Thread Storage and Dispensing System

This invention relates to holders for spools of thread and more particularly to clutch mechanisms for such holders, in order to prevent unwanted rotation or unwinding of the spool, while enabling a withdrawal of a predetermined amount of such thread responsive to a predetermined pulling force.

The term "thread" is used herein as a generic term to designate any suitable thread, string, twine, rope or the like. It is presently thought that dental floss is the specific thread that is most likely to be stored in the holder.

Thread holders of the inventive type have many uses, one of which is to hold a supply of dental floss which is very large relative to the volume enclosed by the outer contours of the holder. The desired general characteristics of such a holder usually requires an almost instantaneous removal of any selected length of thread, a means for cutting and holding the cut end of thread, and a means for securing the spool to prevent it from rotating or unwinding when the thread is not being removed therefrom. The "feel" of the thread being pulled from the holder should be one of a high-quality product.

In addition, when the thread is dental floss, the entire package should be as small as possible for the length of the enclosed thread so that it may be carried about in a pocket or purse, with a minimum of inconvenience. Beyond this, the holder should be attractive, to present a maximum sales appeal. It should also be of a shape and size which is easy for a person to manipulate, even when such person does not have normal dexterity.

Accordingly, an object of the invention is to provide a new and improved holder and packaging system for a spool of thread. Here an object is to provide a holder which can be made almost as small as the maximum-sized spool likely to be used in the holder. Further, an object is to give ready access to almost any desired length of the thread, while restraining the spool to prevent an unwanted unwinding.

Another object of the invention is to provide a basic design and form of thread holder which has general utility for virtually any size of spool or thread, and yet meets the specific needs of a dental floss holder. Here, an object is to provide a holder at a minimum cost.

A further object of the invention is to provide a dental floss holder having a high-quality "feel." Here an object is to provide a dental floss holder which does not become jammed or difficult to use if random unwinding should occur.

In keeping with an aspect of the invention, these and other objects are accomplished by means of a housing (usually plastic) constructed from at least one somewhat cylindrical section, which has a central post coaxially located therein. The thread or floss is wound on a bobbin having a hollow, generally cylindrical hub area molded therein. The clutch comprises a split central post having a generally enlarged cross section for receiving the hollow, cylindrical hub with a frictional gripping between the central post and the hub. The enlarged cross section is preferably distributed along the length of the post to keep the bobbin from tipping or binding. The friction keeps the bobbin from unwinding; however, the friction is not so great that it keeps the floss from pulling smoothly and evenly from the bobbin.

The nature of a preferred embodiment of the invention may be understood from the attached drawing, wherein:

FIG. 1 is a perspective view of the inventive thread holder;

FIG. 2 is a perspective and exploded view of the holder of FIG. 1 and of the spool of thread enclosed therein;

FIG. 3 is a cross-sectional view of the bobbin and split central post taken along line 3--3 of FIG. 2;

FIG. 4 is a similar cross-sectional view, also taken along line 3--3 of FIG. 2, and showing a modification to prevent the thread or floss from jamming the bobbin;

FIG. 5 is a plan view of the bobbin;

FIG. 6 is a perspective view (partly in cross section) showing a second embodiment of the split center post; and

FIG. 7 is a perspective view (partly in cross section) showing yet another embodiment of the invention.

One embodiment of the inventive thread holder (FIG. 1) is especially adapted to store and dispense dental floss. The particular holder, which is shown here, comprises upper and lower holder shells or parts 10, 11, each of which has a generally cylindrical shape. A spool or ball 12 of thread (especially dental floss) is wound on a bobbin 13 for enclosure within the holder, with a loose end E of the thread leaving the holder through hole or opening 14. A top closure plate 15 closes the upper, cylindrical holder part 10 and has at least one semi-pierced detent 16 formed thereon for cutting and anchoring the loose end E of the thread. In this example, there are two such detents 16, 17 on closure plate 15.

The lower holder shell or part 11 comprises a generally cylindrical container having a closed bottom, to give a generally thimble shape.

An alternative embodiment for holding a lesser quantity of thread or floss would use only the lower, thimble-shaped, cylindrical section 11 integrally closed on one end and closed on the other end by a separate plate 15. The assignee of this invention usually makes the single unit, thimble-shaped section 11 with an octagonal, outside cross section, to provide a trademark container. When this single section housing is provided, closure plate 15 fits directly onto section 11, and there is no intervening, upper section 10.

In the two-section housing embodiment of FIG. 1, the rim or top of the lower shell part 11 flares outwardly (at 22) and extends cylindrically upwardly. Therefore, an enlarged circumferential space 22 is provided in the upper peripheral edge of lower part 11 for telescopingly receiving the bottom of the upper part 10. The outwardly flared cylindrical section 22 preferably includes a key or embossment 25 which fits into hole 14, for indexing the upper and lower parts 10, 11, when they are snapped together.

The upper part 10 comprises a generally cylindrical member having a diameter which is substantially the same as the diameter of the lower part 11. The lower edge of upper part 10 has a bead 30 which is approximately the same diameter as the flared cylindrical section 22 on the top of the lower part. Dependent below the bead 30 is a neck 31 of reduced diameter and a gripping portion 33 of slightly larger diameter. The gripping portion 33 is an annular bead surrounding the circumference of member 10.

The lower portion 11 has an internal, circumferential, outwardly projecting bead within the flared cylindrical area 22 which snaps over the gripping portion 33 of the upper part 10. The proportions are such that the dependent sections 31 and 33 slip with friction inside the cylindrical section 22 until bead 30 comes to rest on top of the part 22. When connected, the parts 10 and 11 resist separation, so that it is difficult to separate the holder without prying. To provide greater resistance to separation, parts 10 and 11 may be connected by sonic welding.

The upper interior surface of cylindrical part 10 contains a number of circumferentially-spaced embossments 34 for establishing an upper stop position. Thus, the closure plate 15 may be pressed into the top of upper part 10, to rest on the spaced embossments in a postion which is substantially perpendicular to the axis of the housing cylindrical sections.

At one or two points 40 in the upper rim of the part 10, there is a depression or cut-out which enables the loose end E of the thread to be brought under a semi-pierced detent 16, 17 and to be cut and anchored.

It should now be apparent that a bobbin of thread (especially dental floss) may be placed inside a holder having internal contours which are almost the same shape as, and only slightly larger than, the spool. Thus, there is virtually no wasted space or undue amount of bulk, either inside or outside the housing.

Inside one portion of the housing, here the lower part 11, there is a clutch assembly for preventing any unwanted or random unwinding of the thread on the bobbin 13. In greater detail, the lower cylindrical section has a centrally-located, bifurcated or split post 50 molded therein. This central, bifurcated or split post 50 projects upwardly into the region of the housing which receives the bobbin 13 of dental floss.

The dental floss is wound on bobbin 13 seen in perspective in FIG. 2, plan view in FIG. 5 and in cross section in FIGS. 3 and 4. The bobbin 13 comprises a generally hollow, cylindrical hub region 56 terminated at either end by flanges 58, 59.

In keeping with an aspect of the invention, the clutch action is provided by a combination of the split post 50 having an enlarged central area and the hollow, cylindrical hub area 56. The shape of the central post may vary with the embodiment that is used. Some embodiments also include means for preventing the bobbin from tipping and binding as the spool unwinds.

In greater detail, the central post 50 of the embodiments of FIGS. 2-4 has a generally enlarged or bulbous region 60, as compared to the smaller diameters at 62, 64. The overall diameter of the post 50 is approximately the same as the overall diameter of the cylindrical hub section 56. This means that the end sections 62, 64 are slightly smaller in diameter and the center section 60 is slightly larger in diameter, as compared to the diameter of the hub area 56.

In the embodiment of FIG. 2, upper and lower circular or semi-circular beads 65, 67 are formed above and below the bulbous region 60. These beads do not add very much friction, but they bear against the internal walls of cylindrical hub areas 56 to keep the bobbin from tipping and binding, as the end E is pulled. In the embodiment of FIG. 7, two or more beads are shown as projections 65c,65f,67c,67f formed on the narrow parts 62, 64 of post 50, again to keep the bobbin from tipping. It is important that the beads 65a,65b or 65e, 65f on the upper or split end of the post should be diametrically opposed (i.e., they are equidistant from the floor 66 of the holder 11). This way, the longitudinal forces which resist bobbin tipping are equal and opposite each other, with respect to tipping moments of the bobbin.

As a result of a generally rounded contour on upper end 62, the post 50 slips easily and with a predetermined amount of friction, into the hollow, cylindrical hub area 56. The amount of friction between the post 50 and bobbin 13 may be controlled with great precision since the mold for manufacturing the post and bobbin may be made with such precision.

Two other embodiments of the split post 50 are shown in FIGS. 4 and 6. In FIG. 4, the central post 50a has a centrally located bulbous region 60; however, it does not have the upper and lower beads 65, 67. Instead, the lower bobbin flange 59 is recessed within means for restraining a radial displacement of the bobbin. In this example, the restraining means are a recessed region 70 of housing 11. As the bobbin turns, the flange 59 may ride on the circular wall of recess 70 to prevent bobbin tipping. In FIG. 6, the split post 50b has upper and lower circumferential beads 65c, 65d and 67c, 67d, each of which has a rubbing surface extending over a height H within the cylindrical hub region 56. This height H is adequate to establish a predetermined amount of friction between the bobbin and the post. Again, the circumferential beads 65c, 65d and 67c, 67d are shaped and located to provide equal and opposite forces with respect to tipping moments of the bobbin, thereby stabilizing rotation and resisting any tendency of the bobbin to tip. At least the upper contours of the beads are rounded to guide and direct the bobbin as it slips into the central hub recess 56.

Means are provided for preventing the floss from becoming loose and thereafter jamming under the bobbin. In greater detail, the bobbin may be mounted, as shown in FIG. 3 with the flange 59 of bobbin 13 poised immediately above the internal side of floor 66 of housing section 11. As long as the floss does not come loose from the bobbin, this system functions very well. With the friction of the clutch created by the mechanical interference between post 50 and hub area 56, the floss should never become loose and jamming should never occur.

However, in some usages (especially where the housing 11, 12 is subjected to mechanical shock or vibration), the bobbin 13 may experience an unwanted rotation. The floss might then become slack and fall from the bobbin. As end E is pulled, the loose floss could move into the space between the flange 59 and the floor or bottom 66 of the housing 13, and begin accumulating there. The resulting snarl of floss feeds upon itself, as progressively more of the floss becomes jammed into the space under flange 59.

To forestall such a jammed bobbin, the floor or bottom of the housing 13 may be made in the form shown in FIG. 4. In greater detail, the housing floor or bottom 66a contains the recessed area 70 formed in substantially the shape and dimensions of the flange 59 on the bobbin 13. That recess is just large enough to receive and support the bobbin with little or no added friction.

If there is a significant amount of added friction between flange and the recessed area wall, that amount is subtracted from the friction occurring at the center post. However, the recess is not large enough for the floss to easily pass into it, under any normally expected circumstances. Therefore, if for any reason the floss should loosen and even if a turn or two of the floss should fall from the bobbin and onto flange 59, it would not enter the recess 70 unless a turn of floss falls to a position which exactly fits over the crack between the flange and the side walls of the housing floor 66a. In the unlikely event that this should happen, the turn of floss would almost certainly remain above the bottom of such crack and would not be pulled into the horizontal (as viewed in FIG. 4) space between the lower side of flange 59 and the bottom 66a. When the end E is next pulled, the floss would come out of the crack and return to its normal condition above the housing bottom. The friction between the bobbin and the center post 50 would then restrain rotation and restore normal thread tension.

Hence, it is seen that a jammed condition caused by floss accumulation in the space between flange 59 and floor 66a will not occur under any conditions which are likely to happen. Even if the floss should somehow partially enter the recess, it is most unlikely to reach the space 70. Therefore, it is seen that the recess 70 performs the twin functions of stabilizing rotation to prevent the bobbin from tipping and of preventing the floss from becoming snarled between the bobbin and its holder.

Those who are skilled will readily perceive how changes and modifications may be made, without departing from the teachings of the invention. For example, the various principles may be combined so that the embodiment of FIG. 6 is used in combination with the recess 70 of FIG. 4, for example. Therefore, the appended claims are to be construed to cover all equivalents which fall within the true scope and spirit of the invention.