Patent Application
20110060693
1. Field of the Invention
The present invention relates to vending machines and their methods of operation, and more particularly to devices and methods used for the storage, return, damping, and delivery of large heavy product containers such as 3-gallon and 5-gallon water bottles.
2. Description of the Prior Art
There has been an explosion in every avenue of bottled water use in the United States and the world, driven in large measure by marketing designed to convince the general public of the safety and purity, and capitalizing on public concern about tap water quality. It is believed that more than half of all Americans drink some form of bottled or container filled water; and about one third of the public consumes it regularly. Sales have tripled in the past 10 years, to about $14 billion a year. The industry standard is approximately ten percent (10%), with the expectation that new technologies, such as the present invention, will help sustain this growth into the future. People spend from 240 to over 10,000 times more per gallon for all types of bottled or container filled water than they typically do for tap water.
The current global market for bottled or container filled water is estimated to be about $70 billion USD. Importantly, macroeconomic analysis shows a total available market of more than double this figure, or $159 billion. Leading areas of growth include Eastern Europe, China, Australia, and New Zealand. This mammoth category within the water industry is built upon many consumer trends, including: consumer's unmet demand for pure water in many economically developed nations, and the increase awareness towards living healthier by a growing number of people.
Currently, consumer demand for bottled water is met in a variety of ways. One way is through services which provide dispensers (water coolers) and also provide delivery and pick-up services, delivering full water bottles to be placed in the dispensers and picking up used empty bottles. Pick up and delivery services are expensive since the consumer must pay for the dispenser, the pickup/delivery service, and for the bottled water itself. This has led to making bottled water available in containers for retail purchase at retail markets. However, such bottled water is only available when the market is open for business, and the water is generally not made available in a cool, refreshing drinkable condition. An alternative way for providing bottled water is through water filling machines which allow consumers to bring in large empty water bottles to be refilled. While these refilling stations may be convenient, the water filters inside may not always provide the cleanest, purest water, and there is the risk of contamination if the consumer has not sufficiently cleaned the bottle being filled. It is therefore desirable to provide an automatic vending machine for providing large heavy product containers for holding fluids such as water that may be accessed at any time during the day or night.
Numerous automatic vending machines are known in the art for providing various kinds of products and product containers. However, relatively few existing vending machines are directed toward use with large, heavy product containers such as 3-gallon or 5-gallon water bottles. Maintaining and dispensing such large product containers presents unusual challenges because of the considerable weight associated with these containers when filled. A 5-gallon water container weighs approximately 41.73 pounds when filled. If as few as ten such bottles are to be stored for potential vending, the total weight is 417.26 pounds; if 25 such bottles are stored, the weight increases to over 1,000 pounds (1,043 pounds). If these heavy bottles are placed in a single queue, this entire pressure is borne by the hold-off mechanism. Moreover, as the lowermost bottle is dispensed, if the remaining bottles were to simply drop down, this could result in rupturing of the lower bottles and/or damage to the hold off mechanism because of the great weight.
U.S. Pat. No. 5,967,364 discloses a vending machine that may be adapted for use with large containers. However, the disclosure system having a oscillating member that alternatively holds off and allows dispensing of a product container. There is no damping mechanism to reduce or slow the movement of the containers when the lowermost container is delivered, and the oscillating hold off member could easily be damaged under the weight of the containers above.
U.S. Patent Publication No. 2002/0043509 discloses a storage rack for large water bottles having speed bumps to reduce the speed of the heavy moving jugs. U.S. Patent Publication No. 2006/0263188 discloses a support structure for holding a single large water bottle prior to insertion into water cooler. This invention utilizes one or more support pistons, but is not designed for use with multiple bottles. U.S. Patent Publication No. 2009/0140000 generally discloses an apparatus for supplying 3-gallon and 5-gallon water bottles, but provides no details regarding the manner by which such bottles are identified, selected, removed from storage, placed on conveyors or delivered. Various rack loaders and carts for large bottles are disclosed in U.S. Pat. Nos. 4,929,140, 5,074,013, 5,846,043, and 6,003,654 and in U.S. Patent Publ. No. 2008/0267744, but none of these patents or publications discloses any damping or individual bottle delivery mechanisms.
It is therefore desirable to provide automatic machines, methods and apparatus for use in reliably storing, transferring, vending and returning large heavy containers without damaging or rupturing the containers or spilling their contents.
The present invention provides numerous solutions, systems, machines, devices and methods for reliably delivering and returning large heavy product containers (such as 5-gallon water bottles) automatically without rupturing or otherwise damaging the containers.
In some aspects of the present invention, an internal damping mechanism is provided as part of a larger apparatus for supporting large heavy product containers. In this aspect, a frame is provided for supporting a plurality of pairs of rails for holding the large product containers in a queue with the rails defining a path inside the frame having at least one turn. One or more damping mechanisms are provided at each turn for slowing down the movement of the product containers on the path. Each damping mechanism includes a panel having an end that is pivotally attached to the frame, one or more springs for urging the panel upward to an extended position, and a compressible support member such as an air, gas or oil filled piston, shock absorber, or spring mechanism attached underneath the panel to slow the movement of the panel when contacted by the heavy product container. This slows the downward movement of the container as it makes the turn, in order to avoid rupturing or damaging the container. In different embodiments of the invention, additional damping mechanisms may be provided at each turn in the path. In the preferred embodiments, two damping mechanisms are provided at each turn, one below the other.
In other aspects of the invention, a frame is provided that supports a plurality of pairs of adjustable rails for holding different sized large product containers. In these embodiments, the positions of one or both of the rails may be changed in order to accommodate different sized containers. For example and without limitation, the rails may be established at a certain separation space to support the shoulder and bottom of 5-gallon water bottles on their sides; one or both of these rails may be adjusted to define a shorter separation space in order to accommodate smaller 3-gallon water bottles. In these embodiments, additional, different or removable guides or panels are provided as part of the damping mechanism(s) for adjustable alignment with the adjusted position(s) of one or both of the rails.
Other aspects of the invention include methods of damping or controlling the transfer of large product containers from one level to another in a frame. In these embodiments, a plurality of large, heavy product containers are provided on a frame defining a path with at least one turn, and at least one damping mechanism is provided at each turn. As a product container makes a turn, it contacts a pivotally mounted panel that is being urged upward using one or more springs or other similar biasing devices. The panel is also supported by a compressible member such as an air, gas or oil filled piston, spring or shock absorber. The amount of air, gas or oil in the piston, or the strength of the shock absorber or spring is determined by the anticipated weight of the product containers and the speed at which they are to be allowed to move. The weight of the product container against the panel causes it to slowly move the panel downward, as the compressible member underneath the panel slowly compresses and gives way. This dampens or retards the downward movement of the container in order to avoid sudden jarring motion that could rupture or damage the container or those behind it. In some embodiments, a stop in the form of a bracket, pin, flange or other blocking or obstructing member may be provided underneath the damping panel to prevent it from going below a pre-determined position. Eventually, the panel will reach a lowermost position and the container will gently roll off, either onto another damper or onto a lower set of rails. Once the container is clear of the panel, the springs will return it to its upward, extended position to be ready to receive the next product container. In alternative embodiments, flanges may be provided on the damper panel to guide the position of the product container while in contact with the panel.
In alternative embodiments, a second damping mechanism is provided immediately below the first damping mechanism which operates in substantially the same way as the first damping mechanism. In particular, in these embodiments, a second pivotally mounted panel is provided that is being urged upward using one or more springs or other similar biasing devices. The second panel is also supported by a second compressible member such as an air, gas or oil filled piston, spring or shock absorber. The amount of air, gas or oil in the piston, or the strength of the shock absorber or spring is determined by the anticipated weight of the product containers and the speed at which they are to be allowed to move. The weight of the product container against the second panel causes it to slowly move the second panel downward, as the second compressible member underneath the panel slowly compresses and gives way. This further dampens or retards the downward movement of the container in order to avoid sudden jarring motion that could rupture or damage the container or those behind it. In some embodiments, a second stop in the form of a bracket, pin, flange or other blocking or obstructing member may be provided underneath the second damping panel to prevent it from going below a pre-determined position. Eventually, the second panel will reach a lowermost position and the container will gently roll off onto a lower set of rails. Once the container is clear of the second panel, the springs will return it to its upward, extended position to be ready to receive the next product container. In alternative embodiments, flanges may be provided on the second damper panel to guide the position of the product container while in contact with the second panel.
In other aspects of the invention, a unique delivery mechanism is provided at the end of a path at the lower end of the frame where the large product containers have been fed by gravity. In these embodiments, the delivery mechanism includes a pivotally mounted delivery tray for receiving the first (lower most/frontmost) large product container. These embodiments include two restraining or hold off members attached to the frame adjacent to the delivery tray. The first such hold off member is closest to the delivery tray, and is made of sturdy construction so as to hold off the first product container, and all product containers queued up behind it. The second hold off member is adjacent to the first, and is also made of sturdy construction so as to be able to hold off the second product container, and all product containers queued up behind it. At least one sensor or switch is provided in the delivery tray for detecting the presence of a product container in the tray and for detecting whether said tray is clear of blockage after a product container has been removed from the tray. A linear actuator, linkage, piston or other movable mechanical member attached to said the tray to cause it to open and close. A processor is provided to control the hold off members, and the linear actuator, and to react to input from the sensor(s) in the tray. In some embodiments, a second movable panel is provided in the tray, and the sensor(s) are provided between this panel and the tray, such that pressure on the panel triggers the sensors indicating the presence of either a product container or some other object in the tray.
In other aspects of the invention, methods for delivering a large product containers from an inclined queue are provided. In these embodiments, a processor receives an activation signal from a user interface that a product container is to be delivered. This is generally in response to a user making payment for the product. A sensor in the tray is used to detect whether a product container is in the tray, and also to detect whether any other object is in the tray. If a product container is already in the tray, the processor may simply cause the tray to be opened, allowing the user to remove the product container. The tray may then be closed, with the processor stopping the closing movement if an object is sensed in the tray. The processor may continue trying to close the tray at different intervals, sensing each time whether any object is in the tray which would prevent full closure.
In these embodiments, when the tray is empty, the processor uses a pair of movable members to move a product container into the tray. A first movable member is used to hold off the second and all subsequent product containers in the queue; and a second movable member is used to hold off the first and all subsequent product containers in the queue. The first movable member is activated to hold off the second and subsequent product containers, and the second movable member is released allowing the first product container to transfer by gravity into the tray. The second movable member is then reactivated to hold off any subsequent containers in said queue. Then, the first movable member is activated to release the second product and subsequent product container from the queue. This allows the second product container to move forward where it is held off by the second movable member. At this point, the tray is full and the product queue has been advanced. The tray may then be opened in response to a user request to deliver the product container in the tray.
In alternative embodiments, the tray may be empty until a user requests a product container. In these embodiments, the steps outlined above are carried out by the first and second movable members to advance the frontmost product container into the tray for delivery. After delivery, the queue may then be left in any of the following conditions: with the frontmost product container being held off by the first movable member, with the frontmost product container being held off by the second movable member, or with the frontmost product container in the tray.
In other aspects of the invention, different embodiments are provided for receiving returned (empty) large product containers. In these embodiments, a cabinet is provided that includes a lower storage area or bin that may be accessed through a large side door for removal of accumulated returned containers. An upper return door is provided in association with guide located adjacent to this door. The guide is used for laterally aligning product containers to be inserted through the upper door. A set of sensors are provided in conjunction with the guide to sense whether the product container has been properly oriented in the guide, and to determine the size of the container (e.g. 3-gallon or 5-gallon). In some embodiments, a first sensor may be provided in the neck area of the guide, and/or second sensor may be provided in the body of the guide where the base of a 3-gallon container would make contact, and/or a third sensor may be provided in the body of the guide where the base of a 5-gallon container would make contact. A processor in communication with the door and the sensor(s) can detect the size of the container being returned, and provide an appropriate credit to the user. Upon recognition of a properly aligned container, an acceptance mechanism receives the container, and provides a credit to the user. If the container is misaligned or otherwise not properly sensed, an appropriate message to this effect (e.g. “please check returned container position”) is provided to the user at the interface.
In related aspects of the invention, methods for returning large reusable product containers by a computer controlled system are provided. In these embodiments, a processor receives an activation signal from a user interface that a container is to be returned. The processor causes a closed return door to be released in response to this signal. A product container is then received through the door, and one or more sensors associated with the door sense the alignment of the container received. If the container is sensed as properly aligned, then it is deposited into a bin and a credit is provided to the user at the interface. If the container is sensed as not being properly aligned, then a signal is sent to the user interface to re-align the container and/or the container is rejected.
In some aspects of the invention, a product storage/delivery (vending) unit may be provided alone or in conjunction with a product return unit. In other aspects of the invention, dual or multiple product vending units may be provided alone or in conjunction with dual or multiple product return units. Ordinarily, multiple vending units and multiple delivery units may be controlled by a single user interface. However, in other embodiments, additional user interfaces may be provided for control of single, dual or other groups of vending units and/or return units. In multiple unit embodiments, all vending units may be configured to deliver the same sized containers (e.g. all units vend 5-gallon containers), or one or more units may be configured differently from the other(s) to provide different sized containers (some units vend 3-gallon containers, and others vend and 5-gallon containers.). Similarly, the return units be configured to receive the same or different sized containers (e.g. all units receive 5-gallon containers, or may also receive 3-gallon), or one or more return units may be configured differently from the other(s) to receive different sized containers (some units receive 3-gallon containers, and others receive and 5-gallon containers), or the same return may receive either size container (either a 3-gallon or 5-gallon). Multiple vending and multiple return units, and different combinations of vending and return units, are contemplated within the scope of the invention, all of which may be operated by a single processor.
In particular embodiments, the frame may preferably be configured to hold 25 product containers, and the delivery bin may hold up to 15 containers. Of course, other numbers of product containers are contemplated within the scope of the invention, depending on the space available and the size of the product containers in use.
In preferred embodiments, the payment system should use either debit or credit cards, not cash. However, currency or coin operated payment interfaces may be provided. Ordinarily, interactive LED screens or multi character display modules are used to instruct the consumer, but any suitable display may be used.
In a typical sequence, after card acceptance, an LED screen or other display prompts the user if a container is to be returned. If the answer is yes, the user follows the return procedure to obtain a credit. If not, the user proceeds to make a purchase. Assuming there is a return, the user will then be prompted to open the return door, insert the empty bottle to be returned, and then close the door. If the bottle is sensed as being properly oriented, it will be accepted and the user will be given a credit at the user interface. The bottle will then be dropped into a storage bin. If the bottle is not properly oriented, the user prompted to try again.
Assuming the return is accepted, the user interface (e.g., LED screen or display) will then prompt the consumer regarding any credit provided for the return, and instruct the user to pay any balance due and then retrieve a full bottle from the tray at the end of the vending unit. When the processor gets a signal to deliver a full water bottle to consumer, the tray is automatically tilted out with a bottle for the consumer to lift out. A weight-sensitive panel in the tray detects removal of bottle, and thereafter automatically closes the tray. If any additional weight is added to door (e.g., someone manually holds tray open or places hand in tray), in some embodiments all machine mechanisms may automatically stop and reverse (reopening the tray) to allow any obstruction to be removed. After the obstruction is removed, the tray will continue to shut.
Thereafter, the vending unit will cause a bottle indexing mechanism, which may include a vibrator, to prepare the next bottle for delivery. In these embodiments, the vibrator will operate for two to three seconds to be sure all bottles start to roll/advance forward on the specially designed rail system. The full bottles will advance one space closer to the tray, along a specially designed rail system, with the bottommost bottle landing in the tray, ready for the next purchase.
When full bottles need to be added to the vending unit, an upper left end door is opened. In some embodiments, pulling open this door will activate the damper system to slow bottles as they roll down the specially designed rail system. However, in most embodiments, the damping system is automatically and continuously engaged. In some embodiments, if bottles stop on the rail system, there will be a manual override button to engage a vibrator system to shake lose any stuck bottles. When the vending unit is full, the delivery person shuts and locks the loading door, and the machine is then ready to operate again.
It is to be noted that in some embodiments the walls of the vending unit are insulated, including the exterior panels of the delivery tray and loading doors. Climate control systems (heating or cooling) may be provided inside the vending units to maintain the temperature of the product containers. It is also to be noted that the first and/or second container hold off systems are designed to be constructed of sturdy materials in order to hold off potentially 1,000 pounds (or more) of filled product containers.
It is therefore an object of the present invention to provide machines, devices and methods for use in automatically vending large heavy containers without damaging or rupturing the containers.
It is also an object of embodiments of the present invention to provide methods and apparatus for automatically damping or slowing the movement of large heavy product containers inside a vending machine.
It is also an object of embodiments of the present invention to provide methods and apparatus for automatically delivering large heavy product containers from inside a vending machine.
It is also an object of embodiments of the present invention to provide methods and apparatus for automatically returning empty large product containers to a machine.
Additional objects of the invention will be apparent from the detailed descriptions and the claims herein.
Referring to the drawings wherein the same reference numeral may be used to designate different parts throughout the several views, and referring particularly to the illustrated exemplary embodiment of
An optional product return unit 70 may be provided as a stand alone unit, or provided in conjunction with one or more vending units 30. As shown in the illustrated exemplary embodiments of
The positions of rails 41, 42 of the present invention may be adjusted to accommodate different sized containers. The illustrated exemplary embodiment of
Because large fluid-filled product containers (such as 3- and 5-gallon water bottles) tend to be heavy, it is important to control the movement of such filled containers inside vending unit 30. This is accomplished using a unique damping system, embodiments of which are illustrated in
At least one upper damper, and preferably both an upper and a lower damper are provided at each transition of product containers from an upper level to a lower level inside vending unit 30. Each upper damper includes a panel 51 that is pivotally mounted at one end to frame 40 so that it may move in an arcuate path around the pivot 52. At least one spring 54 (not shown) is provided with each panel 51 to urge the panel to an extended (upward/outward) position. At least one compressible support member 53 is provided below each panel 51, and may be in the form of an air, gas or oil-filled cylinder, shock absorber, hydraulic or pneumatic piston, spring, spring assembly, or the like, or combinations thereof. Each compressible support member 53 is preferably calibrated so as to slowly compress below panel 51 when under the known weight of a filled heavy container in order to delay, slow or otherwise retard the movement of such a heavy product container. It is to be appreciated that if support member(s) 53 is too strong, it will not be moved by the product container; and if support member(s) 53 is too weak, it will move too quickly under the weight of the product container. An optional stop 55 may be provided underneath panel 51 to establish a bottom position for movement of panel 51 to prevent downward movement (bottoming out) of panel 51 beyond the stop. Stop 55 may be in the form of a bracket, pin, flange or other blocking or obstructing member. One or more flanges 56 are provided along edges of panel 51 to guide product containers on panel 51 and align them with rails 41, 42 as they make the transition from an upper level to a lower level inside vending unit 30. In some embodiments, a removable end piece 45 is provided between rails 41, 42 as shown in
In preferred embodiments, a second lower damper is provided beneath each upper damper at each turn on the product container path, in order to more gracefully transition product containers from an upper level to a lower level. See
In some embodiments, as discussed above, the positions of either rails 41 or 42 may be adjusted to accommodate different sized containers. In those situations where a smaller container is to be accommodated (e.g., a 3-gallon water bottle), a corresponding removable guide 58 is provided that may be temporarily installed on damper panels 51 (and 61) to guide the smaller bottle as it travels through the damping mechanism(s), as shown in
An exemplary embodiment of a product delivery system is illustrated in
An exemplary embodiment of a hold off and delivery mechanism is illustrated in
In some embodiments, the such as those illustrated in
It is to be appreciated that the exact sequence of events for holding off and delivering the frontmost product container may be varied from the sequences above. For example, and without limitation, after a container 101 is placed into tray 81, the tray 81 may then be opened to allow the container to be removed, and may also be closed following removal of the container, before any further action is taken by arms 91 or 95 to move a second bottle into position behind arm 91. It is to be appreciated that other variations in the sequences of these steps may be made within the scope of the invention.
An embodiment of a return unit 70 is illustrated in
It is to be appreciated that opening 72 may be provided in other forms or shapes corresponding to other container or bottle forms or shapes, and that different or additional guides and sensors/switches may be provided inside to detect the presence and orientation of such different product containers.
In some embodiments, dual or tandem vending units 30 which may include one or two return units 70 may be provided under the control of a single processor and a single user interface. In such embodiments, both vending units 30 may be configured to deliver the same sized containers (e.g. both vend 5-gallon containers), or one may be configured differently from the other to provide different sized containers (3-gal. and 5-gal.). Similarly, the return units 70 may be configured to receive either sized containers (e.g. 3-gallon or 5-gallon containers), or one may be configured differently from the other to receive different sized containers (3-gal. and 5-gal.). Multiple vending and multiple return units, and different combinations of vending and return units, are contemplated within the scope of the invention, all of which may be operated by a single processor.
Prior to loading a typical vending unit 30 of the present invention, rails 41 and 42 are moved to the proper orientation for the size of container to be loaded. If necessary, one or more guides 58 are attached to damper panels 51, 61 to correspond to the size of container to be used. End pieces 45 are attached to rails 41, 42 near the dampers. Upper door 31 is unlocked and opened, and full container bottles are individually inserted into the unit 30, traveling by gravity down rails 41, 42 and through the damping mechanisms at each corner so as not to gain too much speed which could cause damage to the containers and/or the machine. First hold off arm 91 receives and stops the first such container 101, and other containers queue up behind it, as shown in
To use a typical vending unit 30 of the present invention, a user operates the interface 35 to select (if multiple units 30 are available with different products) and pay for a product container. Once payment is confirmed, the processor causes arms 91 and 95 to operate in order to allow the frontmost product container 101 to be delivered into tray 81. The remaining containers in the queue may be moved forward at that time, or after tray 81 has been opened, or after tray 81 has been closed. Sensor 89 in tray 81 confirms that a full product container is in the tray, and it is opened so that the user may remove the product container. Once removed, sensor 89 recognizes that there is no longer pressure in the tray, which results in tray 81 being closed. If an object (such as the user's hand) is placed in the tray, before being completely closed, sensor 89 will be activated stopping tray 81 from closing, and reversing the tray to an open position to allow the blockage to be removed. The processor will wait until there is no blockage sensed before trying to close the tray. If no product is sensed as having been delivered to the tray 81 (or in the embodiments of
To return a product, the user activates the user interface which results in the unlocking of door 71 of return unit 70. The user then opens the door, inserts the product container into the guide, and closes the door. The container size and orientation are sensed by sensors 77-79. If a properly oriented product container is sensed, it is received into bin 74, and the user is given a credit at the user interface that may be used toward the next purchase from vending unit 30. If the container is misaligned or otherwise not properly sensed, an appropriate message to this effect (e.g. “please check returned container position”) is provided to the user at the interface. An operator may unlock and open door 73 to remove collected containers from bin 74 for reuse or disposal.
It is to be understood that variations and modifications of the present invention may be made without departing from the scope hereof, and that one or more of the different embodiments disclosed herein may be used together with one or more of the other embodiments to provide additional features for the vending machine. It is also to be understood that the present invention is not to be limited by the specific embodiments or combinations of embodiments, components or parts disclosed herein, nor by any of the exemplary embodiments or combinations set forth in the attached illustrations.
This application claims the benefit of U.S. Provisional Application Ser. No. 61/240,834 filed on Sep. 9, 2009 which is incorporated herein by this reference.
| Number | Date | Country | |
|---|---|---|---|
| 61240834 | Sep 2009 | US |
