PAPERBOARD RETRACTABLE DISPENSER DEVICE
20220024631 · 2022-01-27
Inventors
Cpc classification
A45D40/06
HUMAN NECESSITIES
B65H2301/414323
PERFORMING OPERATIONS; TRANSPORTING
A45D40/16
HUMAN NECESSITIES
International classification
Abstract
A retractable dispenser device includes: an externally threaded multi-ply tube comprising a spiral wound first multi-ply material, wherein the first multi-ply material includes one or more inner plies and an outer ply, wherein the outer ply is wider than the one or more inner plies, wherein subsequent windings of the inner plies abut each other such that the outer ply overlaps at each subsequent winding forming an external thread; and an internally threaded multi-ply sleeve comprising a spiral wound second multi-ply material, wherein the second multi-ply material includes an inner ply and one or more outer plies, wherein the inner ply is narrower than the one or more outer plies, wherein subsequent windings of the outer plies abut each other such that the inner ply leaves a gap at each subsequent winding forming an internal thread.
Claims
1. A retractable dispenser device comprising: an externally threaded tube comprising a spiral wound first ply material, wherein the first ply material includes at least one ply, wherein windings of the at least one ply overlaps itself at each subsequent winding forming an external thread whose width is determined by the amount of overlap and whose height is determined by the thickness of the at least one ply; and an internally threaded multi-ply sleeve comprising a spiral wound second multi-ply material, wherein the second multi-ply material includes an inner ply and one or more outer plies, wherein the inner ply is narrower than the one or more outer plies, wherein subsequent windings of the outer plies abut each other such that the inner ply leaves a gap at each subsequent winding forming an internal thread whose width is determined the difference in width between the one or more outer plies and the inner ply and whose depth is determined by the thickness of the inner ply; wherein each of the tube and the sleeve are each wound at a consistent angle; and wherein the external thread of the tube and the internal thread of the sleeve form a cooperating thread pitch.
2. The retractable dispenser device of claim 1, wherein the externally threaded tube comprises a spiral wound first multi-ply material, wherein the first multi-ply material includes one or more inner plies and an outer ply, wherein the outer ply is wider than the one or more inner plies, wherein subsequent windings of the inner plies abut each other such that the outer ply overlaps at each subsequent winding forming an external thread whose width is determined by the difference in width between the one or more inner plies and the outer ply and whose height is determined by the thickness of the outer ply.
3. The retractable dispenser device of claim 1, wherein the first material comprises a paperboard material.
4. The retractable dispenser device of claim 1, wherein the second multi-ply material comprises a paperboard material.
5. The retractable dispenser device of claim 1, further comprising a stem located within the tube.
6. The retractable dispenser device of claim 5, wherein the stem is affixed to the tube.
7. The retractable dispenser device of claim 6, further comprising a base affixed to the stem.
8. The retractable dispenser device of claim 7, wherein the base includes two or more windows providing tactile access to the tube.
9. The retractable dispenser device of claim 7, further comprising a removeable cap that cooperates with the base to enclose the tube and sleeve.
10. The retractable dispenser device of claim 9, wherein: the base surrounds at least a portion of an outer surface of the sleeve; the first multi-ply material and the second multi-ply material are each paperboard; and twisting the tube in a first rotational direction advances a material supported on the stem in a first axial direction relative to the sleeve and twisting the tube in a second rotational direction opposite the first rotational direction advances the material supported on the step in a second axial direction relative to the sleeve, wherein the second axial direction is opposite the first axial direction.
11. The retractable dispenser device of claim 1, wherein the tube further comprises a support surface spanning an interior diameter of the tube.
12. The retractable dispenser device of claim 11, further comprising a base affixed to the tube.
13. The retractable dispenser device of claim 12, wherein the base includes two or more windows providing tactile access to the tube.
14. The retractable dispenser device of claim 12, further comprising a removable cap that cooperates with the base to enclose the tube.
15. The retractable dispenser device of claim 14, wherein: the base surrounds at least a portion of an outer surface of the sleeve; the first multi-ply material and the second multi-ply material are each paperboard; and twisting the tube in a first rotational direction advances a material supported on the stem in a first axial direction relative to the sleeve and twisting the tube in a second rotational direction opposite the first rotational direction advances the material supported on the step in a second axial direction relative to the sleeve, wherein the second axial direction is opposite the first axial direction.
16. A method of forming an internally threaded tube and a corresponding externally threaded tube comprising the steps of: spirally winding a first material to form an externally threaded tube, wherein the first material includes at least one ply, wherein windings of the at least one ply overlaps itself at each subsequent winding forming an external thread whose width is determined by the amount of overlap and whose height is determined by the thickness of the at least one ply; and spirally winding a second multi-ply material to form an internally threaded multi-ply sleeve, wherein the second multi-ply material includes an inner ply and one or more outer plies, wherein the inner ply is narrower than the one or more outer plies, wherein subsequent windings of the outer plies abut each other such that the inner ply leaves a gap at each subsequent winding forming an internal thread whose width is determined by the difference in width between the inner ply and the one or more outer plies and whose depth is determined by the thickness of the inner ply; wherein each of the tube and the sleeve are each wound at a consistent angle; and wherein the external thread of the tube and the internal thread of the sleeve form a cooperating thread pitch.
17. The method of claim 16, wherein the step of spirally winding a first material comprises the step of spirally winding a first multi-ply material to form an externally threaded multi-ply tube, wherein the first multi-ply material includes one or more inner plies and an outer ply, wherein the outer ply is wider than the one or more inner plies, wherein subsequent windings of the inner plies abut each other such that the outer ply overlaps at each subsequent winding forming an external thread whose width is determined by the difference in width between the one or more inner plies and the outer ply and whose height is determined by the thickness of the outer ply; and
18. The method of claim 16, wherein the first material comprises a paperboard material.
19. The method of claim 16, wherein the second multi-ply material comprises a paperboard material.
20. The method of claim 16, wherein a difference between an exterior diameter of the tube and an internal diameter of the sleeve is in the range of 0.003-0.007 inches.
21. The method of claim 16, further comprising the step of forming a top edge of the tube inward to form a lip.
22. The method of claim 16, further comprising the step of forming a bottom edge of the sleeve inward to create a stop.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
[0051]
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[0054]
[0055]
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[0058]
DETAILED DESCRIPTION OF THE INVENTION
[0059] The present disclosure provides an environmentally friendly product dispenser. Examples of the various elements of the dispensing mechanism are described below with reference to the Figures.
[0060]
[0061] In the embodiment shown in
[0062] In an embodiment, an interior 120 of the tube 104 can be fitted with a flat, raised, or recessed support surface that can be made from a paper or other compostable or biodegradable material upon which the product to be dispensed is supported. Alternatively, the product may be supported by the stem 106. For example, the stem 106 can be housed within the tube 104. In this example, the product can be positioned on the top surface of the stem 106 wherein, during operation of the device 100, the product can extend and retract from the sleeve 102.
[0063] The exterior surface of the sleeve 102 may be housed within an even larger base 108. Additionally, a removable cap 110 may be provided to close off the top of the base 108. It is contemplated that the cap can be constructed of paper. In an example, the cap 110 and base 108 may be of like diameter to provide a well-finished dispensing package. The dispensing device 1 can then be opened, closed, dispensed, and retracted.
[0064] In an embodiment, the bottom of the stem 106 may be flattened out to fit close to the inner diameter of the base 108. As an example, the cap 110 and base 108 may employ a curl and disc top 122. It is further contemplated the bottom 124 of the sleeve 102 may be curled inwardly to prevent the tube 104 moving past the bottom 124 of the sleeve 102 during use. In an embodiment, the top of the tube 104 may be curled in to catch the bottom of the product after the product is poured or inserted in to facilitate retraction.
[0065] In one embodiment, a support platform may be provided within the tube 104 to provide a solid surface upon which the product can be housed and dispensed. In another example, the stem 106 provides a solid surface 128 upon which the product to be housed and dispensed can sit and a flared bottom 130 creates a vertical stop for advancing the product through the sleeve 102 and easily mates to the interior of the base 108 in final assembly as shown in
[0066] The support platform or stem 106 can be fit into the tube 104 in a slightly recessed position to allow the product to flow into or sit in the resulting chamber 132. The top edge 134 of the tube 104 can be formed with a slightly narrowing diameter, creating a lip that can ultimately hold onto the product during retraction.
[0067] To provide optimal performance, the gap between the support platform or the stem 106 and the interior of tube 104 should be minimized. For example, when a product is poured into the chamber at fulfillment, any gaps would allow the product to flow beyond the platform ledge and into the base 108, potentially inhibiting performance and causing product loss.
[0068] In an example, the bottom edge 124 of the sleeve 102 can be formed with a slightly smaller diameter to create a bottom “stop” for the tube 104 in the assembled position. The mating can be performed manually, with the interior ply 112 gap of the sleeve 102 mated to the exterior threads 116 of the tube 104 and inserted sufficiently (or mated by pushing in directly in the push/pull design example) to maintain engagement of the components together prior to further assembly. The stem 106 can then be inserted inside the tube 104 component, and finally the entire assembly inserted into the base 108. Holding can be achieved with glue, friction, or any reasonable method that can maintain the components in their proper orientations throughout use.
[0069] Like the tube 104 and the sleeve 102 components, the stem 106, the base 108, and the cap 110 may also be formed using a paper-based substrate. In one embodiment, the base 108 comprises a wall thickness to maintain structural integrity of the dispenser 1. For example, the tube wall thickness may be 0.030-0.050 inches. The base 108 can be short enough to prevent the tube 104 from retracting beyond its thread engagement with the sleeve 102.
[0070] During use, the tube 104 is secured to the stem 106, which is in turn secured to the base 108. The sleeve 102 moves in and out of the base 108 as product is extended or retracted. More specifically, the tube 104, stem 106, and base 108 are secured together and the external threading 116 of the tube 104 engages internal threading 112 of the sleeve 102 along a lower half thereof in an initial starting position. Product is filled into the sleeve 102 and tube 104. As product is used, the user rotates the sleeve 102 about the tube 104, sliding the sleeve 102 gradually into the base 108 and shifting the tube 104 into an upper half of the sleeve 102. The stem 106 may be adhered into the bottom of the base 108 using techniques such gluing, taping, fastening, etc.
[0071]
[0072] The stem 106, base 108, and cap 110 may be formed using a paper-based substrate. The stem 106, base 108, and cap 110 can include a curl-and-disc operation to create a solid top platform, bottom or top, respectively. In such a process, the bottom edge of the base or top edge of the cap 110 can be “curled” inward using a die. For example, the last ˜¼″ of the edge of the tube 104 is rolled from the outside diameter toward the tube interior, creating an interior ledge upon which a solid end stop can rest. The end stop can be a flat circle of paper and can be fitted (with friction or glued in place) and form a functional closure on one end.
[0073]
[0074]
[0075] A further embodiment of the dispensing device 300 is provided in
[0076] For example, the cutouts 309 can be a width and height to allow the consumer to reasonably grasp the tube 306 at two points that are approximately 180 degrees apart and turn slightly to index the tube 306 upward and downward, while leaving enough material between the cutouts 309 to hold the portions of the base 308 above and below together. The one or more cutouts 309 can be created, for example, using cutting dies. For example, a rotary, steel-ruled or through-punch type cutting die may be used. In an example, a frictional cutting apparatus such as a laser or waterjet may be used. The cutting apparatus may be incorporated as a station in a multi-operation machine or performed as a standalone process.
[0077] In some embodiments, the dispenser 300 can maintain a consistent overall length regardless of the position of the tube 304. For example, when a portion of the base 308 is removed in finishing to create two windows 309 that provide access to the tube 306.
[0078] Referring to
[0079] An example of a method of forming an internally threaded tube 400 is shown in
[0080] An example of a method of forming an internally threaded tube 500 is shown in
[0081] Each of the tube 500 and the sleeve 400 is run at an angle that is consistent throughout the process to form a cooperating thread pitch. The tube 500 and the sleeve 400 are wound using the same base ply widths to create a common or sufficiently similar thread pitch. In an embodiment, the first multi-ply material 402 and/or the second multi-ply materials 502 may comprise a paperboard material.
[0082] For example, as shown in
[0083]
[0084] The height of the exterior male thread 406 may be a function of the thickness of the top ply. As an example, PLY 404a and PLY 404b may each be 0.008″ thick and PLY 406 may be 0.014″ thick. In such an example, the exterior male thread would be 0.014″ high.
[0085] Referring to
[0086] The depth of the interior female thread 508 is a function of the thickness of the bottom ply 504. Using the example in the preceding paragraph, PLY 504 and PLY 506a may each be 0.014″ thick and PLY 506b and PLY 506c may each be 0.008″ thick. In such an example, the interior female thread would be 0.014″ deep.
[0087] In order to facilitate cooperation between the sleeve 102 and tube 104, each must be wound such that the resulting thread pitch matches between the two components. In an example, the winding mandrel 420, 520 about which the tubes are wound determines the inner diameter of each tube 104 or sleeve 102.
[0088] Using the process described above, the resulting tube 400 includes threads 408 that are a solid substrate, which cannot be easily collapsed or worn down over time during use. Properly constructed, the threads fit effortlessly into the sleeve 500 which includes a consistent, hard-edge channel 508 (created by the thickness of the bottom paper ply itself) to promote solid tracking and low-friction turning. The thicker the thread-creation plies are, the deeper the threads can engage with the plies, which results in a more robust mechanism. Further, the closeness in size of the contact diameters of each sleeve and tube component can be less critical, as a thicker ply affords more thread mating depth by design. It is contemplated that a paper caliper for the ply can be 0.012-0.016 inches to create significant thread thickness without imparting excess rigidity or spring-back in the ply as the tube is spirally wound, which makes adhesion more difficult and can result in “checking” or minute folds and breaks in the surface of the paper.
[0089] It is contemplated a wide range of substrates can be used to produce the components of the dispenser device 100, 200, 300. However, it is understood that the descriptions provided herein are particularly well-suited for creating a mechanism made from a paper or similar fiber substrate. For practical purposes, it is useful to use a substrate material that allows the product dispensed from the device to be contained and dispensed (and ideally, but not necessarily, filled into the package in a liquid state) without significant adhesion between the product and tube wall. Such adhesion may adversely impact the dispensing of the product or inhibit the smooth movement of the tube within the sleeve. Ideally, the substrate used has a high resistance to grease, oil, and wax (typically measured and conveyed as a numerical “kit” value by a paper mill) to be compatible with the widest range of products, thereby reducing the risk of the product binding to the paper substrate used to create the sleeve.
[0090] The manufacturing process should also take into consideration proper clearances and thread engagement between the mechanical components of the device 100. This includes controlling the size of the winding mandrels 420, 520 that determine the internal diameter of the sleeve 102 and tube 104, as well as controlling the caliper of each substrate ply that makes up the respective finished wall thicknesses of the sleeve 102 and tube 104. For example, the difference between the outside diameter of the tube 104 and the internal diameter of the sleeve 102 may be small to promote engagement while requiring minimal input force to operate the mechanism. For example, a 0.003-0.007 inches differential has been shown to be particularly advantageous to allow for manufacturing variation, and shrinkage and expansion with changes in relative humidity, for a paper-based substrate.
[0091] Controlling the slit width and cut width tolerance of the paper substrate to be put across the spiral winder to build the tube walls can help to ensure the threads on the tube and sleeve have a nearly identical pitch, which is particularly important as any significant pitch discrepancy between the two parts can cause the mechanism to bind and not move smoothly. The “basis width,” or the width of the paper upon which the spiral winder's belt angle is set to result in minimal ply gap for the body of the tube of the tube and sleeve, can be the same for both the tube and the sleeve.
[0092] Although primarily described above with respect to the use of an overlapping and underlapping winding process, the threads of the sleeve 102 and tube 104 can be created by any method capable of producing engagement between the two components.
[0093] In the primary example provided herein, the production method builds up a threaded section of a first component along a narrow, spiraling path to mate into a groove or depression of similar width and depth on the companion component. For example, an inner surface of the sleeve 102 is formed with female threads (i.e., a continuous spiral groove) that receive male threads (i.e., a continuous raised spiral formation) on the outer surface of the tube 104.
[0094] Although the primary manufacturing methods cost-effectively enable the threading to be created in-line by the spiral winding process, alternatively the threads can be added in a secondary process, if deemed preferable. In an example, the threading can be formed by embossing a channel into one component part (e.g., sleeve) and debossing a cooperating ridge one into the companion component part (e.g., tube). This can be done, for example, as the substrate spirally winds across the forming mandrels to form each tube.
[0095] The assembled components form a package that is ready for filling with liquid or pre-formed solid product and stays in the retracted position until opened by the end user.
[0096] It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages.