Automatic paper product dispenser with data collection and method

• US 9,604,811 B2
• Filed: 10/01/2013
• Issued: 03/28/2017
• Est. Priority Date: 10/01/2013
• Status: Active Grant

• Current Assignee: GPCP IP Holdings LLC
• Original Assignee: Georgia-Pacific Consumer Products LP (KOCH Industries Incorporated)
• Inventors: Case, Abby Catherine, Gennrich, David James, Woods, Scott A., Schweitzer, Chad Anthony
• Primary Examiner(s): Severson, Jeremy R
• Application Number:
  US14/043,501
• Publication Number:
  US 20150090832A1
• Time in Patent Office: 1,274 Days
• US Class Current: 1/1
• CPC Class Codes: A47K 10/3612 with drive and pinch rollers
• CPC Class Codes: A47K 10/3618 The drive roller pressing against the paper roll
• CPC Class Codes: A47K 10/3625 with electronic control means
• CPC Class Codes: A47K 10/44 with mechanical dispensing means for prehension of the next sheet to be dispensed
• CPC Class Codes: A47K 2010/3226 collecting data of usage
• CPC Class Codes: A47K 2010/3668 Detection of the presence of a user
• CPC Class Codes: B65H 16/005 Dispensers, i.e. machines for unwinding only parts of web roll
• CPC Class Codes: B65H 2220/02 indicating an entity which is controlled, adjusted or changed by a control process, i.e. output
• CPC Class Codes: B65H 2511/11 Length
• CPC Class Codes: B65H 2551/10 Command input means
• CPC Class Codes: B65H 2553/27 Electro mechanical thermal sensors, e.g. thermocouples, pyroelectric sensors, temperature sensitive sensor
• CPC Class Codes: B65H 26/06 responsive to predetermined lengths of webs
• CPC Class Codes: B65H 2701/1924 Napkins or tissues, e.g. dressings, toweling, serviettes, kitchen paper and compresses
• CPC Class Codes: B65H 2801/12 Single-function printing machines, typically table-top machines
• CPC Class Codes: B65H 35/10 from or with devices for breaking partially-cut or perforated webs, e.g. bursters
• CPC Class Codes: B65H 45/142 Pocket-type folders
• CPC Class Codes: G07F 11/045 for sheet shaped or pliable articles
• CPC Class Codes: Y10T 225/321 Preliminary weakener
• CPC Class Codes: Y10T 225/393 Web restrainer

Abstract

Sheet product dispensers and methods are provided. A sheet product dispenser includes a loading station for sheet material, a sheet feeding mechanism configured to feed the sheet material, a presentation station for presenting one or more discrete sheet products to an end user, a sensor downstream of the feeding mechanism and upstream of the presentation station configured to detect a presence of the discrete sheet products, and a controller configured to facilitate dispensing of the one or more discrete sheet products in response to a signal, and to determine and store data associated with the dispensing of the sheet products.

Claims

1. A sheet product dispenser, comprising:

a loading station for loading a roll of sheet material;

a sheet feeding mechanism configured to feed sheet material from the roll;

a presentation station for presenting one or more discrete sheet products of the sheet material to an end user;

a folding station configured for folding the sheet material downstream of the sheet feeding mechanism and prior to presentation at the presentation station;

a sheet product conveying mechanism configured to convey the one or more discrete sheet products to the presentation station;

a separation mechanism for separating the one or more discrete sheet products from the sheet material, the separation mechanism configured to drive the sheet feeding mechanism at a first speed and the sheet product conveying mechanism at a second speed that is higher than the first speed;

a sensor downstream of the sheet feeding mechanism and upstream of the sheet product conveying mechanism, the sensor being configured to detect a presence of the sheet material; and

a controller configured to facilitate dispensing of the one or more discrete sheet products to the presentation station in response to a signal, the controller also being configured to receive and store data comprising data associated with the sensor.

2. The dispenser of claim 1, wherein the sheet product conveying mechanism comprises a pair of pinch rollers.

3. The dispenser of claim 2, wherein the folding station comprises a buckle chamber adjacent to the pair of pinch rollers, such that a portion of the sheet material enters the buckle chamber and a fold in the sheet material is forced through the pair of pinch rollers.

4. The dispenser of claim 1, wherein the sensor is an infrared sensor.

5. The dispenser of claim 1, further comprising a user interface configured to transmit the signal to the controller.

6. The dispenser of claim 5, wherein:

the user interface comprises a hand-wave sensor, and

the controller is configured to facilitate dispensing of a predetermined number of discrete sheet products in response to the signal.

7. The dispenser of claim 6, further comprising an internal rotary switch configured to be set to the predetermined number of discrete sheet products to be dispensed in response to the signal.

8. The dispenser of claim 6, wherein the number of requested discrete sheet products associated with the signal is the predetermined number of discrete sheet products to be dispensed in response to the signal.

9. The dispenser of claim 5, wherein:

the user interface comprises one or more buttons, each button being associated with a predetermined number of discrete sheet products to be dispensed in response to the signal, and

the controller is configured to facilitate dispensing of the predetermined number of discrete sheet products associated with a selected button in response to the signal being transmitted from the selected button.

10. The dispenser of claim 9, wherein the number of requested discrete sheet products associated with the signal is the predetermined number of discrete sheet products to be dispensed from the selected button.

11. The dispenser of claim 1, further comprising a second sensor configured to detect an absence of discrete sheet products at the presentation station, and transmit the signal to the controller upon detection of the absence of discrete sheet products at the presentation station, wherein the controller is configured to facilitate dispensing of a predetermined number of discrete sheet products in response to the signal.

12. The dispenser of claim 11, wherein the number of requested discrete sheet products associated with the signal is the predetermined number of discrete sheet products to be dispensed in response to the signal.

13. The dispenser of claim 11, wherein the data further comprises the time between the discrete sheet products entering the presentation station and the absence of discrete sheet products at the presentation station.

14. The dispenser of claim 1, further comprising a motor operably connected to the controller and configured to drive the sheet feeding mechanism in response to the signal, wherein the data further comprises:

a time at which the motor is turned on, a time at which the motor is turned off, a time between the motor bring turned on and the motor bring turned off, or a combination thereof.

15. The dispenser of claim 14, wherein:

the data comprises a number of requested discrete sheet products associated with the signal and a number of discrete sheet products associated with the sheet material detected by the sensor, and

the controller is configured to compare the number of requested discrete sheet products associated with the signal and the number of discrete sheet products associated with the sheet material detected by the sensor, and turn off the motor when the number of discrete sheet products associated with the sheet material detected by the sensor matches the number of requested discrete sheet products associated with the signal.

16. The dispenser of claim 1, wherein the sheet material is perforated.

17. The dispenser of claim 1, wherein the data is stored in a text line item format.

18. The dispenser of claim 1, wherein the folding station comprises a tucker fold mechanism.

19. The dispenser of claim 1, wherein the sensor is configured to detect a presence of the sheet material at the folding station.

20. A method of dispensing sheet products, comprising:

feeding a sheet material from a roll via a sheet feeding mechanism;

separating one or more discrete sheet products from the roll via a separation mechanism;

folding the sheet material at a folding station downstream of the sheet feeding mechanism;

dispensing the one or more folded discrete sheet products to an end user at a presentation station via a sheet product conveying mechanism, in response to a signal received by a controller;

detecting a presence of the sheet material via a sensor downstream of the sheet feeding mechanism and upstream of the sheet product conveying mechanism; and

collecting and storing data comprising data associated with the sensor,

wherein the separation mechanism is configured to drive the sheet feeding mechanism at a first speed and the sheet product conveying mechanism at a second speed that is higher than the first speed.

21. The method of claim 20, further comprising transmitting the signal to the controller from a user interface.

22. The method of claim 20, further comprising:

detecting an absence of discrete sheet products at the presentation station; and

transmitting the signal to the controller upon detection of the absence of discrete sheet products at the presentation station,

wherein the dispensing comprises dispensing a predetermined number of discrete sheet products in response to the signal.

23. The method of claim 20, wherein folding the one or more discrete sheet products comprises feeding a portion of the sheet material to a buckle chamber adjacent to the sheet product conveying mechanism and forcing a fold in the sheet material through the sheet product conveying mechanism, wherein the sheet product conveying mechanism comprises a pair of pinch rollers.

24. The method of claim 20, wherein the folding station comprises a tucker fold mechanism.

25. The method of claim 20, wherein the sensor is configured to detect a presence of the sheet material at the folding station.

26. A system for dispensing sheet products, comprising:

at least one memory that stores computer-executable instructions; and

at least one controller configured to access the at least one memory, wherein the at least one controller is configured to execute the computer-executable instructions to;

receive, from an interface, a signal indicative of a request for a number of discrete sheet products to be dispensed to an end user at a presentation station via a sheet product conveying mechanism;

direct, in response to receipt of the signal, the feeding of a sheet material from a roll via a sheet feeding mechanism, the separation of one or more discrete sheet products from the roll via a separation mechanism, and the folding of the sheet material at a folding station downstream of the sheet feeding mechanism;

receive, from a sensor downstream of the sheet feeding mechanism and upstream of the sheet product conveying mechanism, a detection indicator indicative of detection of a presence of the sheet material by the sensor;

determine data comprising data associated with the sensor; and

direct the storage, in one or more data stores, of at least a portion of the data,

wherein the separation mechanism is configured to drive the sheet feeding mechanism at a first speed and the sheet product conveying mechanism at a second speed that is higher than the first speed.

27. The system of claim 26, wherein the one or more data stores comprise at least a portion of the at least one memory.

28. The system of claim 26, wherein the at least one controller is configured to execute the computer-executable instructions to direct the storage, in one or more data stores, of at least a portion of the data in a text line item format.

29. The system of claim 26, wherein the interface comprises a user interface configured to transmit the signal, and the number of requested discrete sheet products associated with the signal is a predetermined number of discrete sheet products to be dispensed in response to the signal.

30. The system of claim 26, wherein:

the interface comprises a second sensor configured to detect an absence of discrete sheet products at the presentation station and transmit the signal to the at least one controller upon detection of the absence of discrete sheet products at the presentation station;

the number of requested discrete sheet products associated with the signal is a predetermined number of discrete sheet products to be dispensed in response to the signal; and

the data further comprises a time between the discrete sheet products entering the presentation station and the absence of discrete sheet products at the presentation station.

31. The system of claim 26, wherein:

the at least one controller is configured to execute the computer-executable instructions to direct a motor operably connected to the at least one controller to drive the sheet feeding mechanism in response to the signal; and

the data further comprises;

a time at which the motor is turned on, a time at which the motor is turned off, a time between the motor bring turned on and the motor bring turned off, or a combination thereof.

32. The system of claim 31, wherein:

the data comprises the number of requested discrete sheet products associated with the signal and a number of discrete sheet products associated with the sheet material detected by the sensor; and

the at least one controller is configured is configured to execute the computer-executable instructions to compare the number of requested discrete sheet products associated with the signal and the number of discrete sheet products associated with the sheet material detected by the sensor, and direct stoppage of the motor when the number of discrete sheet products associated with the sheet material detected by the sensor matches the number of requested discrete sheet products associated with the signal.

33. A method for dispensing sheet products, comprising:

receiving from an interface, by at least one controller configured to access at least one memory, a signal indicative of a request for a number of discrete sheet products to be dispensed to an end user at a presentation station via a sheet product conveying mechanism;

directing, by the at least one controller, in response to receipt of the signal, the feeding of a sheet material from a roll via a sheet feeding mechanism, the separating of one or more discrete sheet products from the roll via a separation mechanism, and the folding of the sheet material at a folding station downstream of the sheet feeding mechanism;

receiving, by the at least one controller, from a sensor downstream of the sheet feeding mechanism and upstream of the sheet product conveying mechanism, a detection indicator indicative of detection of a presence of the sheet material by the sensor;

determining, by the at least one controller, data comprising data associated with the sensor; and

directing, by the at least one controller, the storage, in one or more data stores, of at least a portion of the data

wherein the separation mechanism is configured to drive the sheet feeding mechanism at a first speed and the sheet product conveying mechanism at a second speed that is higher than the first speed.

34. The method of claim 33, wherein:

directing the feeding of a sheet material via a sheet feeding mechanism comprises directing a motor operably connected to the at least one controller to drive the sheet feeding mechanism in response to the signal; and

the data further comprises;

a time at which the motor is turned on, a time at which the motor is turned off, a time between the motor bring turned on and the motor bring turned off, or a combination thereof.

35. The method of claim 34, wherein:

the data comprises the number of requested discrete sheet products associated with the signal and a number of discrete sheet products associated with the sheet material detected by the sensor; and

the method further comprises;

comparing, by the at least one controller, the number of requested discrete sheet products associated with the signal and the number of discrete sheet products associated with the sheet material detected by the sensor; and

directing stoppage, by the at least one controller, of the motor when the number of discrete sheet products associated with the sheet material detected by the sensor matches the number of requested discrete sheet products associated with the signal.