Waste minimizing paper dispenser

BACKGROUND OF THE INVENTION

P-0001[0001] 1. Field of the Invention

P-0002[0002] The field of the present invention is paper dispensers. In particular dispensers which dispense paper stored on rolls.

P-0003[0003] 2. Priority

P-0004[0004] The present application is a continuation of U.S. patent application Ser. No. 09/780,733, now U.S. Pat. No. ______, the disclosure of which is incorporated herein by reference.

P-0005[0005] 3. Background

P-0006[0006] As is readily apparent, a long-standing problem is to keep paper towels available in a dispenser and at the same time use up each roll as completely as possible to avoid paper waste. As part of this system, one ought to keep in mind the person who refills the towel dispenser. An optimal solution would make it as easy as possible and as “fool-proof” as possible to operate the towel refill system and have it operate in such a manner as the least amount of waste of paper towel occurs. This waste may take the form of “stub” rolls of paper towel not being used up.

P-0007[0007] Transfer devices are used on some roll towel dispensers as a means of reducing waste and decreasing operating costs. These transfer devices work in a variety of ways. The more efficient of these devices automatically begin feeding from a reserve roll once the initial roll is exhausted. These devices eliminate the waste caused by a maintenance person when replacing small rolls with fresh rolls in an effort to prevent the dispenser from running out of paper. These transfer devices, however, tend to be difficult to load and/or to operate. Consequently, these transfer devices are less frequently used, even though they are present.

P-0008[0008] The current transfer bar mechanisms tend to require the maintenance person to remove any unwanted core tube(s), remove the initial partial roll from the reserve position, and position the initial partial roll into the now vacant stub roll position. This procedure is relatively long and difficult, partly because the stub roll positions in these current paper towel dispensers tend to be cramped and difficult to get to.

P-0009[0009] In order to keep a roll available in the dispenser, it is necessary to provide for a refill before the roll is used up. This factor generally requires that a “refill” be done before the current paper towel roll is used up. If the person refilling the dispenser comes too late, the paper towel roll will be used up. If the refill occurs too soon, the amount of paper towel in the almost used-up roll, the “stub” roll, will be wasted unless there is a method and a mechanism for using up the stub roll even though the dispenser has been refilled. Another issue exists, as to the ease in which the new refill roll is added to the paper towel dispenser. The goal is to bring “on-stream” the new refill roll as the last of the stub roll towel is being used up. If it is a task easily done by the person replenishing the dispensers, then a higher probability exists that the stub roll paper towel will actually be used up and also that a refill roll be placed into service before the stub roll has entirely been used up. It would be extremely desirable to have a paper towel dispenser which tended to minimize paper wastage by operating in a nearly “fool proof” manner with respect to refilling and using up the stub roll.

P-0010[0010] As an enhancement and further development of a system for delivering paper towel to the end user in as cost effective manner and in a user-friendly manner as possible, an automatic means for dispensing the paper towel is desirable, making it unnecessary for a user to physically touch a knob or a lever.

SUMMARY OF THE INVENTION

P-0011[0011] The present invention is directed towards a waste minimizing paper dispenser. A rotatable carriage includes first and second roll holders adapted to hold first and second rolls of paper, respectively. The carriage is rotatable between first and second orientations. In the first orientation, the first roll of paper is held in a primary position and the second roll of paper is held in a secondary position. In the second orientation, the first roll of paper is held in a secondary position and the second roll of paper is held in the primary position. Paper from at least one of the two rolls is fed into a feed mechanism for dispensation. A roll sensor detects the amount of paper on the roll held in the primary position. Paper on the roll held in the secondary position is held in a transfer mechanism. When the paper on the roll held in the primary position is reduced to less than a predetermined diameter, the transfer mechanism feeds paper from the roll held in the secondary position into the feed mechanism. Thereafter, paper from both rolls is dispensed until one of the two rolls is exhausted.

P-0012[0012] During operation, when the roll held in the primary position is exhausted, the carriage may be rotated to move the roll held in the secondary position into primary position. Alternatively, the carriage in a smaller dispenser may be adapted to rotate the roll held in the secondary position into the primary position when that roll is depleted to less than a predetermined diameter.

P-0013[0013] Accordingly, it is an object of the present invention to provide an improved paper towel dispenser. Other objects and advantages will appear hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

P-0014[0014] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, wherein like reference numerals refer to similar components:

P-0015[0015]FIG. 1 is a side elevation of the dispenser with the cover closed, with no internal mechanisms visible;

P-0016[0016]FIG. 2 is a perspective view of the dispenser with the cover closed, with no internal mechanisms visible;

P-0017[0017]FIG. 3 shows a view of the carousel support, the locking bar and the transfer bar;

P-0018[0018]FIG. 4A is a perspective view of the of the dispenser with the carousel and transfer bar, fully loaded with a main roll and a stub roll;

P-0019[0019]FIG. 4B is a side view of the locking bar showing the placement of the compression springs;

P-0020[0020]FIG. 4C shows the locking mechanism where the locking bar closest to the rear of the casing is adapted to fit into a mating structure in the rear casing;

P-0021[0021]FIG. 5 is a perspective, exploded view of the carousel assembly;

P-0022[0022]FIG. 6A is a side elevation view of the paper feeding from the stub roll while the tail of the main roll is positioned beneath the transfer bar;

P-0023[0023]FIG. 6B is a side elevation view of the stub roll is completely exhausted, so that the transfer bar tucks the tail of the main roll into the feed mechanism;

P-0024[0024]FIG. 7A is a side elevation view of the carousel ready for loading when the main roll reaches a specific diameter;

P-0025[0025]FIG. 7B is a side elevation view of the locking bar being pulled forwardly to allow the carousel to rotate 180°, placing the main roll in the previous stub roll position;

P-0026[0026]FIG. 7C shows the extension springs which tend to maintain the transfer bar legs in contact with the stub roll;

P-0027[0027]FIG. 7D shows the cleanable floor of the dispenser;

P-0028[0028]FIG. 8A shows a schematic of the proximity circuit;

P-0029[0029]FIG. 8B (prior art) shows the schematic for the National Semiconductor dual comparator LM<b>393</b>;

P-0030[0030]FIG. 9A shows the square wave output at U<b>1</b>A, pin <b>1</b>;

P-0031[0031]FIG. 9B shows the RC exponential waveforms at pins <b>5</b>; and

P-0032[0032]FIG. 9C shows the RC exponential waveforms at pin <b>6</b>.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

P-0033[0033] The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is merely made for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.

P-0034[0034] An embodiment of the invention comprises a carousel-based dispensing system with a transfer bar for paper towels, which acts to minimize actual wastage of paper towels. As an enhancement and further development of a system for delivering paper towel to the end user in a cost effective manner and in as user-friendly manner as possible, an automatic means for dispensing the paper towel is desirable, making it unnecessary for a user to physically touch a knob or a lever. An electronic proximity sensor is included as part of the paper towel dispenser. A person can approach the paper towel dispenser, extend his or her hand, and have the proximity sensor detect the presence of the hand. The embodiment of the invention as shown here, is a system, which advantageously uses a minimal number of parts for both the mechanical structure and for the electronic unit. It has, therefore, an enhanced reliability and maintainability, both of which contribute to cost effectiveness.

P-0035[0035] An embodiment of the invention comprises a carousel-based dispensing system with a transfer bar for paper towels, which acts to minimize actual wastage of paper towels. The transfer bar coupled with the carousel system is easy to load by a service person; consequently it will tend to be used, allowing stub rolls to be fully utilized. In summary, the carousel assembly-transfer bar comprises two components, a carousel assembly and a transfer bar. The carousel rotates a used-up stub roll to an up position where it can easily be replaced with a full roll. At the same time the former main roll which has been used up such that its diameter is less than some p inches, where p is a rational number, is rotated down into the stub roll position. The tail of the new main roll in the upper position is tucked under the “bar” part of the transfer bar. As the stub roll is used up, the transfer bar moves down under spring loading until the tail of the main roll is engaged between the feed roller and the nib roller. The carousel assembly is symmetrical about a horizontal axis. A locking bar is pulled out to unlock the carousel assembly and allow it to rotate about its axis, and is then released under its spring loading to again lock the carousel assembly in place.

P-0036[0036] A side view, FIG. 1, of the dispenser <b>20</b> with the cover <b>22</b> in place shows an upper circular bulge <b>24</b>, providing room for a full roll of paper towel, installed in the upper position of the carousel. The shape of the dispenser is such that the front cover tapers inwardly towards the bottom to provide a smaller dispenser volume at the bottom where there is a smaller stub roll of paper towel. The shape tends to minimize the overall size of the dispenser. FIG. 2 shows a perspective view of the dispenser <b>20</b> with cover <b>22</b> in place and the circular (cylindrical) bulge <b>24</b>, together with the sunrise-like setback <b>26</b> on the cover <b>22</b>, which tends to visually guide a hand toward the pseudo-button <b>28</b>, leading to activation of a proximity sensor (not shown). A light emitting diode (LED) <b>130</b> is located centrally to the pseudo-button <b>28</b>. The LED <b>130</b> (FIG. 3) serves as an indication that the dispenser <b>20</b> is on, and dispensing towel. The LED <b>130</b> may be off while the dispenser is not dispensing. Alternatively, the LED <b>130</b> may be lit (on), and when the dispenser <b>20</b> is operating, the LED <b>130</b> might flash. The LED <b>130</b> might show green when the dispenser <b>20</b> is ready to dispense, and flashing green, or orange, when the dispenser <b>20</b> is operating to dispense. Any similar combination may be used. The least power consumption is where the LED <b>130</b> only lights during a dispensing duty cycle. The sunrise-like setback <b>26</b> (FIG. 2) allows a hand to come more closely to the proximity sensor (not shown).

P-0037[0037]FIG. 3 shows the main elements of the carousel assembly <b>30</b>. The carousel arms <b>32</b> have friction reducing rotating paper towel roll hubs <b>34</b>, which are disposed into the holes of a paper towel roll (<b>66</b>, <b>68</b>, FIG. 4A). The locking bar <b>36</b> serves to lock and to release the carousel for rotation about its axis <b>38</b>. The locking bar <b>36</b> rides on one of the corresponding bars <b>40</b>. The two corresponding bars <b>40</b> serve as support bars. Cross-members <b>42</b> serve as stiffeners for the carousel assembly <b>30</b> and also serve as paper guides for the paper to be drawn over and down to the feed roller <b>50</b> and out the dispenser <b>20</b>. These cross members are attached in a rigid fashion to the corresponding bars <b>40</b> and in this embodiment do not rotate.

P-0038[0038] The legs <b>46</b> of the transfer bar <b>44</b> do not rest against the friction reducing rotating paper towel roll hubs <b>34</b> when there is no stub roll <b>68</b> present but are disposed inward of the roll hubs <b>34</b>. The bar part <b>88</b> of the transfer bar <b>44</b> will rest against a structure of the dispenser, for example, the top of modular electronics unit <b>132</b>, when no stub roll <b>68</b> is present. The bar part <b>88</b> of the transfer bar <b>44</b> acts to bring the tail of a new main roll of paper towel <b>66</b> (FIG. 4A) down to the feed roller <b>50</b> which includes intermediate bosses <b>146</b> (FIG. 3) and shaft <b>144</b>. The carousel assembly is disposed within the fixed casing <b>48</b>. The cover is not shown.

P-0039[0039] Feed roller <b>50</b> serves to feed the paper towels <b>66</b>, <b>68</b> (FIG. 4A) being dispensed onto the curved dispensing ribs <b>52</b>. The curved dispensing ribs <b>52</b> are curved and have a low area of contact with the paper towel dispensed (not shown). If the dispenser <b>20</b> gets wet, the curved dispensing ribs <b>46</b> help in dispensing the paper towel to get dispensed by providing low friction and by holding the dispensing towel off of the wet surfaces it would otherwise contact.

P-0040[0040] The feed roller <b>50</b> is typically as wide as the paper roll, and includes drive rollers <b>142</b> and intermediate bosses <b>146</b> on the drive shaft <b>144</b>. The working drive rollers or drive bosses <b>142</b> (FIG. 3) are typically an inch or less in width, with intermediate bosses <b>146</b> (FIG. 3) located between them. Intermediate bosses <b>146</b> are slightly less in diameter than the drive rollers or drive bosses <b>142</b>, having a diameter 0.015 to 0.045 inches less than the drive rollers or drive bosses <b>142</b>. In this embodiment, the diameter of the intermediate bosses <b>146</b> is 0.030 inches less than the drive roller <b>142</b>. This configuration of drive rollers or drive bosses <b>142</b> and intermediate bosses <b>146</b> tends to prevent the dispensing paper towel from becoming wrinkled as it passes through the drive mechanism and reduces friction, requiring less power to operate the feed roller <b>50</b>.

P-0041[0041] A control unit <b>54</b> operates a motor <b>56</b>. Batteries <b>58</b> supply power to the motor <b>56</b>. A motor <b>56</b> may be positioned next to the batteries <b>58</b>. A light <b>60</b>, for example, a light-emitting diode (LED), may be incorporated into a low battery warning such that the light <b>60</b> turns on when the battery voltage is lower than a predetermined level.

P-0042[0042] The cover <b>22</b> of the dispenser is preferably transparent so that the amount of the main roll used (see below) may be inspected, but also so that the battery low light <b>60</b> may easily be seen. Otherwise an individual window on an opaque cover <b>22</b> would need to be provided to view the low battery light <b>60</b>. Another approach might be to lead out the light by way of a fiber optic light pipe to a transparent window in the cover <b>22</b>.

P-0043[0043] In a waterproof version of the dispenser, a thin piece of foam rubber rope is disposed within a u-shaped groove of the tongue-in-groove mating surfaces of the cover <b>22</b> and the casing <b>48</b>. The dispensing shelf <b>62</b> is a modular component, which is removable from the dispenser <b>20</b>. In the waterproof version of the dispenser <b>20</b>, the dispensing shelf <b>62</b> with the molded turning ribs <b>52</b> is removed. By removing the modular component, dispensing shelf <b>62</b>, there is less likelihood of water being diverted into the dispenser <b>20</b> by the dispensing shelf <b>62</b>, acting as a funnel or chute should a water hose or spray be directed at the dispenser <b>20</b>, by the shelf and wetting the paper towel. The paper towel is dispensed straight downward. A most likely need for a waterproof version of the dispenser is where a dispenser is located in an area subject to being cleaned by being hosed down. The dispenser <b>20</b> has an on-off switch which goes to an off state when the cover <b>22</b> is pivoted downwardly. The actual switch is located on the lower face of the nodule <b>54</b> and is not shown.

P-0044[0044] In one embodiment, the user may actuate the dispensing of a paper towel by placing a hand in the dispenser's field of sensitivity. There can be adjustable delay lengths between activations of the sensor.

P-0045[0045] There is another aspect of the presence of water on or near the dispenser <b>20</b>. A proximity sensor (not visible) is more fully discussed below, including the details of its operation. However, as can be appreciated, the sensor detects changes of capacitance such as are caused by the introduction of an object with a high dielectric constant relative to air, such as water, as well as a hand which is about 70% water. An on-off switch <b>140</b> is provided which may be turned off before hosing down and may be turned on manually, afterwards. The switch <b>140</b> may also work such that it turns itself back on after a period of time, automatically. The switch <b>140</b> may operate in both modes, according to mode(s) chosen by the user.

P-0046[0046] A separate “jog” off-on switch <b>64</b> is provided so that a maintenance person can thread the paper towel <b>66</b> by holding a spring loaded jog switch <b>64</b> which provides a temporary movement of the feed roller <b>50</b>.

P-0047[0047]FIG. 4A shows the dispenser case <b>48</b> with the carousel assembly <b>30</b> and transfer bar <b>44</b>. The carousel assembly <b>30</b> is fully loaded with a main roll <b>66</b> in the secondary position and a stub roll <b>68</b> in the primary position, both mounted on the carousel arms <b>32</b> to rotate on the rotating reduced friction paper towel roll hubs <b>34</b> (only shown from the back of the carousel arms <b>32</b>). In the carousel assembly <b>30</b>, the two carousel arms <b>32</b>, joined by corresponding bars <b>40</b> and cross members <b>42</b>, rotate in carousel fashion about a horizontal axis defined by the carousel assembly rotation hubs <b>38</b>. The locking bar <b>36</b> is supported, or carried, by a corresponding bar <b>40</b>. The corresponding bar <b>40</b> provides structural rigidity and support. The locking bar <b>36</b> principally serves as a locking mechanism. Each paper towel roll <b>66</b>, <b>68</b> has an inner cardboard tube which acts as a central winding core element, and which provides in a hole in paper towel roll <b>66</b>, <b>68</b> at each end for engaging the hubs <b>34</b>.

P-0048[0048]FIG. 5 shows the carousel assembly <b>30</b> in exploded, perspective view. The number of parts comprising this assembly is small. From a reliability point of view, the reliability is increased. From a manufacturing point of view, the ease of manufacture is thereby increased and the cost of manufacture is reduced. The material of manufacture is not limited except as to the requirements of cost, ease of manufacture, reliability, strength and other requirements imposed by the maker, demand.

P-0049[0049] When the main roll, <b>66</b> (FIG. 4A) and the stub roll <b>68</b>, (FIG. 4A) are in place, the carousel arms <b>32</b> are connected by these rolls <b>66</b> and <b>68</b> (FIG. 4A). Placing cross-members <b>42</b> to connect the carousel arms <b>32</b> with the locking <b>36</b> and corresponding <b>40</b> bar results in better structural stability, with racking prevented. The locking bar <b>36</b>, which was shown as a single unit locking bar <b>36</b> in the previous figures, acts as a locking bar <b>36</b> to lock the carousel assembly <b>30</b> in the proper orientation. It acts also as the release bar, which when released, allows the carousel assembly <b>30</b> to rotate. Two compression springs <b>70</b>, <b>72</b> are utilized to center the locking bar <b>36</b>.

P-0050[0050]FIG. 4B is a side view of the locking bar showing the placement of the compression springs. The compression springs <b>70</b>, <b>72</b> also tend to resist the release of the locking bar <b>36</b>, insuring that a required force is needed to unlock the locking bar <b>36</b>. The required force is typically between 0.5 lbf and 3.0 lbf, or more. In this embodiment, the force is 2.0 lbf when the spring in a fully compressed position, and 1.1 lbf when the spring is in the rest position. In the rest position, the forces of the opposing springs offset each other.

P-0051[0051] The actual locking occurs as shown in FIG. 4C. The locking bar <b>36</b> closest to the rear of the casing <b>48</b> is adapted to fit into a generally unshaped mating structure <b>118</b> which is adapted to hold the locking bar <b>36</b> and prevent it and the carousel assembly <b>30</b> from rotating. When the locking bar <b>36</b> is pulled away from the rear of the casing <b>48</b>, the locking bar <b>36</b> is disengaged from the mating structure <b>118</b>. The mating structure has an upper “high” side <b>120</b> and a lower “low” side <b>122</b>, where the low side has a “ramp” <b>124</b> on its lower side. As the locking bar <b>36</b> is pulled out to clear the high side <b>120</b>, the carousel assembly <b>30</b> is free to rotate such that the top of the carousel assembly <b>30</b> rotates up and away from the back of the casing <b>48</b>. As the carousel assembly <b>30</b> begins to rotate, the user releases the locking bar <b>36</b> which, under the influence of symmetrically placed compression springs <b>70</b>, <b>72</b> returns to its rest position. As the carousel assembly rotates, the end of the symmetrical locking bar <b>36</b> which originally was disposed toward the user now rotates and contacts the ramp <b>124</b>. A locking bar spring, e.g., <b>70</b> or <b>72</b>, is compressed as the end of the locking bar <b>36</b> contacting the ramp <b>124</b> now moves up the ramp <b>124</b>. The end of the locking bar <b>36</b> is pressed into the space between the low side <b>122</b> and the high side <b>120</b>, as the end of the locking bar <b>36</b> slides past the low side <b>122</b>. A locked position for the carousel assembly <b>30</b> is now reestablished.

P-0052[0052]FIG. 5 shows the carousel arms <b>32</b> adapted to receive the loading of a new roll of towel <b>66</b> (FIG. 4A). The arms <b>32</b> are slightly flexible and bent outward a small amount when inserting a paper towel roll <b>66</b> (FIG. 4A) between two opposite carousel arms <b>32</b>. A friction reducing rotating paper towel roll hub <b>34</b> is inserted into a hole of a paper towel roll <b>66</b> (FIG. 4A), such that one roll hub <b>34</b> is inserted into a hole son each side of the paper towel roll <b>66</b> (FIG. 4A). Also shown in FIG. 5 are the tamper resistant fasteners <b>74</b>, which attach the friction-reducing rotating paper towel roll hubs <b>34</b> to the carousel arms <b>32</b>.

P-0053[0053]FIG. 5 shows the surface <b>76</b> of the roll hubs <b>34</b> and the surface <b>78</b> of the carousel arms <b>66</b>, which contact each other. These contact surfaces <b>76</b>, <b>78</b> may be made of a more frictionless material than that of which the carousel arms <b>32</b> and the roll hubs <b>34</b> are made. For example, a plastic such as polytetrafluoroethylene (PTFE), e.g., TEFLON®, may be used, as a thin layer on each of the contacting surfaces. The paper towel dispenser <b>20</b> and its components may be made of, including but not limited to, plastic, metal, an organic material which may include but is not limited to wood, cardboard, treated or untreated, a combination of these materials, and other materials for batteries, paint, if any, and waterproofing.

P-0054[0054]FIG. 6A shows the paper <b>80</b> feeding from the stub roll <b>68</b> while the tail <b>82</b> of the main roll <b>66</b> is positioned beneath the transfer bar <b>44</b>. The legs (visible leg <b>46</b>, other leg not shown) of the transfer bar <b>44</b> rests against the stub roll. When the diameter of the stub roll <b>68</b> is larger by a number of winds of paper towel than the inner roll <b>84</b>, the legs <b>46</b> of the transfer bar <b>44</b> dispose the bar <b>88</b> of the transfer bar <b>44</b> to be rotated upward from the feed roller <b>50</b>.

P-0055[0055]FIG. 6B shows the situation where the stub roll <b>68</b> is exhausted, so that the transfer bar <b>44</b> tucks the tail <b>82</b> of the main roll <b>66</b> into the feed mechanism <b>86</b>. FIG. 6B shows the stub roll <b>68</b> position empty, as the stub roll has been used up. The stub roll core <b>84</b> is still in place. As the stub roll <b>68</b> is used up, the legs <b>46</b> of the transfer bar <b>44</b> move up toward the stub roll core (inner roll) <b>84</b>, and the bar <b>88</b> of the transfer bar is disposed downward toward the feed roller <b>50</b> and toward the top of a structural unit of the dispenser <b>20</b> (FIG. 2), such as the top of the electronics module <b>132</b> (FIG. 3). Initially the main roll <b>66</b> is in reserve, and its tail <b>82</b> in an “idling” position such that it is under the transfer bar <b>44</b>. The main roll <b>66</b> and its tail <b>82</b> are not initially in a “drive” position. However, as the stub roll <b>68</b> is used up, the downward motion of the bar transfer bar, <b>44</b> driven by its spring loading, brings the bar <b>88</b> of the transfer bar <b>44</b> down to engage the main roll tail <b>82</b> with the feed roller <b>50</b>.

P-0056[0056]FIG. 7A shows the carousel assembly <b>30</b> ready for loading when the main roll <b>66</b> reaches a specific diameter. The diameter of the main roll <b>66</b> may be measured by comparison of that diameter with the widened “ear” shape <b>122</b> (FIG. 4A) on each end of the carousel arms <b>32</b>. That part of each carousel arm <b>32</b> is made to measure a critical diameter of a main roll <b>66</b>. The carousel assembly <b>30</b>′ is tilted forward when it is locked. The carousel assembly <b>30</b> may rotate unassisted after the locking bar <b>36</b> is released, due to the top-heavy nature of the top roll. That is, the torque produced by the gravitational pull on the main-roll <b>66</b> is larger than that needed to overcome friction and the counter-torque produced by the now empty stub roll <b>68</b>.

P-0057[0057]FIG. 7B shows the process of loading where the service person pulls the locking bar <b>36</b> and allows the carousel to rotate <b>1800</b>, placing the main roll <b>66</b> in the previous stub roll <b>68</b> position. Now a new full sized roll <b>66</b> can be loaded onto the main roll <b>66</b> position. The transfer bar <b>44</b> automatically resets itself. The transfer bar <b>44</b> is spring loaded so as to be disposed with the transfer bar legs <b>46</b> pressed upward against the stub roll <b>68</b> or the stub roll core <b>84</b>. The transfer bar legs <b>46</b> are adapted to be disposed inward of the roll hubs <b>34</b> so the bar <b>88</b> of the transfer bar <b>44</b> will have a positive stop at a more rigid location, in this case, the top of the electronics module <b>132</b> (FIG. 2).

P-0058[0058]FIG. 7C shows the extension springs <b>126</b>, <b>128</b> which tend to maintain the transfer bar legs <b>46</b> in contact with the stub roll <b>68</b> or stub roll core <b>84</b>.

P-0059[0059] The transfer bar <b>44</b> contains the two extension springs <b>126</b>, <b>128</b>. The spring forces are typically 0.05 lbf to 0.5 lbf in the bar <b>44</b> lowered position and 0.2 lbf to 1.0 lbf in the bar <b>44</b> raised position. In this embodiment, the spring forces are 0.2 lbf in the lowered position an 0.43 lbf in the raised position. The force of the two springs <b>126</b>, <b>128</b> is additive so that the transfer bar <b>44</b> is subject to a total spring force of 0.4 lbf in the lowered position and 0.86 lbf in the raised position.

P-0060[0060] While modular units (FIG. 7D) such as the electronics module <b>132</b>, the motor <b>56</b> module, and the battery case <b>150</b>, are removable, they fit, or “snap” together so that the top of the electronics unit <b>132</b>, the top of the motor <b>56</b> module and remaining elements of the “floor” <b>148</b> of the dispensing unit <b>20</b> form a smooth, cleanable surface. Paper dust and debris tend to accumulate on the floor <b>148</b> of the dispenser <b>20</b>. It is important that the dispenser <b>20</b> is able to be easily cleaned as part of the maintenance procedure. A quick wiping with a damp cloth will sweep out and pick up any undesirable accumulation. The removable modular dispensing shelf <b>64</b> may be removed for rinsing or wiping.

P-0061[0061] The feed roller <b>50</b> may be driven by a motor <b>56</b> which in turn may be driven by a battery or batteries <b>58</b>, driven off a 100 or 220V AC hookup, or driven off <b>20</b> a transformer which is run off an AC circuit. The batteries may be non-rechargeable or rechargeable. Rechargeable batteries may include, but not be limited to, lithium ion, metal hydride, metal-air, nonmetal-air. The rechargeable batteries may be recharged by, but not limited to, AC electromagnetic induction or light energy using photocells.

P-0062[0062] A feed roller <b>50</b> serves to feed the paper towel being dispensed onto the curved dispensing ribs <b>52</b>. A gear train (not visible) may be placed under housing <b>86</b>, (FIG. 3) for driving the feed roller. A control unit <b>54</b> (FIG. 3) for a motor <b>56</b> (FIG. 3) may be utilized. A proximity sensor (not shown) or a hand-operated switch <b>64</b> may serve to turn the motor <b>56</b> on and off.

P-0063[0063] As an enhancement and further development of a system for delivering paper towel to the end user in as cost effective manner and user-friendly manner as possible. An automatic means for dispensing the paper towel is desirable, making it unnecessary for a user to physically touch a knob or a lever. Therefore, a more hygienic dispenser is present. This dispenser will contribute to less transfer of matter, whether dirt or bacteria, from one user to the next. The results of washing ones hands will tend to be preserved and hygiene increased.

P-0064[0064] An electronic proximity sensor is included as part of the paper towel dispenser. A person can approach the paper towel dispenser, extend his or her hand, and have the proximity sensor detect the presence of the hand. Upon detection of the hand, a motor is energized which dispenses the paper towel. It has long been known that the insertion of an object with a dielectric constant into a volume with an electromagnetic field will tend to modify the properties, which the electromagnetic field sees. The property of the hand, a dielectric constant close to that of water, is enough to alter the net capacitance of a suitable detector circuit.

P-0065[0065] An embodiment of the invention comprises a balanced bridge circuit. See FIG. 8A. The component U<b>1</b>A <b>90</b> is a comparator (TLC<b>3702</b><b>158</b>) configured as an oscillator. The frequency of oscillation of this component, U<b>1</b>A <b>90</b>, of the circuit may be considered arbitrary and non-critical, as far as the operation of the circuit is concerned. The period of the oscillator is set by the elements Cref <b>92</b>, Rhys <b>94</b>, the trim resistance, Rtrim <b>96</b>, where the trim resistance may be varied and the range resistors Rrange <b>152</b> are fixed. The resistors Rrange <b>152</b> allow limits to be placed-on the range of adjustment, resulting in an easier adjustment. The adjustment band is narrowed, since only part of the total resistance there can be varied. Consequently a single potentiometer may be used, simplifying the adjustment of Rtrim <b>96</b>. A value for Rrange <b>152</b> for the schematic shown in FIG. 8A might be 100 kΩ. Rtrim <b>96</b> might have an adjustment range of 10 kΩ to 50 kΩ. The output signal at pin <b>198</b> of component U<b>1</b>A <b>90</b> is a square wave, as shown in FIG. 9A. Cref <b>92</b> is charged by the output along with ANT <b>100</b>, both sustaining the oscillation and measuring the capacitance of the adjacent free space. The signals resulting from the charging action are applied to a second comparator, U<b>1</b>B <b>102</b>, at pins <b>5</b><b>104</b> and <b>6</b><b>106</b> (FIG. 8A). These signals appear as exponential waveforms, as shown in FIG. 9B and FIG. 9C.

P-0066[0066] The simplest form of a comparator is a high-gain differential amplifier, made either with transistors or with an op-amp. The op-amp goes into positive or negative saturation according to the difference of the input voltages because the voltage gain is typically larger than 100,000, the inputs will have to be equal to within a fraction of a millivolt in order for the output not to be completely saturated. Although an ordinary op-amp can be used as comparator, there are special integrated circuits intended for this use. These include the LM<b>306</b>, LM<b>311</b>, LM<b>393</b><b>154</b> (FIG. 8A), LM<b>393</b>V, NE<b>627</b> and TLC<b>3702</b><b>158</b>. The LM<b>393</b>V is a lower voltage derivative of the LM<b>393</b><b>154</b>. The LM<b>393</b><b>154</b> is an integrated circuit containing two comparators. The TLC<b>3702</b><b>158</b> is a micropower dual comparitor with CMOS push-pull <b>156</b> outputs. FIG. 8B (prior art) is a schematic which shows the different output structures for the LM<b>393</b> and the TLC<b>3702</b>. The dedicated comparators are much faster than the ordinary op-amps.

P-0067[0067] The output signal at pin <b>198</b> of component U<b>1</b>A <b>90</b>, e.g., a TL<b>3702</b><b>158</b>, is a square wave, as shown in FIG. 2A. Two waveforms are generated at the inputs of the second comparator, U<b>2</b>B <b>102</b>. The first comparator <b>90</b> is running as an oscillator producing a square-wave clocking signal, which is input, to the clock input of the flip-flop U<b>2</b>A <b>108</b>, which may be, for example, a Motorola D flip-flop, No. 14013.

P-0068[0068] Running the first comparator as a Schmitt trigger oscillator, the first comparator U<b>1</b>A <b>90</b> is setup to have positive feedback to the non-inverting input, terminal <b>3</b><b>110</b>. The positive feedback insures a rapid output transition, regardless of the speed of the input waveform. Rhys <b>94</b> is chosen to produce the required hysteresis, together with the bias resistors Rbias<b>1</b><b>112</b> and Rbias<b>2</b><b>114</b>. When these two bias resistors, Rbias<b>1</b><b>112</b>, Rbias<b>2</b><b>114</b> and the hysteresis resistor, Rhys <b>94</b>, are equal, the resulting threshold levels are ⅓ V+ and ⅔V+, where V+<b>158</b> is the supply voltage. The actual values are not especially critical, except that the three resistors Rbias<b>1</b><b>112</b>, Rbias<b>2</b><b>114</b> and Rhys <b>94</b>, should be equal, for proper balance.

P-0069[0069] The value of 294 kΩ maybe used for these three resistors, in the schematic shown in FIG. 8A.

P-0070[0070] An external pullup resistor, Rpullup<b>1</b><b>116</b>, which may have a value, for example, of 470 Ω, is only necessary if an open collector, comparator such as an LM<b>393</b><b>154</b> is used. That comparator <b>154</b> acts as an open-collector output with a ground-coupled emitter. For low power consumption, better performance is achieved with a CMOS comparator, e.g., TLC<b>3702</b>, which utilizes a cmos push-pull output <b>156</b>. The signal at terminal <b>3</b><b>110</b> of U<b>1</b>A charges a capacitor Cref <b>92</b> and also charges an ANT sensor <b>100</b> with a capacitance which Cref <b>92</b> is designed to approximate. A value for Cref for the schematic of FIG. 8A, for the most current board design, upon which it depends, is about 10 pF. As the clocking square wave is effectively integrated by Cref <b>92</b> and the capacitance of ANT <b>100</b>, two exponential signals appear at terminals <b>5</b><b>104</b> and <b>6</b><b>106</b> of the second comparator U<b>1</b>B, through the Rprotect <b>160</b> static protection resistors. Rprotect <b>160</b> resistors provide limiting resistance which enhances the inherent static protection of a comparitor input lines, particularly for the case of pin <b>5</b><b>104</b> of U<b>1</b>B <b>102</b>. In the schematic shown in FIG. 8A, a typical value for Rprotect <b>160</b> might be 2 kΩ. One of the two exponential waveforms will be greater, depending upon the settings of the adjustable resistance Rtrim <b>96</b>, Cref <b>92</b>, and ANT <b>100</b>. The comparator U<b>1</b>B <b>102</b> resolves small differences, reporting logic levels at its output, pin <b>7</b><b>118</b>. As the waveforms may initially be set up, based on a capacitance at ANT <b>100</b> of a given amount. However, upon the intrusion of a hand, for example, into the detection field of the antenna ANT <b>100</b>, the capacitance of ANT <b>100</b> is increased significantly and the prior relationship of the waveforms, which were set with ANT <b>100</b> with a lower capacitance, are switched over. Therefore, the logic level output at pin <b>7</b><b>118</b> is changed and the d flip-flop <b>108</b> state is changed via the input on pin <b>5</b> of the D flip-flop <b>108</b>.

P-0071[0071] The second comparator <b>102</b> provides a digital quality signal to the D flip-flop <b>108</b>. The D flip-flop, U<b>2</b>A <b>108</b>, latches and holds the output of the comparator U<b>1</b>B <b>90</b>. In this manner, the second comparator is really doing analog-to-digital conversion. A suitable D flip-flop is a Motorola 14013.

P-0072[0072] The presence, and then the absence, of a hand can be used to start a motorized mechanism on a paper towel dispenser, for example. An embodiment of the proximity detector uses a single wire or a combination of wire and copper foil tape that is shaped to form a detection field. This system is very tolerant of non-conductive items, such as paper towels, placed in the field. A hand is conductive and attached to a much larger conductor to free space. Bringing a hand near the antenna serves to increase the antenna's apparent capacitance to free space, forcing detection.

P-0073[0073] The shape and placement of the proximity detector's antenna (FIG. 8A, 100) turns out to be of some importance in making the proximity sensor work correctly. Experimentation showed that a suitable location was toward the lower front of the dispenser unit. The antenna (FIG. 8A, 100) was run about two-thirds the length of the dispensing unit, in a modular, replaceable unit above the removable dispensing shelf <b>62</b> (FIG. 3). This modular unit would be denoted on FIG. 3 as <b>120</b>.

P-0074[0074] A detection by the proximity detection circuit (FIG. 8A) in the module <b>120</b> sets up a motor control flip flop so that the removal of the hand will trigger the start of the motor cycle. The end of the cycle is detected by means of a limit switch which, when closed, causes a reset of the flip-flop and stops the motor. A cycle may also be initiated by closing a manual switch.

P-0075[0075] A wide range of sensitivity can be obtained by varying the geometry of the antenna and coordinating the reference capacitor. Small antennae have short ranges suitable for non-contact pushbuttons. A large antenna could be disposed as a doorway-sized people detector. Another factor in sensitivity is the element applied as Rtrim. If Rtrim <b>96</b> is replaced by an adjustable inductor, the exponential signals become resonant signals with phase characteristics very strongly influenced by capacitive changes. Accordingly, trimming with inductors may be used to increase range and sensitivity. Finally, circuitry may be added to the antenna <b>100</b> to improve range and directionality. As a class, these circuits are termed “guards” or “guarding electrodes,” old in the art, a type of shield driven at equal potential to the antenna. Equal potential insures no charge exchange, effectively blinding the guarded area of the antenna rendering it directional.

P-0076[0076] The antenna design and trimming arrangement for the paper towel dispenser application is chosen for adequate range and minimum cost. The advantages of using a guarded antenna and an adjustable inductor are that the sensing unit to be made smaller.

P-0077[0077] From a safety standpoint, the circuit is designed so that a detection will hold the motor control flip-flop in reset, thereby stopping the mechanism. The cycle can then begin again after detection ends.

P-0078[0078] The dispenser has additional switches on the control module <b>54</b>. FIG. 3 shows a “length-of-towel-to-dispense-at-one-time” (“length”) switch <b>134</b>. This switch <b>134</b>, is important in controlling how long a length of paper towel is dispensed, for each dispensation of towel. It is an important setting for the owner of the dispenser on a day-to-day basis in determining cost (to the owner) versus the comfort (to the user) of getting a large piece of paper towel at one time.

P-0079[0079] A somewhat similar second switch <b>136</b> is “time-delay-before-can-activate-the-dispensing-of another-paper-towel” (“time-delay”) switch <b>136</b>. The longer the time delay is set, the less likely a user will wait for many multiple towels to dispense. This tends to save costs to the owner. Shortening the delay tends to be more comfortable to a user.

P-0080[0080] A third switch <b>138</b> is the sensitivity setting for the detection circuit. This sensitivity setting varies the resistance of Rtrim <b>96</b> (FIG. 8A). Once an effective antenna <b>100</b> (FIG. 8A) configuration is set up, the distance from the dispenser may be varied. Typical actual use may require a sensitivity out to one or two inches, rather than four or six inches. This is to avoid unwanted dispensing of paper towel. In a hospital setting, or physicians office, the sensitivity setting might be made fairly low so as to avoid unwanted paper towel dispensing. At a particular work location, on the other hand, the sensitivity might be set fairly high, so that paper towel will be dispensed very easily.

P-0081[0081] While it is well known in the art how to make these switches according to the desired functionalities, this switch triad may increase the usefulness of the embodiment of this invention. The system, as shown in the embodiment herein, has properties of lowering costs, improving hygiene, improving ease of operation and ease of maintenance. This embodiment of the invention is designed to consume low power, compatible with a battery or battery pack operation. In this embodiment, a 6 volt DC supply is utilized. A battery eliminator may be use for continuous operation in a fixed location. There is a passive battery supply monitor that will turn on an LED indicator if the input voltage falls below a specified voltage.

P-0082[0082] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.