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Dispenser Systems

20230263344 · 2023-08-24

    Inventors

    Cpc classification

    International classification

    Abstract

    A moulded fibrous end plug (3) and dispenser system comprising the same, the end plug for use in mounting a roll of sheet material to a dispenser and having a roll facing side comprising formations configured to be insertable into an opening in an end of a roll of sheet material and for securing the end plug to the roll of sheet material, the end plug further comprising an opposite dispenser facing side comprising formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser. The formations of the roll facing side configured to be insertable into the opening in the end of the roll of sheet material include a plurality of domes (7). The formations of the roll facing side for securing the end plug to the roll of sheet material include protuberances (26) configured to provide an interference fit securing the end plug to the roll.

    Claims

    1. A moulded fibrous end plug for use in mounting a roll of sheet material to a dispenser, wherein the end plug has a roll facing side comprising formations configured to be insertable into an opening in an end of a roll of sheet material in use, the formations of the roll facing side including formations for securing the end plug to the roll of sheet material; and an opposite dispenser facing side comprising formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser.

    2-6. (canceled)

    7. The moulded fibrous end plug of claim 1 wherein the formations of the roll facing side configured to be insertable into the opening in the end of the roll of sheet material include a plurality of domes.

    8. (canceled)

    9. (canceled)

    10. The moulded fibrous end plug of claim 7 wherein each dome is upstanding from a base of the roll facing side of the end plug, wherein the end plug comprises a flange around the periphery thereof, the base of the roll facing side of the end plug comprising a roll facing surface of the peripheral flange.

    11. The moulded fibrous end plug of claim 7 wherein each dome comprises a base portion and an upper portion, wherein an outer wall of the dome comprises a first portion in the base portion of the dome upstanding from a base of the roll facing side of the end plug and a second, sloping portion in the upper portion of the dome, the second, sloping portion being inclined relative to the first portion .

    12. The moulded fibrous end plug of claim 7 wherein the domes are spaced from one another by connecting portions, each connecting portion extending between the central portion of the roll facing side of the end plug and a base of the roll facing side of the end plug, wherein each connecting portion comprises one or more sloping portion; wherein the connecting portion comprises an opening.

    13. The moulded fibrous end plug of claim 12 wherein the dispenser facing side of the end plug comprises a plurality of sloping surfaces configured to cooperate with a surface of a ramp structure of the roll holder portion of the dispenser to enable the end plug to be mounted to the roll holder portion, wherein the sloping surfaces of the dispenser facing side are provided by the dispenser facing sides of sloping portions of the connecting portions.

    14. The moulded fibrous end plug of claim 7 wherein the domes surround a central portion of the roll facing side of the end plug.

    15. The moulded fibrous end plug of claim 14 wherein the central portion defines a planar roll facing surface.

    16. The moulded fibrous end plug of claim 14 wherein the central portion is located at a level between the base of the roll facing side of the end plug and the tops of the domes.

    17. The moulded fibrous end plug of claim 14 wherein each dome extends between the central portion of the roll facing side and the roll facing surface of a peripheral flange of the end plug.

    18. The moulded fibrous end plug of claim 14 wherein the dispenser facing side of the end plug comprises an annular structure defining a central bore for receiving a projection defined by a roll holder portion of the dispenser, wherein the central bore is a closed ended bore, wherein the closed end of the bore is provided by a roll facing surface of a portion of the end plug whose opposite surface provides the central portion of the roll facing side of the end plug.

    19. The moulded fibrous end plug of claim 18 wherein the dispenser facing side of the end plug comprises a plurality of reinforcing ribs extending between the annular structure and a peripheral region of the end plug on the dispenser facing side, optionally wherein each rib extends across a recess in the dispenser facing side of the end plug corresponding to a dispenser facing side of a dome.

    20. The moulded fibrous end plug of claim 7 wherein the formations of the roll facing side for securing the end plug to the roll of sheet material include formations configured to provide an interference fit securing the end plug to the roll, wherein the formations for providing the interference fit comprise protuberances, and wherein each protuberance projects outwardly from a respective one of the domes.

    21. The moulded fibrous end plug of claim 20 wherein a protuberance is associated with each dome.

    22. The moulded fibrous end plug of claim 20 wherein each dome comprises a base portion and an upper portion, wherein an outer wall of the dome comprises a first portion in the base portion of the dome upstanding from a base of the roll facing side of the end plug and a second, sloping portion in the upper portion of the dome, the second, sloping portion being inclined relative to the first portion, wherein the protuberance has a height at least as great as a height of the base portion of the dome.

    23. The moulded fibrous end plug of claim 1 wherein the dispenser facing side of the end plug further comprises one or more sloping surfaces configured to cooperate with a ramp structure of the roll holder portion, wherein the sloping surfaces are provided by a reverse side of formations on the roll facing side of the end plug.

    24. The moulded fibrous end plug of claim 1 wherein the end plug is formed from a material comprising a mixture of fibres and binder, and wherein the binder provides a matrix holding the fibres of the moulded fibrous end plug in place.

    25. The moulded fibrous end plug of claim 24 wherein the binder comprises one or more biodegradable biopolymer or starch.

    26. (canceled)

    27. (canceled)

    28. The moulded fibrous end plug of claim 1 wherein the fibers are cellulosic fibers.

    29. The moulded fibrous end plug of claim 1 wherein the end plug comprises from 10-40% fibers based on total solids content and/or wherein the end plug comprise at least 50% binder based on total solids content.

    30-47. (canceled)

    Description

    BRIEF DESCRIPTION OF THE DRAWINGS

    [0177] Various embodiments will now be described, by way of example only, and with reference to the accompanying drawings in which:

    [0178] FIG. 1 illustrates one exemplary embodiment of a dispenser with which the end plugs described herein may be used;

    [0179] FIG. 2 is a front on view illustrating the front face of the roll holder portion which comprises formations which may cooperate with the formations of the dispenser facing side of an end plug in accordance with an embodiment of the invention to mount the end plug to the dispenser;

    [0180] FIG. 3 is a side on view of the roll holder portion of the embodiment of FIG. 2;

    [0181] FIG. 4 is a perspective view of the roll holder portion of the embodiment of FIG. 2;

    [0182] FIG. 5 illustrates the way in which the roll facing side of an end plug may be used to mount an end plug to a roll 120;

    [0183] FIG. 6 illustrates a moulded fibrous end plug for a dispenser system in accordance with a first embodiment of the invention from the roll facing side;

    [0184] FIG. 7 is a view from above of the moulded fibrous end plug of FIG. 6 from the dispenser facing side;

    [0185] FIG. 8 illustrates the end plug of FIGS. 6 and 7 from one side, with the roll facing side uppermost as in FIG. 6;

    [0186] FIG. 9 is a section through the end plug of the embodiment of FIGS. 6-8 along the line 9-9 shown in FIG. 7, illustrating both the roll facing and dispenser facing sides thereof;

    [0187] FIG. 10 is an exploded view showing how the end plug 1 may be moved in the direction of the arrow to engage the roll holder portion of a dispenser in accordance with FIGS. 2-4, and illustrating the cooperating features in more detail;

    [0188] FIG. 11 is a cross sectional view which illustrates the end plug of FIGS. 6-10 once mounted to the roll holder portion;

    [0189] FIG. 12 illustrates a moulded fibrous end plug in accordance with another embodiment of the invention, being a perspective view of the end plug with the roll facing side uppermost;

    [0190] FIG. 13 is a top plan view of the dispenser facing side of the end plug of FIG. 12;

    [0191] FIG. 14 is a view of the roll facing surface of the end plug of FIGS. 12 and 13 from above;

    [0192] FIG. 15 is a section along the line 15-15 of FIG. 14;

    [0193] FIG. 16 is a perspective view of the dispenser facing side of the end plug of FIGS. 12-15.

    [0194] FIG. 17 is a perspective view of another embodiment of a moulded fibrous end plug in accordance with the invention, with the roll facing side uppermost;

    [0195] FIG. 18 is a top view from the dispenser facing side of the end plug of FIG. 17;

    [0196] FIG. 19 is a perspective view from the dispenser facing side of the end plug of FIGS. 17 and 18;

    [0197] FIG. 20 is a perspective view from above from the roll facing surface of a moulded fibrous end plug in accordance with a yet further embodiment of the invention;

    [0198] FIG. 21 is a view from above of the dispenser facing surface of the end plug of FIG. 20;

    [0199] FIG. 22 is a perspective view from above from the roll facing surface of a moulded fibrous end plug in accordance with a yet further embodiment of the invention;

    [0200] FIG. 23 is a view from above of the dispenser facing surface of the end plug of FIG. 22;

    [0201] FIG. 24 is a cross sectional view of the end plug of the embodiment of FIGS. 22 and 23 taken along the line 24-24 of FIG. 22;

    [0202] FIG. 25 is a perspective view of a roll holder portion of a dispenser from the roll facing side thereof suitable for use with the end plug of the embodiment of FIGS. 22-24;

    [0203] FIG. 26 is a view from above illustrating the end plug of FIGS. 22-24 mounted on the roll holder portion of FIG. 25;

    [0204] FIG. 27 is a sectional view along the line 27-27 of FIG. 26;

    [0205] FIG. 28 is a perspective view of another roll holder portion of a dispenser from the roll facing side thereof suitable for use with the end plug of a further embodiment shown in FIGS. 29-31;

    [0206] FIG. 29 is a view from above and one side illustrating the end plug of a further embodiment mounted on the roll holder portion of FIG. 28;

    [0207] FIG. 30 is a view from above of the arrangement shown in FIG. 29 illustrating the end plug mounted on the roll holder portion of FIG. 28;

    [0208] FIG. 31 is a sectional view along the line 31-31 of FIG. 30;

    [0209] FIG. 32 is a flow chart illustrating certain steps in the manufacture of a moulded fibrous end plug in accordance with one exemplary embodiment of the invention;

    [0210] and FIG. 33 schematically illustrates certain of the steps of FIG. 32.

    [0211] FIG. 1 illustrates one exemplary embodiment of a dispenser with which the end plugs described herein may be used. This dispenser is merely used as an example to illustrate how a roll holder portion may cooperate with the end plug to mount a roll to a dispenser. It will be appreciated that other dispenser types may be used. The configuration of the roll holder portion of the dispenser, and its relationship to other dispenser parts e.g. the configuration of any dispenser arms, may vary from that shown. Furthermore, while the invention will be exemplified in relation to a roll holder portion which is not rotatable relative to the dispenser arm, in other embodiments, the end plug may, as previously described, fixedly mount the roll to a roll holder portion, which is rotatable relative to another part of the dispenser. For example, the roll holder portion may be in the form of a rotatable hub.

    [0212] The dispenser illustrated is a wall mounted dispenser, as may be found, for example in a washroom or other hand washing facility. However, end plugs may be used with other types of dispenser. The dispenser may be an electronic hands-free dispenser, although this is not necessarily the case.

    [0213] Returning now to the exemplary arrangement of FIG. 1, which is in accordance with WO 2012/073203A2 (corresponding to US2012138723A1), the dispenser 100 includes a pair of dispenser arms 102, each having a roll holder portion 104 at the distal end thereof. A roll receiving space 106 is defined between the arms 102. The dispenser arms 102 are able to resiliently deflect outwardly relative to one another during insertion or removal of a roll, being biased to return to their original, closer position.

    [0214] The roll holder portions of a dispenser with which an end plug of the present invention is used may be of the configuration illustrated in FIG. 1, or indeed any of the configurations described in WO 2012/073203A2 above, or indeed, any other desired configuration.

    [0215] In use the end plug (already inserted in the end of a roll) is pushed on to the front face of the roll holder portion to mount the end plug, and hence the roll thereto.

    [0216] The general principles of providing a mounting between an end plug and roll holder portion using cooperating formations on the dispenser facing side of the end plug and the roll holder portion of the dispenser are described in WO 2012/073203A2.

    [0217] One alternative example of a roll holder portion 50 which may be used with end plugs in accordance with some exemplary embodiments of the invention is shown in FIG. 2.

    [0218] FIG. 2 is a front on view illustrating the front face of the roll holder portion which comprises formations which may cooperate with the formations of the dispenser facing side of an end plug in accordance with an embodiment of the invention to mount the end plug to the dispenser. In this example, the formations cooperate with one another to rotatably mount the end plug to the roll holder portion. FIG. 3 is a side on view of the roll holder portion of FIG. 2. FIG. 4 is a perspective view of the roll holder portion.

    [0219] The roll holder portion 50 includes a base 52, defining a front face of the roll holder portion. A cylindrical projection 54 extends from the base 52. A circumferentially extending structure 56 partially surrounds the projection 54 so as to define an annular space 58 therebetween. The structure 56 defines a circumferentially extending wall 60 which defines the outer edge of the annular space 58. A ramp structure 62 extends from the top of the wall 60 to the base 52.

    [0220] In this example, the roll holder portion 50 includes a male formation, the cylindrical projection 54. The formations of the dispenser facing side of the end plug may then comprise a female part for receiving the cylindrical projection. The cylindrical projection 54 and the female part of the dispenser facing side of the end plug are complimentary to one another. The formations of the dispenser facing side of the end plug are configured such that they may cooperate with the formations of the roll holder portion to mount the end plug to the roll holder portion. For example, the formations of the dispenser facing side may be configured such that a female part thereof may cooperate with the formations of the roll holder portion to enable the female part to receive the male part e.g. cylindrical projection. Thus, the female part may be configured such that it fits into the annular space 58 to mount the end plug to the dispenser. The formations of the dispenser facing side of the end plug should be such that they do not interfere with any of the formations of the roll holder portion i.e. the roll facing side thereof to prevent fitting together of the end plug and roll holder portion as required for providing a secure mounting, and, where applicable, to allow relative rotation between the end plug and roll holder portion.

    [0221] Of course, the roll holder portion may differ from that shown, and the formations of the end plug should be configured as appropriate to enable the formations of the dispenser facing side of the end plug to cooperate with the formations of a particular roll holder portion with which the end plug is intended to be used. For example, rather than a single formation defining a cylindrical projection 54 of the roll holder portion, such a projection may formed by a plurality of formations. The cylindrical projection is then defined by a set of formations of the roll holder portion. This set of formations and a set of one or more formations of the dispenser facing side of the end plug (e.g. defining a cooperating female part thereof) may define ones of a pair of complimentary parts of the dispenser facing side of the end plug and the roll holder portion. The formations of the roll holder portion need not define a cylinder. For example, provided that an outer diameter corresponding to an outer circular boundary drawn around each of the formations defining the projection may snugly fit within the annular formation of the dispenser facing side of the end plug, the arrangement may operate in the same manner as the example of FIGS. 2-4. Likewise, an annular space may be defined surrounding the projection of the roll holder portion in a manner other than that shown e.g. by a plurality of formations surrounding the projection. The formations need not define a circumferentially extending structure. For example, a series of spoke- like formations extending radially on the face of the roll holder portion may be disposed with their proximal ends spaced from the outer edge of the projection to define an annular space. Similarly there may be more than one ramp portion.

    [0222] An end plug may be used to ensure that a roll of sheet material is only used with a dispenser with which it is intended to be used e.g. to ensure optimum performance. For example, a dispenser, particularly although not necessarily an electronic dispenser, may be configured to operate most effectively with a particular type of sheet material (e.g. basis weight) and/or configuration of roll. This may ensure that the dispenser operates reliably without jamming, with greater energy efficiency if electronic, without risk of malfunction and/or safety risk etc. It will be seen from the above example, that the formations of the dispenser facing side of an end plug may be configured such that they will only allow the end plug to be mounted to a particular dispenser, having a roll holder portion with appropriate complimentary formations

    [0223] While the embodiment illustrated permits relative rotation between the end plug and roll holder portion, such that the end plug may rotate with a roll during dispensing, in alternative embodiments, the formations of the dispenser facing side of the end plug may cooperate to provide a keyed connection with the roll holder portion, such that the roll holder portion and end plug are maintained in a fixed rotational relationship. The roll holder portion may then be rotatably mounted to an adjacent portion of the dispenser to enable rotation of the roll and roll holder portion relative to another part of the dispenser during dispensing. For example, the keyed connection may be with a projecting sensor part of the roll holder portion. A recess on the dispenser facing surface of the end plug may cooperate with the sensor part to provide the keyed connection. The recess may, for example, be an opening in the end plug, or the reverse side of a dome of the end plug. The roll holder portion may then be rotatably mounted to an arm of the dispenser, such as via a mounting portion e.g. hub fixed to the distal end of the arm. In such embodiments the roll holder portion is rotatable relative to the mounting portion. The mounting portion of the dispenser may comprise a further sensor part forming a sensor arrangement together with the sensor part of the roll holder portion. For example, the roll holder portion may comprise a magnet, providing a “target” of a sensor arrangement for sensing rotation e.g. counting a number of rotations of the roll holder portion relative to the dispenser arm. The mounting portion may comprise a probe part of the sensor arrangement, which detects the proximity of the magnet as it moves past the probe on rotation of the roll holder portion.

    [0224] FIG. 5 illustrates the way in which the roll facing side of an end plug may be used to mount an end plug to a roll 120. The Figure illustrates one exemplary embodiment of a roll with which the end plug may be used. This Figure, which is in accordance with WO 2012/073203A2, is merely exemplary in general of the way in which an end plug is used. The end plug 101 includes a roll facing side 105 having formations which are insertable into an opening in an end of a roll of sheet material to secure the end plug to the roll, and a dispenser facing side 103 having formations which cooperate with a roll holder portion of a dispenser to mount the end plug thereto. The formations associated with the roll facing and dispenser facing sides 105, 103 of an end plug in accordance with the invention, which is made from a moulded fibrous material, may differ from those shown in FIG. 5, which illustrates a plastic end plug 101. Examples of such differences are discussed below in relation to certain exemplary embodiments. However, the principles of operation of the end plug will be the same. The roll is a roll of sheet material 108, such as paper towel. However, the sheet material may be of any other type of web material which is suitable for dispensing from a roll. For example, the roll may be a roll of paper material, e.g. for use in providing a hand towel, facial tissue, toilet tissue, or a nonwoven material, e.g. for use in providing a wiper etc. The sheet material may or may not include perforations. The roll dispenses sheet material from the periphery 109 thereof, and is rotatably mounted to a dispenser such that the roll may be rotated to allow the dispensing of material in use.

    [0225] The roll has ends 121, 123. The roll 120 includes a central bore 126 extending from one end to the other along a central axis 110 thereof. In the illustrated embodiment, the bore 126 is defined by the central bore of a core 122 of the roll. The core 122 may be of any suitable material, such as cardboard, paperboard etc. For example, it may be spirally wound core. However, it will be appreciated that the end plugs described herein are not limited to use in the context of a cored roll, and may be used with any roll having an opening in an end thereof into which the formations of the roll facing side 105 may be inserted. For example, a coreless roll may include openings in the form of indentations extending only a small distance along the axis thereof at each end into which the formations of the roll facing side 105 can be inserted, or may similarly have a central bore, extending from one end to the other. Where the end plug is used with a cored roll, it may be referred to as a “core plug”.

    [0226] The end plug 101 is inserted into the opening provided by the end of the bore 126 at the end 121 of the roll with the roll facing side 105 leading as schematically shown in FIG. 5. The formations of the roll facing side which extend from the base 107, are inserted into the end of the bore 126 at the end 121 of the roll. The formations include formations which cooperate with the periphery of the bore 126, provided by the radially inner surface of the core 122 in this case, to provide an interference fit between the end plug 101 and the roll 120.

    [0227] The end plug 101 may be mounted into the roll by pushing the end plug into the end of the bore 126 after manufacture of the roll, as part of a manufacturing process to provide a refill product comprising the roll with the end plugs fitted, which can be supplied to the user. Thus, in such arrangements, the end plugs are inserted by machine. The roll may be packaged with end plugs inserted in both ends for supply to a user.

    [0228] While the insertion of the end plug has been illustrated by reference to the end 121 of the roll, it will be appreciated that another end plug of identical construction will be inserted into the opposite end 123 of the roll, in this case cooperating with the opposite end of the central bore 126. While the invention has been illustrated by reference to the case in which a roll includes end plugs at both ends, depending upon the configuration of a dispenser with which it is intended to be used, it is envisaged that an end plug might only be inserted into an opening at one end of a roll to mount the roll to a dispenser.

    [0229] Certain embodiments of end plugs having a configuration which is particularly advantageous in the context of the use of a moulded fibrous material will now be described. It will be understood, however, that the provision of a moulded fibrous end plug is advantageous per se e.g. in comparison to the plastic end plugs described in WO 2012/073203A2, and the invention is not limited to the use of structures of the type described below.

    [0230] FIG. 6 illustrates a moulded fibrous end plug 1 for a dispenser system in accordance with a first embodiment of the invention from the roll facing side.

    [0231] The end plug 1 has a roll facing side 5, which is uppermost in FIG. 6, and a dispenser facing side 3, which is lowermost. The features of the roll facing side may be seen more clearly in FIG. 7, which is a view from above from the dispenser facing side. FIG. 8 illustrates the end plug of FIGS. 6 and 7 from one side, with the roll facing side uppermost as in FIG. 6.

    [0232] The features of the end plug 1 will now be described by reference to FIGS. 6-8. The roll facing side 5 of the end plug 1 includes formations configured to be inserted into an opening in the end of a roll of sheet material in use in order to secure the roll cap 1 to the roll. The formations provide an interference fit to the outer periphery of the opening.

    [0233] As seen in FIG. 6, the roll facing side 5 includes four domes 7. The domes 7 are of identical construction, and the features of each dome will be described by reference to one of the domes. It will be appreciated that it is not necessary for the end plug to include 4 domes. For example, the number of domes may be in the range of from 2-6 domes, such as from 3-5 domes.

    [0234] The domes 7 surround a central portion 12 of the roll facing side of the end plug. The central portion 12 is centred about the axis X-X of the end plug 1. The central portion 12 may be substantially circular.

    [0235] Each dome 7 includes a planar top surface 9, an inner wall 11 and an outer wall 13. The inner and outer walls 11, 13 and radially inner and outer walls with respect to a central axis X-X of the end plug. Each dome includes a base portion 2 and an upper portion 4. The outer wall 13 includes a first portion 15 in the base portion of the dome and a second, sloping portion 17 in the upper portion of the dome. The sloping portion 17 is inclined with respect to the base portion 15. The angle θ defined between the sloping portion 17 and the first portion 15 of the outer wall 13 may be selected as desired. For example, the angle θ may be in the range of from 20 to 40 degrees, and in some exemplary embodiments is 30 degrees.

    [0236] The end plug includes a peripheral flange 20. The domes 7 are upstanding from a base 18 of the roll facing side of the end plug. The base 18 is defined by a roll facing surface 22 of the peripheral flange 20.

    [0237] The first portion 15 of the outer wall 13 of the dome is upstanding from the base 18 and may extend substantially perpendicular to the base 18. A smooth transition region from the base to the bottom of the outer wall 13 may be disregarded in determining the orientation of the first portion 15 of the outer wall relative to the base 18.

    [0238] The inner wall 11 of the dome extends between the top surface 9 of the dome and the central portion 12 of the end plug 1. The central portion 12 is located at a level between a level of the tops 9 of the domes 7 and the base 18 of the end plug. The top surfaces 9 of the domes, the central portion 12, and the base 18 all lie in different planes.

    [0239] The domes further comprise sidewalls 10 connecting the inner and outer walls 11, 13 thereof.

    [0240] Connecting portions 24 separate the domes from one another. Each connecting portion 24 extends between the central portion 12 of the roll facing side of the end plug and the base 18 thereof. Each connecting portion includes a sloping portion defining a sloping surface 37 on the roll facing side of the end plug, and, in the embodiment of FIG. 6 is a sloping connecting portion. In the embodiment illustrated in FIG. 6, the connecting portion slopes over the entire length thereof. It will be appreciated that the connecting portions may be of differing configuration to that shown in the embodiment of FIGS. 6-8. For example, they may comprise an upper sloping portion and a lower portion upstanding from e.g. substantially perpendicular to the base, or may include multiple panels in a circumferential direction at different orientations to one another, or may include an opening therein etc. While the sloping portions define a planar sloping surface 37 in the embodiment shown, other embodiments are possible e.g. exhibiting a curvature.

    [0241] The domes are of a contoured shape as shown, and may include smooth transition regions between the walls thereof. Each wall may be made up of multiple portions, which may define a smooth transition or an inflection point therebetween. Any portion of a wall may be planar, or may be curved. The embodiment of FIG. 6 is only one possible example of a shape of the domes.

    [0242] The configuration and/or relative spacing of the domes may differ from that shown in the embodiment of FIGS. 6-8. For example, the domes may be more or less closely spaced, and need not necessarily have a planar top surface. The inclination of the outer wall may differ from that shown e.g. to include curved portions, or more than inflection point etc.

    [0243] The outer walls 13 of the domes 7 include protuberances 26. One protuberance 26 is provided per dome, and is used in providing an interference fit to the periphery of an opening in an end of a roll of sheet material in use. The protuberances 26 are discrete protuberances. Each protuberance 26 is able to resiliently deflect in order to provide such an interference fit. The protuberance projects radially from the radially outer wall of the dome for engaging the periphery of an opening of a roll in use. As shown in FIGS. 6-8, the protuberances have a height that is at least as great as the height of the base portion 15 of the outer wall, and may extend through a transition between the base and upper regions (2, 4 /15, 17) of the wall 13.

    [0244] The number, configuration and/or position of the protuberances may differ from that shown. For example, the protuberances may be of lesser height, need not be provided in respect of each dome, and/or may be provided associated with the connecting portions 24 rather than the domes. From 2-6 protuberances may be provided in some exemplary arrangements. Where the protuberances are associated with the domes, the domes may help to support the protuberances and assist in obtaining a secure connection to the roll.

    [0245] The domes, connecting portions and all formations located inboard of the flange 18 are inserted into the opening in an end of a roll in use to secure the end plug to the roll. The flange 18 will be pressed against the material defining the end of the roll and surrounding the opening.

    [0246] The features of the dispenser facing side 3 of the end plug 1 will now be described by reference to FIGS. 7 and 9. FIG. 9 is a section through the end plug along the line 9-9 shown in FIG. 7, illustrating both the roll facing and dispenser facing sides thereof.

    [0247] The peripheral flange 20 defines a dispenser facing surface 30. This lies in a plane defining a front face of the dispenser facing side 3 (which may also be taken to define a base of the dispenser facing side).

    [0248] The roll facing side includes an annular formation 32, which is shown as a cylinder. The annular formation 32 includes a central bore 34, coaxial with the central axis X-X of the end plug. The central bore 34 is closed at the distal end thereof i.e. the end closer to the interior of the end plug. The closed end 36 of the bore is provided by a dispenser facing surface of a portion of the end plug wall whose roll facing surface provides the central region 12 of the roll facing side. In other words, the closed end of the bore is corresponds to the dispenser facing surface of the central portion 12.

    [0249] The annular formation 32 is configured to receive a projection of a roll holder portion of a dispenser in use to mount the end plug to the roll holder portion as will be described in more detail below.

    [0250] The dispenser facing side further comprises sloping surfaces 38 provided by the dispenser facing surface of the portions of the end plug wall whose roll facing surface provides the sloping surfaces 37 of the connecting portions 24 of the roll facing side. The sloping surfaces 38 are configured to engage a ramp structure of the roll holder portion when the end plug is mounted thereto in use as will be described in more detail below.

    [0251] As may be seen more clearly by reference to FIG. 7, the domes 7 create corresponding recesses 40 on the dispenser facing side 3.

    [0252] The end plug illustrated in FIGS. 6-9 may be used with a dispenser as shown in FIG. 1, or FIGS. 2-4. These merely illustrates some embodiments of a dispenser with which the end plugs described herein may be used. It will be appreciated that other dispenser types may be used.

    [0253] The way in which the formations of the dispenser facing side of the end plug of the embodiment of FIGS. 6-9 may cooperate with the formations of a roll holder portion of a dispenser as shown in FIGS. 2-4 to mount the end plug thereto will now be described.

    [0254] FIG. 10 is an exploded view showing how the end plug 1 may be moved in the direction of the arrow to engage the roll holder portion, and illustrating the cooperating features in more detail. FIG. 11 is a cross sectional view which illustrates the end plug once mounted to the roll holder portion.

    [0255] The width d of the wall of the annular formation 32 of the dispenser facing side of the end plug is such that it may be inserted into the annular space 58 to rotatably mount the end plug to the roll holder portion. The projection 54 is received in the annular formation 32. Thus, the bore 34 within annular formation 32 has a diameter to enable it to snugly receive the projection 54. The annular formation and projection thus define complimentary parts which mate with one another. The inclination of the sloping surfaces 38 of the dispenser facing surface is such that the surfaces may engage against the ramp 63 as the end plug rotates relative to the roll holder portion while permitting the annular formation 32 to be fully inserted into the annular space 58. It is not necessary for formations of the dispenser facing side of the end plug to necessarily engage a ramp, where provided, as long as the formations of the dispenser facing side are suitably configured so as not to interfere with the ability to properly fit the end plug onto the roll holder portion to obtain a secure mounting thereto, whether or not this is a rotatable mounting. Further, it will be appreciated that a ramp need not be used, but may be desirable in some cases to facilitate loading of a roll by a user. A suitable annular space similar to annular space 58 may similarly be defined where no ramp is used.

    [0256] As mentioned above, the configuration of the roll holder portion may differ from that shown. The dispenser facing side of the end plug should be suitable configured to cooperate with the formations of a roll holder portion of a dispenser with which the end plug is intended to be used.

    [0257] An end plug may be used to ensure that a roll of sheet material is only used with a dispenser with which it is intended to be used e.g. to ensure optimum performance. For example, a dispenser, particularly although not necessarily an electronic dispenser, may be configured to operate most effectively with a particular type of sheet material (e.g. basis weight) and/or configuration of roll. This may ensure that the dispenser operates reliably without jamming, with greater energy efficiency if electronic, without risk of malfunction and/or safety risk etc. It will be seen from the above example, that the formations of the roll holder portion of a dispenser may be configured in a particular manner such that they will only allow the correct end plug, with appropriate formations which may cooperate with those features, to be mounted thereto. The end plug and roll holder portion should cooperate with one another to enable any complimentary formations to fit together as intended, and to not interfere with the intended mounting of the end plug to the roll holder portion. This may be ensured by controlling the dimensions of the cooperating formations appropriately e.g. the wall of the annular formation of the end plug must have a thickness enabling it to provide a snug fit to the projection of the roll holding portion, but such that it may still fit and rotate within the annular space provided on the roll holder portion face. Similarly, as discussed below, a sloping formation of an end plug must not interfere with any ramp structure of the roll holder portion so as to prevent the projection from being properly received in the annular formation of the end plug to provide a secure mounting.

    [0258] While the cooperation between the moulded fibrous end plug and the roll holder portion of a dispenser has been exemplified in relation to the case in which relative rotation is permitted between the end plug and roll holder portion, such that the end plug may rotate with a roll relative to the roll holder portion during dispensing, in alternative embodiments, the formations of the dispenser facing side of the end plug may cooperate with the formations of a roll holder portion to provide a keyed connection with the roll holder portion, such that the roll holder portion and end plug are maintained in a fixed rotational relationship. The roll holder portion may then be rotatably mounted to an adjacent portion of the dispenser to enable rotation of the roll and roll holder portion relative to another part of the dispenser during dispensing. For example, the roll holder portion may be rotatably mounted to a dispenser arm via a mounting portion e.g. hub fixed to the dispenser arm, with the roll holder portion rotating relative to the mounting portion. Depending upon the configuration of the roll holder portion, some modification to the moulded fibrous end plug may be required in order to provide a keyed connection. FIGS. 20 and 21 illustrate an exemplary embodiment of a moulded fibrous end plug which may provide a keyed connection to a dispenser roll holder portion.

    [0259] The moulded fibrous end plug in accordance with the invention, as illustrated by reference to the exemplary embodiment of FIGS. 6-11 may be mounted to a roll in the manner described by reference to FIG. 5. Although FIG. 5 does not illustrate a moulded fibrous end plug in accordance with the invention, the principle of operation is the same.

    [0260] The end plug 1 is inserted into the opening provided by the end of the bore 126 at the end 121 of the roll with the roll facing side 5 leading. The formations of the roll facing side which extend from the base 22, including the domes 7 are inserted into the end of the bore 126 at the end 121 of the roll. The protuberances 26 cooperate with the periphery of the bore 126, provided by the radially inner surface of the core 122 in this case, to provide an interference fit between the end plug 1 and the roll 120.

    [0261] The end plug 1 may be mounted into the roll by pushing the end plug into the end of the bore 126 after manufacture of the roll, as part of a manufacturing process to provide a refill product comprising the roll with the end plugs fitted, which can be supplied to the user. Thus, in such arrangements, the end plugs are inserted by machine. The roll may be packaged with end plugs inserted in both ends for supply to a user.

    [0262] While the insertion of the end plug has been illustrated by reference to the end 121 of the roll, it will be appreciated that another end plug of identical construction will be inserted into the opposite end 123 of the roll, in this case cooperating with the opposite end of the central bore 126. While the invention has been illustrated by reference to the case in which a roll includes end plugs at both ends, depending upon the configuration of a dispenser with which it is intended to be used, it is envisaged that an end plug might only be inserted into an opening at one end of a roll to mount the roll to a dispenser.

    [0263] The use of the end plug 1 will now be described.

    [0264] An end plug 1 as described by reference to FIGS. 6-11 is inserted into an opening at one end of a roll of sheet material to be mounted to a dispenser, in the same manner described by reference to FIG. 5. Typically another such end plug is also inserted into an opening at the other end of the roll of sheet material. This may be performed during manufacture of a refill roll product. The formations of the roll facing side of the end plug provide a secure interference fit to the roll. The roll and its end plug(s) provides a single unit for (re)filling a dispenser. The user may remove any outer packaging from the roll refill product before fitting the roll to a dispenser. The dispenser may be, but need not be of the type exemplified in FIGS. 1 or 2-4.

    [0265] In order to fit the roll to a dispenser, the user first removes any depleted roll along with its end plugs from the dispenser. The user then pushes the dispenser facing side of the end plug at one end of the roll onto the roll holder portion of a dispenser, such as described by reference to FIGS. 1 or 2-4. In the case of a dispenser of the type shown in FIG. 1, the dispenser arm 102 deflects outwardly to enable the roll to be pushed onto the roll holder portion. The formations associated with the dispenser facing side 3 cooperate with the formations of the roll holder portion 104 to mount the end plug, and hence that end of the roll, to the dispenser arm, for example in the manner described in FIGS. 10 and 11. Where an end plug is associated with the other end of the roll, as may be the case for use with a dispenser of the type shown in FIG. 1, the formations of the dispenser facing side of the end plug at that end of the roll similarly cooperate with the formations of the roll holder portion of the other dispensing arm, to mount that end of the roll to the dispenser. The ends of the roll may be mounted sequentially or substantially simultaneously. In this way, the end plug(s) securely mount the ends of the roll to the dispenser, in the illustrated embodiment, to permit rotation between the roll and the roll holder portions of the dispenser.

    [0266] In use, the end plugs remain securely in place in the ends of the roll during use of the dispenser, e.g. during rotation of the roll relative to the roll holder portion. Once the roll is depleted, the roll along with the end plugs may be removed from between the dispenser arms in a reverse of the initial installation procedure. Where the roll is cored roll, the remainder of the roll product will be the core with the end plugs inserted in its ends. The end plug may be configured such that it may not be removed from the roll without damage, such that it is intended to be disposed of once the roll is depleted, rather than being reused. The end plugs of the present invention are made of a fibrous moulded material, and may therefore be recycled along with the core in a paper recycling stream. This avoids problems associated with conventional plastic end plugs which would need to be removed from the core to enable appropriate recycling of the plastic end plugs and paper core in separate streams. Even if the roll is not a cored roll, the end plugs of the present invention may readily be recycled in a standard paper stream.

    [0267] The end plugs of the present invention are advantageously biodegradable. This offers further sustainability advantages, whether or not the end plugs are recycled in a paper stream. For example, the end plugs may be composted, whether at home or industrially.

    [0268] It is believed that the domed structure of the end plugs described herein is particularly advantageous in providing a sustainable fibrous end plug which may function reliably in the same manner as a plastic end plug. It will be appreciated that plastic materials may be of inherently higher strength than moulded fibrous materials as used in the embodiments described herein. It has been recognised that in order to provide corresponding levels of strength, it is advantageous to modify the shape of the end plug in comparison to the shape of an end plug formed from plastic, in particular on the roll facing side.

    [0269] It has been found that the domed configuration may assist in providing a fibrous end plug which has advantageous strength properties enabling it to function reliably to retain the roll mounted to the dispenser even during the forces which may arise in use during dispensing e.g. where the end plug rotates relative to a roll holder portion of the dispenser. The domed construction may assist in maintaining the secure fit to the roll, and may also assist in supporting the formations of the dispenser facing side which cooperate with the formations of the roll holder portion e.g. an annular formation which receives a projection of the roll holder portion. The domes also provide overall structural integrity to the end plug. The construction may also assist in providing the end plug with the strength to maintain its integrity when pushed into a roll e.g. during manufacture of a roll refill product.

    [0270] The domes impart the surface of the roll facing side with a pattern of alternating peaks and troughs. It is believed that these peaks and troughs may impart strength to the overall structure of the end plug.

    [0271] Of course, the provision of a fibrous moulded end plug is, in itself, advantageous. Thus, the invention resides in general in the provision of such an end plug, and the domed construction illustrated in the exemplary embodiments is an advantageous feature, but need not necessarily be used.

    [0272] FIGS. 12-16 illustrate a moulded fibrous end plug 200 in accordance with another embodiment of the invention.

    [0273] FIG. 12 illustrates the end plug in a perspective view with the roll facing side uppermost.

    [0274] The end plug 200 is similar to the end plug 1 previously described, and corresponding features are labelled incremented by 200. The end plug 200 is used in the same manner as the end plug 1. Only the significant differences will be described. As in the earlier embodiment, the roll facing side 205 includes four domes 207, with protuberances 226 and a peripheral flange 220. The domes have tops 209 and sidewalls 210. A central portion 212 is defined between the domes. This embodiment illustrates the different configurations the domes may have. In this embodiment, each dome extends around the central axis of the end plug by a greater angle than in the earlier embodiment of FIGS. 6-11, with the extent of the connecting portions 24 correspondingly reduced. As in the earlier embodiment, the connecting portions 224 include sloping portions defining sloping surfaces 237 on the roll facing side.

    [0275] FIG. 13 is a top plan view of the dispenser facing side 203. FIG. 14 is a view of the roll facing surface from above, while FIG. 15 is a section along the line 15-15 of FIG. 14, showing the sloping surfaces 238 and 237 more clearly. FIG. 16 is a perspective view of the dispenser facing side.

    [0276] This embodiment illustrates an optional feature of reinforcing ribs 250 which may be associated with the dispenser facing side 205. Such ribs may be used with end plugs of other constructions, including any of the earlier and later described embodiments if desired.

    [0277] The reinforcing ribs are seen more clearly in FIGS. 13 and 16, which respectively are a top plan view of the dispenser facing side 203, and a perspective view thereof. The dispenser facing side includes similar formations to the earlier embodiment, including an annular formation 232. Recesses 240 are defined corresponding to the reverse side of the domes on the roll facing side. Sloping surfaces 238 are defined corresponding to the reverse side of the sloping portion of the connecting portion 224 which defines the sloping surface 237 on the roll facing side. The sloping surfaces 238 cooperate with a ramp structure of a roll holder portion as in the earlier embodiment, while the annular formation 232 receives a projection thereof.

    [0278] With reference to FIG. 16, each rib defines a proximal end 252 and a distal end 254. The proximal end is joined to a radially outer surface of a wall of the annular formation 232 at the base thereof on the dispenser facing side. The distal end 254 is connected to the interior surface of a peripheral wall of the dispenser facing side, corresponding to the dispenser facing surface of the first portion 215 of the outer wall of the dome 207 in the base region of the dome. A first radially extending surface 256 of the rib 250 is located closer to the roll in use. An opposite second radially extending surface 258 of the rib located further from the roll extends along the interior of the dome 207 on the dispenser facing side thereof i.e. along the surface of the recess defined by the dome on the dispenser facing side of the end plug. Each rib is of identical construction.

    [0279] The ribs act to reinforce the end plug. The ribs may help to stabilise the annular formation 232 enabling it to better withstand forces arising in use, and may also stabilise the domes, extending along the dispenser facing surface thereof.

    [0280] It will be appreciated that the number and position of the ribs may differ from that shown. For example, it is not necessary that one rib is provided per dome. The width and height of the ribs may vary. For example, the height over which the proximal and distal ends of the ribs extend over the peripheral wall of the dispenser facing side and/or the wall of the annular formation may vary. While the ribs 250 are shown as extending across the recesses 240 on the dispenser facing sides of the domes 207, alternatively ribs 250 could instead be provided on the dispenser facing side between the domes 207.

    [0281] A yet further exemplary embodiment of an end plug 300 in accordance with the invention is shown in FIGS. 17-19.

    [0282] FIG. 17 is a perspective view of the end plug with the roll facing side 305 uppermost. FIG. 18 is a top view from the dispenser facing side 303, and FIG. 19 is a perspective view from the dispenser facing side.

    [0283] As previously, corresponding reference numerals to those used with the first embodiment of FIGS. 6-11 will be used, incremented by 300. This embodiment illustrates a yet further possible configuration of the domes and the connecting portions therebetween. The end plug 300 is used in the same manner as the earlier embodiments. The protuberances 326 for providing an interference fit are associated with the connecting portions 324 rather than the exterior of the domes in this embodiment. Each dome includes a recessed portion 321 defined along the outer surface thereof. As previously, the dispenser facing side includes an annular formation 332 for receiving a projection of a roll holder portion, and the dispenser facing surfaces 338 of the sloping portions of the connecting portions 324 (which define sloping surfaces 337 on the roll facing side) may cooperate with a ramp structure of a roll holder portion as in the earlier embodiments. In this embodiment, the sloping portions of the connecting portions on the roll facing side are curved with increasing height from the base (and so the sloping surfaces 338 on the dispenser facing side are correspondingly curved).

    [0284] A further embodiment of a fibrous end plug 400 in accordance with the invention is shown in FIGS. 20 and 21. This further embodiment is similar to the earlier embodiments, and the corresponding feature use the same reference numerals as those of the first embodiment, incremented by 400. Only the significant differences will be described.

    [0285] FIG. 20 is a perspective view from above from the roll facing surface. FIG. 21 is a view from above of the dispenser facing surface 403.

    [0286] As in the earlier embodiments, the end plug 400 includes a plurality of domes 407 surrounding a central portion 412 and separated by connecting portions 424. In this embodiment, the connecting portions include sloping portions including sloping surfaces 437 as previously, but in this embodiment, each connecting portion 424 includes an opening 480. The provision of openings in this manner may be useful in controlling the overall strength of the end plug. Introducing openings may be used to decrease the strength of the end plug if required to obtain a desired strength level. The reverse side of the connecting portion 424 defines sloping surfaces e.g. 438 on the dispenser facing side.

    [0287] The dispenser facing side 403 includes various formations provided by the reverse side of formations of the roll facing side. Thus, recesses 440 are provided corresponding to the domes 407, and sloping surfaces are defined provided by the reverse of portions of the connecting portions 424. The formations on the dispenser facing side, as previously, are such that they do not interfere with the ability to mount the end plug securely to a dispenser, with a projection of the dispenser received in the bore 434 of the annular formation 432. Various surfaces on the dispenser facing side may engage a ramp of a dispenser where provided i.e. of the type shown in FIGS. 2-4, 10 and 11, while still permitting the end plug to be properly mounted on to the dispenser roll holder portion.

    [0288] The end plug of FIGS. 20 and 21 is also suitable for use with other dispenser types, in which the end plug is required to be non-rotatably mounted thereto. One or more opening may receive a respective formation of the roll holder portion to retain the end plug in a fixed rotational position relative to the roll holder portion. The edges of the opening may cooperate with the formation of the roll holder portion to prevent relative rotation between the roll holder portion and end plug. For example, the edges of an opening may cooperate with a projecting sensor part of the roll holder portion in this way. An example of such a roll holder portion is described below in relation to FIGS. 20 and 21. Of course, other arrangements may be envisaged to provide a keyed fit, e.g. using a recess in the end plug, not necessarily in the form of an opening, which may receive a formation of the roll holder portion to provide a keyed fit therebetween. Examples are shown in FIGS. 23-31 below.

    [0289] It will be appreciated that openings as shown in the embodiment of FIGS. 20 and 21 may be introduced into any of the other embodiments illustrated if desired. One or more openings may be provided even where a keyed connection between the roll holder portion and end plug is not required, e.g. to tailor the strength of the end plug for a desired application. Thus the embodiment of FIGS. 20 and 21 is not limited to use in arrangements where a non-rotatable connection is required between the end plug and roll holder portion. Similarly, the embodiment of FIGS. 20 and 21 may be produced without openings in the connecting portions if higher strength is required. A keyed fit to a dispenser may be provided in other ways e.g. by cooperation between a projecting portion of the roll holder portion and one of the recesses 440 provided by the reverse of the domes, if a keyed fit to a dispenser is required. Examples of such arrangements are described below by reference to FIGS. 21-31.

    [0290] While in some exemplary embodiments above, a reverse side of connecting portions connecting domes has been illustrated as sloping, and cooperating with a ramp formation of a dispenser roll holder portion to permit mounting of the end plug thereto, it will be appreciated that more generally, the formations of the dispenser facing side should be configured so as not to interfere with the required mounting of the end plug to the roll holder portion, whether rotatable or not. Thus, any surfaces defined on the dispenser facing side, which may be provided by the reverse of formations on the roll facing side, should be configured so as not to interfere with the intended mounting of the end plug. Such surfaces may include sloping surfaces, and may, for example, be provided by the reverse of the domes and/or connecting portions.

    [0291] The use of the end plug of the further embodiments is as described with respect to the first embodiment of FIGS. 6-11. The only difference is that, in some embodiments, the roll holder portion may rotate with the end plug relative to a cooperating portion of the dispenser. For example, the roll holder portion may be rotatable relative to a mounting portion e.g. hub fixed to the arm of the dispenser.

    [0292] A further embodiment of a fibrous end plug 500 in accordance with the invention is shown in FIGS. 22-25. This further embodiment is similar to the earlier embodiments, and the corresponding feature use the same reference numerals as those of the first embodiment, incremented by 500. Only the significant differences will be described.

    [0293] FIG. 22 is a perspective view from above from the roll facing surface. FIG. 23 is a view from above of the dispenser facing surface 503. FIG. 24 is a cross sectional view through the end plug 500 along the line 24-24 of FIG. 22.

    [0294] As in the earlier embodiments, the end plug 500 includes a plurality of domes 507 surrounding a central portion 512 and separated by connecting portions 524. In this embodiment, the connecting portions include sloping portions including sloping surfaces 537 as previously. In this embodiment, in contrast to that of FIGS. 21 and 22, the connecting portions are free from openings. This may provide a stronger end plug.

    [0295] The dispenser facing side 503 includes various formations provided by the reverse side of formations of the roll facing side. Thus, recesses 540 are provided corresponding to the domes 507, and sloping surfaces are defined provided by the reverse of portions of the connecting portions 524. The formations on the dispenser facing side, as previously, are such that they do not interfere with the ability to mount the end plug securely to a dispenser, with a projection of the roll holder portion received in the bore 534 of the annular formation 532.

    [0296] Various surfaces on the dispenser facing side may engage a ramp or other formation of a dispenser where provided i.e. of the type shown in FIGS. 2-4, 10 and 11, while still permitting the end plug to be properly mounted on to the dispenser roll holder portion.

    [0297] The end plug of FIGS. 22-24 is, like the end plug of FIGS. 20 and 21, also suitable for use with other dispenser types, in which the end plug is required to be non-rotatably mounted to a roll holder portion (which is, in turn, rotatably mounted to a mounting portion of the dispenser). One or more of the recesses 540 provided by the dispenser facing side of the domes 507 may receive a respective formation of the roll holder portion to retain the end plug in a fixed rotational position relative to the roll holder portion. The edges of the recess may cooperate with the formation of the roll holder portion to prevent relative rotation between the roll holder portion and end plug. In the illustrated embodiment, each of the domes is of identical construction, and thus defines a recess 540 on the reverse side thereof configured to receive a cooperating formation of the roll holder portion. This may provide greater ease of use, as the end plug may be mounted to the roll holder portion by locating the projecting part of the roll holder portion in the recess defined by any one of the domes. Of course, it is not necessary that each recess defined on the reverse side of a dome is capable of receiving a projecting part of the roll holder portion, provided that the or each projecting part of the roll holder portion present may be appropriately fitted within a recess associated with the dispenser facing side of the end plug to provide the desired connection therebetween. The domes may be configured so as to be tailored to receive the particular configuration of projecting part associated with a roll holder portion with which the end plug is intended to be used, so as to prevent the use of the end plug with a dispenser which is not that intended.

    [0298] In the embodiment illustrated, the dispenser facing side of the end plug 500 does not include reinforcing ribs extending across the recesses 540 defined by the dispenser facing sides of the domes. This may avoid the ribs interfering with insertion of the projecting part of the roll holder portion into the recess 540 defined by a dome. It may be seen that ribs 550 are instead provided in the region between the domes on the dispenser facing surface. Such ribs are optional. It is also envisaged that ribs could be used e.g. being associated with some of the domes, e.g. other than the dome or domes which is to receive the projecting part, and/or being located elsewhere other than in the recesses defined by the domes.

    [0299] The embodiment of FIGS. 22-24 illustrates how, by appropriate configuration of the domes, the reverse side of a dome may be used to provide a keyed connection to a projecting part of a roll holder portion. Thus, an end plug of this general construction may be used either to provide a keyed or rotatable connection with a roll holder portion. Some dimensional changes may be required to fit a given roll holder portion. Of course, the end plugs of the previously described embodiments (by reference to any one of FIGS. 1-21) may similarly be used to provide a keyed connection to a roll holder portion by appropriate configuration of the reverse side of the domes relative to a part of a roll holder portion with which they are to cooperate.

    [0300] The use of the end plug of the further embodiments is as described with respect to the earlier embodiments. In some embodiments, as will now be exemplified, the roll holder portion may rotate with the end plug.

    [0301] FIG. 25 is a perspective view from the front and one side illustrating the front face of a roll holder portion 569 with which the end plug 500 may be used. The roll holder portion 569 is in the form of a hub. The front face comprises formations which may cooperate with the formations of the dispenser facing side of an end plug in accordance with an embodiment of FIGS. 22-24 to mount the end plug to the dispenser. In this example, the formations cooperate with one another to provide a keyed connection between the end plug and the roll holder portion. FIG. 26 is a front on view showing the end plug mounted on the roll holder portion, and FIG. 27 is a sectional view along the line 27-27 of FIG. 26 showing the cooperation between formations of the roll holder portion 569 and the dispenser facing side of the end plug 500.

    [0302] The roll holder portion 569 includes a cylindrical projection 575. An annular structure 581 circumferentially surrounds the projection 575 so as to define an annular space 573 therebetween. The structure 581 defines a circumferentially extending wall which defines the radially outer edge of the annular space 573. The roll holder portion 569 includes a peripheral flange 571 which defines a front face of the roll holder portion from which the annular structure 581 and cylindrical projection 575 are upstanding.

    [0303] In this example, the cylindrical projection 575 of the roll holder portion 569 is received in the bore 534 of the annular formation 532 of the end plug. The annular formation 532 of the end plug fits within the annular space 575 of the roll holder portion.

    [0304] The roll holder portion 569 also includes a projecting sensor part 577 which comprises a magnet. The sensor part 577 forms part of a sensor arrangement for sensing rotation of the roll (with the end plug and roll holder portion) relative to a dispenser arm in use. The sensor arrangement may be used to detect a number of revolutions of the roll. This may be used, e.g. to determine an amount of product remaining etc. The remainder of the sensor arrangement is associated with a portion of the dispenser with respect to which the roll holder portion rotates. For example, in embodiments, the roll holder portion 569 is rotatably mounted to a mounting portion e.g. hub, fixed on a distal end of an arm of the dispenser. Such an arrangement would be similar to that shown in FIG. 1, with the mounting portion provided in the position of the roll holder portion 104 as shown, and with the roll holder portion 569 rotatably mounted to the mounting portion. The mounting portion may comprise a probe portion of the sensor arrangement for detecting the proximity of the magnet part of the dispenser associated with the roll holder portion 569. The probe portion is thus rotationally fixed relative to the dispenser arm. In some exemplary arrangements the probe portion may be electrically connected to a sensor module of the sensor arrangement e.g. using a wired connection. The sensor module may form part of a dispenser module for controlling operation of the dispenser where the dispenser is an electronic dispenser. The sensor module may comprise a processor. In this way, the probe may detect when the magnet passes the probe during rotation of the roll holder portion relative to the mounting portion in use, and hence may determine a number of rotations of the roll.

    [0305] Referring to FIG. 27, when the end plug 500 is mounted to the roll holder portion 569, the sensor part 577 is located within the apex of one of the recesses 540 provided by the reverse of a dome 507 to provide a keyed connection between the end plug 500 and the roll holder portion 569. The apex is provided by the reverse of the top 509 of the dome 507. The roll facing side of the roll holder portion and the dispenser facing side of the end plug are configured to enable the end plug 500 to be fitted over the roll holder portion 569 to result in the sensor part 577 being located in the apex defined on the reverse side of the dome.

    [0306] A further embodiment of an end plug 600 in accordance with the invention will be described with respect to FIGS. 28-31. FIG. 28 is a front perspective view of a roll holder portion 669 with which the end plug may be used to provide a keyed connection. FIG. 29 is a perspective view which illustrates the end plug 600 mounted on the roll holder portion 669 from the roll facing side, while FIG. 30 shows the end plug 600 mounted on the roll holder portion 669 from above.

    [0307] The end plug 600 is of similar configuration to the end plug 500 described by reference to FIGS. 22-27, and may be used in a similar manner. The end plug 600 differs mainly in dimensional detail to accommodate the sensor portion of a roll holder portion 669 which differs in configuration to the roll holder portion 569. The end plug 600 includes domes 607, protuberances 626, a central portion 612 and a flange 671.

    [0308] The end plug 600 includes domes 607 and other features corresponding to those of the earlier embodiment. The reference numerals denoting corresponding features have been incremented relative to the first embodiment by 600. The end plug 600 is configured to cooperate with the roll holder portion 669 such that the sensor portion 677 of the roll holder portion 669 fits within the apex defined on the reverse side of one of the domes 607 i.e by the recess 640 on the reverse side of the dome, to provide the keyed connection. The dispenser facing side of the end plug 600 is of a similar configuration to that of the end plug 500 i.e. including an annular structure defining a bore for receiving a cylindrical projection of the roll holder portion.

    [0309] The roll holder portion 669 is similar to the roll holder portion 569, having a cylindrical projection 675 (which again is shown as a hollow cylinder), and an annular structure 681 surrounding the projection 675 and having a radially inner wall defining an annular space 673 between the annular structure 681 and the projection 675.

    [0310] FIGS. 29 and 30 show the end plug 600 mounted on the roll holder portion 669. The cylindrical projection 675 is received in a bore of the annular formation of the roll facing side of the end plug 600. FIG. 31 is a section taken along the line 31-31 of FIG. 30 which illustrates how the projecting sensor 677 is received in the apex defined by the recess 640 on the reverse side of one of the domes 607 to provide a keyed connection between the roll holder portion and the end plug. The roll holder portion 669 is rotatably mounted to a dispenser as previously described with respect to the roll holder portion 559. Thus, the roll holder portion 669 may be rotatably mounted to a mounting portion e.g. hub fixed to an arm of the dispenser, and including a probe part of the sensor arrangement. Of course, the same end plug 600 could alternatively be used to provide a rotatable connection to a roll holder portion, where the roll holder portion and dispenser facing side of the end plug 600 are appropriately configured i.e. such that a keyed connection is not provided e.g. where the roll holder portion does not include a projecting part that is located within a dome to provide a keyed connection.

    [0311] The end plug of the present invention in any of its embodiments is a fibrous end plug.

    [0312] The end plug is formed from a mixture of fibers and binder. The binder provides a matrix holding the fibers in place. Any suitable binder may be used, but the binder is advantageously biodegradable. The binder preferably comprises one or more biodegradable biopolymer, and preferably comprises starch. In exemplary embodiments the starch is potato starch.

    [0313] The fibres used in making the end plug may be of any suitable type, and are preferably biodegradable fibers, such as cellulosic fibers. Advantageously the fibers are recycled fibers.

    [0314] The end plug may comprise one or more additional substances. For example, these may be residue from substances used to facilitate manufacture and/or may be substances added to impart the finished end plug with desired properties. The end plug may comprise one or more of; at least one colouring agent, at least one preservative, at least one strengthening agent, at least one stabilizer, at least one filler and at least one rising agent. Preferably any such additional substances are natural and/or biodegradable substances.

    [0315] The material of the moulded end plug may comprise a foamed structure.

    [0316] By way of example only, one suitable material for the moulded end plug is PaperFoam®, obtainable from the company PaperFoam® with headquarters in the Netherlands (currently of Hermesweg 22, 3771 ND Barneveld, The Netherlands).

    [0317] A biodegradable end plug in accordance with the invention may comply with any one or ones (and preferably with each) of the following standards; EN 13432, ASTM D6868, TÜV Austria OK Industrial Compost or TÜV Austria OK Home Compost. The end plug may alternatively or additionally be certified as biobased in accordance with any one or ones of; USDA Certified Biobased Product, TÜV Austria OK Biobased (rank 4). The end plug may alternatively or additionally be UL validated as recyclable. The end plug may be UL validated as recyclable with a 99% recovery rate of available fibers.

    [0318] The end plug is obtained using a moulding process. The process may be an injection moulding process in which the material from which the end plug is to be formed is injected into an appropriately configured mould.

    [0319] The mould may include two parts, having formations for producing the desired formations of the roll facing and dispenser facings sides of the end plug respectively. When closed, the mould may define a mould cavity corresponding the shape of the end plug to be produced.

    [0320] Examples of materials which may be used in producing the end plug are described in US 5849152A entitled “Process for the production of shaped bodies from biodegradable material and shaped body” of Rapido Waagen-und Maschinenfabrik GmbH. By way of example only, one suitable material for the moulded end plug is PaperFoam® obtainable from the company PaperFoam® with headquarters in the Netherlands (currently of Hermesweg 22, 3771 ND Barneveld, The Netherlands).

    [0321] One exemplary method for producing the end plug will now be described, by reference to FIGS. 32 and 33. FIG. 32 is a flow chart illustrating one exemplary method for making the end plug, while FIG. 33 illustrates schematically the steps of moulding the end plug in one exemplary embodiment, corresponding to steps 2-4 of FIG. 32.

    [0322] In step 1, a slurry is produced comprising fibers, binder and liquid. In exemplary embodiments, the fibers are cellulosic fibers obtained from recycled material e.g. paper. The fibers may be obtained by comminuting waste paper material. The material may be comminuted in an initial step prior to producing the slurry. In exemplary embodiments the binder is starch, e.g. potato starch. The liquid is water. The starch may be added to the water in powder form to produce the slurry. One or more additives may be added into the mixture to provide the slurry. The additives may be used to impart the material of the final end plug with desired properties. For example, one or more colouring agent, one or more emulsifier, one or more preservative, one or more strengthening agent, one or more filler In exemplary embodiments the additives include a rising agent, such as yeast. This may provide a foamed material. The additives are sustainable e.g. biodegradable additives.

    [0323] In one example, the slurry is composed of; 65% starch (e.g. potato or tapioca), 15-20% fibers e.g. cellulosic fibers, 10% liquid (e.g. water), and 15-20% additives, which may include additives of the type exemplified above, and preferably include a rising agent, such as yeast. The additives may be in the form of a sustainable pre-mix made up of biodegradable materials obtainable from PaperFoam®.

    [0324] The components of the slurry are mixed together to combine them. In some exemplary embodiments, the components of the slurry are mixed by stirring in a tank for a given period, for example 3 minutes. This may help to obtain a desired consistency of the slurry for introduction to a mould, and, where a rising agent, such as yeast is used, may support action of the rising agent.

    [0325] In step 2, the slurry is introduced to a mould 500. The slurry may optionally be transferred from a mixing tank to a holding tank for storage and/or transport to a moulding station prior to introduction to the mould.

    [0326] The slurry is in the form of a thick paste when introduced to the mould. In preferred embodiments, no dewatering of the slurry occurs after initial formation of the slurry and before it is introduced into the mould.

    [0327] The slurry is introduced through the mould by injecting the slurry under pressure into the closed mould e.g. along a path indicated by the arrow in FIG. 33 step 2. It will be appreciated that the slurry may be introduced into the mould at more than one location e.g. including one or more locations which will result in the slurry being introduced into the mould cavity at positions which will correspond to a centre and/or a periphery of the end plug to be produced.

    [0328] The mould includes two parts 502, 504, having formations for producing the desired formations of the roll facing and dispenser facing sides of the end plug respectively. When closed, the mould defines a mould cavity corresponding the shape of the end plug to be produced. Once the slurry has been injected into the mould, the mould parts may be moved closer relative to one another. This may help to enable the slurry to fill the mould cavity. The dimensions of the cavity defined by the mould when in its closed configuration and with their mould parts located at their closest spacing, will define the wall thickness of the end plug. The mould is a metal mould, for example aluminium.

    [0329] In step 3, the slurry is baked in the mould. At least some of the liquid content of the slurry introduced into the mould may evaporate from the mould during the baking step. The liquid may evaporate through openings provided for this purpose in the mould. The heating may bake the slurry in the mould. The step of baking the slurry in the mould may resemble a waffle baking process. The baking process may cause the binder material to form a matrix holding the fibres in place and retaining the resulting end plug in its moulded shape. For example, when the binder is starch, the heating step causes gelatinization and/or cross-linking of the starch material. The material of the end plug is heated to final dryness in the mould. In preferred embodiments no additional mould is used during the process of producing the end plug. During baking, the slurry may be heated to any suitable temperature, and in some exemplary embodiments heated to a temperature of around 400° F. (204° C.). The duration of the heating may be selected as desired, and may depend upon factors such as the viscosity of the slurry, proportion of binder used, the nature of the components of the slurry, and the shape of the moulded end plug to be produced.

    [0330] In step 4 the baked end plug 506 is ejected from the mould. The end plug is finished and ready to be inserted into the end of a roll. This may occur as part of a different process in a different location. Thus, the end plugs may be packaged and shipped for use in producing a refill roll product. It will be appreciated that FIG. 33 illustrates the mould and end plug produced therefrom in only a schematic manner, and does not show the formations on the dispenser and roll facing sides.

    [0331] It has been found that a process as described above in which the end plug is produced by baking a slurry in a mould may be advantageous in providing improved definition in the shape of the end plug and surface properties.

    List of Clauses:

    [0332] 1. A moulded fibrous end plug for use in mounting a roll of sheet material to a dispenser, wherein the end plug has a roll facing side comprising formations configured to be insertable into an opening in an end of a roll of sheet material in use, the formations of the roll facing side including formations for securing the end plug to the roll of sheet material;

    [0333] and an opposite dispenser facing side comprising formations configured to cooperate with formations of a roll holder portion of a dispenser in use for mounting the end plug to the dispenser.

    [0334] 2. The moulded fibrous end plug of clause 1 wherein at least some of the formations of the dispenser facing side of the end plug are provided by a reverse side of formations of the roll facing side of the end plug.

    [0335] 3. The moulded fibrous end plug of clause 1 or clause 2 wherein the formations of the roll facing side configured to be insertable into the opening in the end of the roll of sheet material include a plurality of domes.

    [0336] 4. The moulded fibrous end plug of clause 3 wherein from 2-6 and optionally from 2-4 domes are provided.

    [0337] 5. The moulded fibrous end plug of clause 3 or clause 4 wherein the domes are of identical construction.

    [0338] 6. The moulded fibrous end plug of any one of clauses 3 to 5 wherein each dome is upstanding from a base of the roll facing side of the end plug, optionally wherein the end plug comprises a flange around the periphery thereof, the base of the roll facing side of the end plug comprising a roll facing surface of the peripheral flange.

    [0339] 7. The moulded fibrous end plug of any one of clauses 3 to 6 wherein the domes surround a central portion of the roll facing side of the end plug.

    [0340] 8. The moulded fibrous end plug of clause 7 wherein the central portion defines a planar roll facing surface.

    [0341] 9. The moulded fibrous end plug of clause 7 or clause 8 wherein the central portion is located at a level between the base of the roll facing side of the end plug and the tops of the domes.

    [0342] 10. The moulded fibrous end plug of any one of clauses 7 to 9 wherein each dome extends between the central portion of the roll facing side and the roll facing surface of a peripheral flange of the end plug.

    [0343] 11. The moulded fibrous end plug of any one of clauses 7 to 10 wherein the dispenser facing side of the end plug comprises an annular structure defining a central bore for receiving a projection defined by a roll holder portion of the dispenser, wherein the central bore is a closed ended bore, wherein the closed end of the bore is provided by a roll facing surface of a portion of the end plug whose opposite surface provides the central portion of the roll facing side of the end plug.

    [0344] 12. The moulded fibrous end plug of clause 11 wherein the dispenser facing side of the end plug comprises a plurality of reinforcing ribs extending between the annular structure and a peripheral region of the end plug on the dispenser facing side, optionally wherein each rib extends across a recess in the dispenser facing side of the end plug corresponding to a dispenser facing side of a dome.

    [0345] 13. The moulded fibrous end plug of any one of clauses 3 to 12 wherein each dome comprises a base portion and an upper portion, wherein an outer wall of the dome comprises a first portion in the base portion of the dome upstanding from a base of the roll facing side of the end plug and a second, sloping portion in the upper portion of the dome, the second, sloping portion being inclined relative to the first portion, optionally wherein an angle subtended between the first and second portions of the outer wall is in the range of from 20-40 degrees, such as 30 degrees.

    [0346] 14. The moulded fibrous end plug of any one of clauses 3 to 13 wherein the domes are spaced from one another by connecting portions, each connecting portion extending between the central portion of the roll facing side of the end plug and a base of the roll facing side of the end plug, wherein each connecting portion comprises one or more sloping portion; optionally wherein the connecting portion comprises an opening.

    [0347] 15. The moulded fibrous end plug of clause 14 wherein the dispenser facing side of the end plug comprises a plurality of sloping surfaces configured to cooperate with a surface of a ramp structure of the roll holder portion of the dispenser to enable the end plug to be mounted to the roll holder portion, wherein the sloping surfaces of the dispenser facing side are provided by the dispenser facing sides of sloping portions of the connecting portions.

    [0348] 16. The moulded fibrous end plug of any preceding clause wherein the dispenser facing side of the end plug comprises a plurality of reinforcing ribs, optionally wherein the formations of the roll facing side include a plurality of domes, and each rib extends across a recess in the dispenser facing side of the end plug corresponding to a dispenser facing side of a dome.

    [0349] 17. The moulded fibrous end plug of any one of clauses 1 to 16 wherein the dispenser facing side of the end plug further comprises one or more sloping surfaces configured to cooperate with a ramp structure of the roll holder portion, wherein the sloping surfaces are provided by a reverse side of formations on the roll facing side of the end plug.

    [0350] 18. The moulded fibrous end plug of any preceding clause wherein the formations of the roll facing side for securing the end plug to the roll of sheet material include formations configured to provide an interference fit securing the end plug to the roll.

    [0351] 19. The moulded fibrous end plug of clause 18 as dependent upon clause 3 wherein the formations for providing the interference fit comprise protuberances, wherein each protuberance projects outwardly from a respective one of the domes.

    [0352] 20. The moulded fibrous end plug of any preceding clause wherein the end plug is formed from a material comprising a mixture of fibres and binder.

    [0353] 21. The moulded fibrous end plug of clause 20 wherein the binder comprises one or more biodegradable biopolymer.

    [0354] 22. The moulded fibrous end plug of clause 20 or clause 21 wherein the binder comprises starch, for example potato or tapioca starch.

    [0355] 23. The moulded fibrous end plug of any one of clauses 20 to 22 wherein the binder provides a matrix holding the fibres of the moulded fibrous end plug in place.

    [0356] 24. The moulded fibrous end plug of any preceding clause wherein the fibers are cellulosic fibers.

    [0357] 25. The moulded fibrous end plug of any preceding clause wherein the end plug comprises from 10-40% fibers based on total solids content and/or wherein the end plug comprise at least 50% binder based on total solids content.

    [0358] 26. The moulded fibrous end plug of any preceding clause wherein the end plug is biodegradable.

    [0359] 27. The moulded fibrous end plug of any preceding clause, wherein the end plug is injection moulded.

    [0360] 28. A roll product comprising a roll of sheet material having an opening in an end thereof, and a moulded fibrous end plug in accordance with any one of clause 1 to 27 secured to the end of the roll with the formations of the roll facing side of the end plug configured to be insertable into an opening in an end of a roll of sheet material being inserted into the opening in the end of the roll.

    [0361] 29. A dispenser system comprising;

    [0362] a moulded fibrous end plug in accordance with any one of clauses 1 to 27 and a dispenser comprising a roll holder portion comprising formations configured to cooperate with the formations of the dispenser facing side of the end plug for mounting the end plug to the dispenser in use.

    [0363] 30. A dispenser system comprising; [0364] a dispenser for a roll of sheet material, the dispenser comprising a roll holder portion; [0365] a roll of sheet material having an opening in an end thereof; [0366] and a moulded fibrous end plug in accordance with any one of clauses 1 to 27 secured to the end of the roll of sheet material; [0367] wherein the formations of the roll facing side of the end plug configured to be insertable into an opening in an end of a roll of sheet material are inserted into the opening in the end of the roll of sheet material; [0368] and wherein the formations associated with the dispenser facing side of the end plug cooperate with formations of the roll holder position of the dispenser to mount the end plug to the dispenser.

    [0369] 31. The dispenser system of clause 30 wherein the dispenser facing side of the end plug cooperates with the holder portion to rotatably mount the end plug to the holder portion of the dispenser.

    [0370] 32. A method of using an end plug in accordance with any one of clauses 1 to 27 comprising using the end plug to mount a roll of sheet material to a roll holder portion of a dispenser.

    [0371] 33. The method or dispenser system of any one of clauses 29 to 32 wherein the formations of the dispenser facing side of the end plug and the formations of the roll holder portion which cooperate with one another include respective sets of one or more formations that are complimentary to one another.

    [0372] 34. A method of manufacturing a moulded fibrous end plug in accordance with any one of clauses 1 to 27 comprising providing the moulded fibrous end plug using a moulding process, optionally wherein the moulding process is an injection moulding process.

    [0373] 35. A method of manufacturing a moulded fibrous end plug in accordance with any one of clauses 1 to 27 comprising; [0374] providing a slurry comprising fibers, binder and liquid; [0375] introducing the slurry into a mould; [0376] and heating the slurry in the mould to provide the moulded fibrous end plug.

    [0377] 36. The method of clause 35 wherein the binder comprises a polymeric binder, and the heating step causes gelatinization and/or cross-linking of the polymeric binder material to provide a matrix holding the fibers in place.

    [0378] 37. The method of clause 35 or 36 wherein the method comprises heating the mixture to a temperature of at least 150° C., or at least 180° C.

    [0379] 38. The method of any one of clauses 35 to 37 wherein the step of introducing the slurry in to the mould comprises injecting the slurry into the mould.

    [0380] 39. The method of any one of clauses 34 to 38 wherein the mould is a metal mould, for example an aluminium mould.