IR pulses per second.
However, other pulse rates may be used to accommodate specific user
and dispenser requirements.
[0037] FIGS. 4 and 5 illustrate possible locations and angular
orientation of the IR transmitters 84 within the area of throat 24.
In the embodiment of FIG. 4, the sensor 80 and detection zone A are
shown. In the embodiment depicted in FIG. 5, the transmitters 84
are mounted adjacent to the front wall of the dispensing throat 24
and are angled towards the rear of the dispenser. The angle of the
transmitters may vary widely, depending on the particular
configuration of the dispenser and mounting configurations. In
selected embodiments, this angle may be, for example, 15 degrees.
With this configuration, a user must purposefully place their hand
or other object below the housing 16 and towards the back of the
housing in order to be "detected" and initiate a dispense
cycle.
[0038] It may also be desirable to provide the dispenser 10 with
the capability to prevent a subsequent dispensing cycle if a sheet
of material has been dispensed but not removed. A separate "hanging
sheet" detector may be provided and integrated with the control
circuitry for this purpose. However, in the illustrated embodiment,
the IR detection sensor configuration also serves this purpose.
Referring to FIG. 5, a hanging sheet of material is represented by
86. This sheet 86 substantially blocks the transmission of the
active IR signal from the transmitters into the detection zone A.
The web material itself does not adequately reflect the IR signal
to the receiver so that the hanging sheet does not generate a valid
detection signal. Thus, an object placed into the detection zone A
while a sheet is hanging is not likely to cause a dispensing cycle
until the hanging sheet has been removed or is purposefully pushed
out of the detection zone A.
[0039] Various control circuits and component arrays may be
configured by those skilled in the art to accomplish the desired
features of the system of the present invention.
[0040] It should be appreciated by those skilled in the art that
various modifications and variations may be made to features of the
dispenser described herein, particularly to the mechanical and
control circuitry aspects of the dispenser, without departing from
the scope and spirit of the invention. It is intended that the
invention include all such variations.
* * * * *