Apparatus and Methods for Compacting Recyclable Items

COPYRIGHT RIGHTS

{0001] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by any one of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] The present application claims priority from U.S. Patent Application No. 60/815,029, filed June 20, 2006, and U.S. Patent Application No. 60/840,597, filed August 28, 2006, the contents of which are incorporated herein in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED R&D (0003) Not applicable.

PARTIES OF JOINT RESEARCH AGREEMENT |0004J Not applicable.

REFERENCE TO SEQUENCE LISTING, TABLE, OR COMPUTER PROGRAM LISTING [0005] Not applicable.

BACKGROUND OF THE INVENTION Field of the Invention

|0006] The present invention relates to methods and systems for compacting items. Description of the Related Art

(0007] With the increase in waste disposal costs and the increase in sensitivity to preserving the ecology, different approaches have been used to encourage people to recycle waste products. For example, many states have instituted refunds for the return of plastic bottles and aluminum cans. However storing bottles and carrying bottles and cans to a

recycling center is often cumbersome. Thus, many individuals do not bother providing bottles and cans for recycling.

[0008] Thus, despite many years of incentives and a long felt need, conventional techniques have not provided an adequate system or method for facilitating recycling, particularly in the household setting.

SUMMARY OF THE INVENTION

[00091 The present invention relates to methods and systems for compacting items.

[00101 An example embodiment provides a compactor, comprising: a top panel defining a first opening configured to receive items to be compacted; a spring loaded door configured to movably seal the first opening; a first crush surface; a second crush surface; a foot activated lever configured to urge at least the first crush surface towards the second crush surface when pressed downward; and a location for a removable container to receive an item compacted via the first and second crush surfaces positioned lower than the first and/or second crush surfaces.

[00111 An example embodiment provides a manually operated compactor, comprising: an upper side defining a first opening configured to receive an item to be compacted and a second opening configured to receive an item that is not be compacted; a first compacting structure; a second compacting structure; a foot activated lever configured to urge at least the first compacting structure towards the second compacting structure when pressed downward; a location for a removable container to receive an item compacted via the first and second compacting structures positioned lower than the first and/or second compacting structures.

[0012] An example embodiment provides a method of assembling a compactor, comprising: assembling a first portion of a frame, including a foot activated crusher mechanism; attaching a bottom assembly to the first portion of the frame, including a tip inhibition mechanism; attaching a top assembly to the first portion of the frame, including a first opening for receiving items intended to be compacted and a second opening intended to receive items being disposed of without compacting; attaching a front panel assembly including a door to the first portion of the frame; providing one or more compactor handles;

and providing a first container intended to be positioned at least partly under the second opening.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013J Example embodiments of a compactor unit and methods of using the same are disclosed herein are illustrated in the accompanying drawings, which are for illustrative purposes only. The drawings comprise the following figures.

[0014] Figures IA-C illustrates various views of an example compactor unit.

J0015] Figure 2 illustrates an exploded view of the example compactor unit.

[0016J Figure 3 illustrates an exploded view of an example compactor frame.

[0017] Figure 4 illustrates an example compactor mechanism.

JOOJSJ Figure 5 illustrates a bottom view of an example top panel

[0019] Figure 6 illustrates a first cut away view of the example compactor unit.

[0020] Figure 7 illustrates a second cut away view of the example compactor unit.

J0021] Figures 8A-E illustrate example containers.

[0022] Figure 9 illustrates an example process of using the example compactor unit.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0023] A compactor that compresses or compacts items, such as plastic and aluminum beverage containers being disposed of by a user, is described herein. The compaction action can be accomplished via a manually activated lever or by a motor. The compactor unit can be configured to be free standing or to be fixedly mounted in a cabinet.

[0024] In an example embodiment, a compactor unit includes a body housing. By way of example, the housing may be square, rectangular, or cylindrical in shape. Other shapes can be used as well. The housing can be made out of metal, stainless steel, plastic, rubber, other material, or a combination thereof. The housing includes one or more skin/panel portions.

[0025J Optionally, a first skin portion has three walls which forms three vertical walls of the compactor unit and a panel portion forms a fourth wall of the compactor unit. Other configures can be used as well. For example, each wall can be formed in whole or in part by a separate panel or skin. By way of further example, the top and bottom sides can be

configured as removable or fixed panels or shells. Different sides and surfaces can have different colorings, textured surface, and be comprised of different materials. For example, the front side can be one color (e.g., black) and the other vertical sides can be a different color or material (e.g., stainless steel). Optionally, one or more cutouts are provided on the skin to accommodate one or more handles.

|0026] The compactor unit optionally includes a base having a footprint larger in one or more dimensions than compactor unit housing. The base optionally includes one or more slots or other openings. A portion of or the entire base can be in the form of a railing. The railing can have a flattened bottom and one or more flattened other sides. The frame back and/or vertical braces (illustrated in Figures 3 and 4) are optionally assembled to the base. The base can be fixedly or removably coupled to the bottom side, can be integrated with the bottom, can be coupled to the side walls, and/or can be coupled to a frame assembly. The base can be used to enhance the stability of the compactor unit unit. Optionally, one or more feet, such as rubber, plastic, cloth, or metal feet, or feet of other materials can be affixed to the bottom of the base or bottom side to protect the surface on which the compactor unit rests.

[0027] The housing optionally includes one or more hand grips via which a user can grasp and lift or more the compactor unit. For example, the grips can be recessed into one or more sides of the housing and/or one or more grips can protrude from the housing or body of the compactor unit.

[0028] In an example embodiment, a compactor unit includes a foot or hand activated mechanism, such as a lever, coupled to an internal compacting mechanism. The lever can extend outward from the housing, such as through a housing slot or opening. Optionally, text, an icon, and/or other marking (e.g., an arrow and the phrase "open") can be printed on the compactor unit housing and/or a door (described below) to indicate how the lever is to be used. The base, or a portion thereof, can be sized to extend under a portion of the lever or the entire lever. This ensures that the compactor unit will not tip over when the lever is depressed.

|0029] In an example embodiment, the lever includes a pedal portion having a pedaJ head which can be engaged by a user foot. Optionally, the pedal has a rubber surface or

cover (e.g., the pedal head is optionally cast with overanolded rubber). Optionally, the pedal has a generally flat surface that is substantially parallel to the base. Optionally, the lever surface is ribbed and/or includes an insignia, logo, pattern and/or text embossed thereon to reduce slippage when a foot is placed thereon. Optionally, the lever is configured to provide sufficient leverage so that a school age child can operate the lever.

[0030J Optionally, if the lever is to be hand activated, the lever includes a grip portion configured to be gripped by a hand.

(0031 [ If the compactor mechanism is motorized, the lever can be omitted and a motor, power supply, and motor control (e.g., a button or switch) is provided.

I0032J The compactor unit optionally includes a lid that is pivotally hinged or otherwise coupled to the body/skin/panel of the compactor unit. For example, the lid can be pivotally coupled to the body at one end so that the lid can be opened by a user. Optionally, the lid includes two portions each pivotally coupled at one end to the body. Optionally, the lid is spring loaded so that when the user presses the top of the lid or a lever, the spring or springs are released from compression and urges the lid to open.

[00331 Optionally, the Hd at one end curves downward. Optionally, the lid includes a rim around all or a portion of the top surface of the lid. Optionally, one, two, three, or four of the compactor unit housing sides or walls extend above the lid when the lid is in the closed position so that the sides act as a rim.

|0034] When the lid is opened, one or more receiving areas are exposed. The receiving areas are optionally defined by a top panel portion having cutouts. By way of example, one or more of the receiving areas can be sized and configured to receive recyclable items that are not to be compacted by the compacting mechanism described herein. For example, one or more receiving areas can be provided to receive glass bottles, newspapers, magazines, plastic bags, ink cartridges, copier cartridges, substantially non-compressible or compactable items, etc.

\0035] The receiving areas can be in the form of a removable container or liner inserted into a matching top panel opening. For example, a container can be removed by pulling the container upward. A bag, such as a trash bag or a plastic supermarket bag, can be inserted into and used to line one or more of the containers. Optionally, one or more of the

receiving areas can include a wall, rim, or lip that extends past a surface that defines the receiving area. The wall, rim, or Hp can be used to retain the trash bag or plastic bag in place so that the bag does not completely fall into the receiving area when an item is placed therein. In addition, the rim can be used to at least partly support the container or liner when inserted into a corresponding top panel opening (e.g., to prevent the container or liner from falling through the opening). Optionally a support is provided underneath one or more of the receiving areas.

(0036| The compactor lid optionally includes an opening (e.g. round, square, rectangle or other shape) sized to receive a container. For example, the opening can have a diameter or other dimension selected to restrict the diameter of a bottle or can that can be inserted into the opening to be no greater than can be handled by the compactor mechanism. The opening is positioned so that when the lid is closed, the opening overlays an opening in the top panel or wall to the compactor. Optionally, a safety door (e.g., one or more spring loaded panels) is provided that opens inwardly when a user puts pressure on the door panels when the user inserts an item through the opening. Optionally, the safety door includes a locking mechanism to better ensure that a child does not place improper items through the opening.

[0037] Optionally, the compactor lid or housing includes text, an icon, and/or other marking (e.g., an arrow and the phrase "open") to indicate how the lid is to be opened.

|0038] One or more doors are optionally provided on one or more sides of the compactor unit. By way of example, a door is optionally pivotally coupled to the compactor skin, panel, or frame by one or more hinges (e.g., a top hinge and a bottom hinge, a piano hinge, etc.) and/or using one or more retaining devices (e.g., clevis pins, cotter pins, retaining ring, etc.). The door can sized to be less than half or more than half of the area of the wall where the door is located. The door can be configured to open about a vertical axis relative to the base or to open about a horizontal axis relative to the base. A door plate can be attached to the door.

[0039] The door is optionally located on the same side (e.g., the front side) of the compactor as the lever. Optionally, the door or housing skin/panel includes text, an icon, and/or other marking (e.g., an arrow and the phrase "open") to indicate how the door is to be

opened. The door optionally includes a latch (e.g., a magnetic latch, a magnetic catch latch, a mechanical latch, a grabber catch latch) and/or a keyed lock. The latch can be affixed to the frame or housing using screws, welding, press fit, or otherwise. The door optionally includes a cut-out or notched portion via which the pedal or other, lever protrudes when the door is in the closed position.

[0040] When opened, the door exposes a removable container which is configured to hold items, such as cans or plastic bottles, which have been inserted into the lid opening, compacted by the compacting unit, and dropped down into the container. Optionally, the container includes a rim or lip about the top of the container wall which can be used to retain a trash bag or plastic bag in place. By example, the removable container can be made of plastic, metal, rubber, or other material. Optionally, a removable lid is provided for the container. For example, the Hd can be in the form of a snap-on lid or a latched lid (e.g., wherein one or more latches are provided on the container that hold the lid in place when in the closed position).

|0041] The removable container can optionally be stackable so that a user can efficiently store one or more of the containers. For example, the container walls can be flared out from the base.

[0042] In an example embodiment, the compaction mechanism includes two surfaces. As a result of user action (e.g., the user moves the lever or activates a motor control) the surfaces are moved toward each other (e.g., one of the surfaces is moved towards the other surface, or both surfaces are moved toward each other). A compactable item placed between the surfaces is compacted between the two surfaces. The compacted item then falls into the receiving container.

[0043] Figures IA-C illustrates an example embodiment of a compactor unit In Figure IA, the unit 100 has an openable top lid 109 and a front door in the closed position 1 12. A circular opening 108 is provided in the top lid 109 to receive items for compaction. By way of example, the circular opening ] 08 can be sized to receive at least 24 ounce cans (e.g., aluminum cans) or bottles, or to receive cans and bottles of smaller sizes. This example embodiment includes a foot operated pedal 106. In this example embodiment, the pedal 106 has a rubber cover to reduce slippage. The rubber cover further includes an icon. A base is

provided that extends beyond the front face of the unit 1 16 to prevent the unit 100 from tipping (e.g., when the pedal 106 is depressed). Handhold/grips 102, 104 are provided via which a user can grasp, lift, and move the unit 100. A front panel 111 is optionally fixed in normal use (e.g., not openable or readily openable by an end user) to shield a user from the compacting mechanism. The sides and rear of the unit 100 are formed by a panel 107. The panel 107 forms, in part, a raised ridge 1 14 which aids in preventing fluids and waste, from rolling or falling off the unit 100.

[0044J Figure IB illustrates the compactor unit 100 with the top lid 109 open, revealing two container areas 118, 120. For example, the larger area 1 18 of the two container areas can be used receive and store glass bottles, newspapers and the like. The smaller area 120 of the two container areas can be used to receive and store plastic bags (e.g., plastic grocery bags Type 2 made from high-density polyethylene film and Type 4 bags made from low density or linear-low density polyethylene film), or other items. Fewer or additional containers of the same or different sizes and shapes can optionally be included. In this illustration, the door 1 12 is open, revealing a removable bin 122 which is positioned to receive compacted items. An opening 124 is configured to line up with the Hd opening 108 when the lid 109 is in the closed position. Figure 1C illustrates a top plan view of the example compactor unit 100 with the lid 109 in the closed position, thereby closing the opening 108.

[0045] Figure 2 illustrates an exploded drawing of an example compactor unit. In this example, there is the three sided outer skin 107 which may be formed of stainless steel, plastic or other materials. By way of further example, the outer surface can be steel, plastic or other materials. The skin 107 is configured to be mounted to a frame assembly 202. By way of example, the skin 107 can be attached to the frame assembly 202 using one or more fastening mechanisms (e.g., tabs, pern nuts, nuts and bolts, clips, a receiving slot into which an edge of the skin is inserted, welding, or other attachment techniques). The front panel 1 J 1, top shell pane] 128128 and a bottom shell panel 210 can likewise be fastened to the frame 202 and/or the skin 107 (e.g., using tape, glue, etc.). Optionally, the bottom shell 210 is inserted between the base 116 and frame components. In this example, the door 1 12 is pivotally coupled to the front panel 11 1. The top lid 109 can be inserted into the top shell

128, and held in place using pins (e.g., stainless steel or bright zinc plated pins), or otherwise attached.

(0046J Two containers or pods 206, 208 are inserted into receiving openings in the top shell panel 128. A decorative and/or protective ring 305 is inserted into the lid opening. For example, the ring 305 can be a metal or plastic ring. The ring 305 can be glued on to the top lid 109, taped on, or otherwise affixed. When the lid 109 is in the closed position, in this example the receiving openings in the panel 128 are covered (e.g., to make the unit 100 more attractive). When the lid 109 is in the closed position, a "waterfall" appearance is provided, wherein the lid 109 front end curves downward and appears to flow into the front of the unit 100, without a sharp corner. The removable container 122, sized to fit through the door 112 discussed above is provided. When placed in the compactor unit 100, the container (e.g., a plastic tub) 122 rests on the upper surface of the bottom shell panel 210. Optionally lid 214 is provided to close the container 122.

|0047] This example embodiment further includes the illustrated example frame assembly 202, although other frame assemblies can be used with more, fewer, or different frame components. Figure 3 illustrates an illustrated of the components of the example frame 202. In this example, four substantially vertical brace members 308, 310, 316 are provided that are located at corresponding corners of the compactor unit. Front brackets 302 are coupled to the front brace members 308, 310. Brackets 318 are coupled to the rear brace members 316. A pedal 106 extends between two of the vertical members 308, 310. Side bracket braces 312, 320 are provided coupling vertical members to adjacent vertical members. A compactor mechanism 314, also referred to herein as a crusher assembly, is provided. The frame components can be coupled together using one or more fastening mechanisms (e.g., tabs, pern nuts, nuts and bolts, clips, welding, or other attachment techniques).

[0048] Figure 3 also illustrates the example base 1 16, safety lid assembly 126 (used to provide a closure for the lid opening to the compactor mechanism), and ring insert 205 for the lid opening to the compactor mechanism.

|0049] Figure 4 illustrates in greater detail the compactor mechanism 314. In this example embodiment, when the pedal 106 is in a rest state, a crush plate 408 is angled with

respect to a crush arm 404 so that the bottom of the crush plate 408 meets and/or overlaps a bottom portion of the crush arm. For example, the crush plate can be pivotally coupled to the crush arm 404. Optionally, the crush plate 408 is welded in place to the frame back. Optionally, the crush plate face can be planar, v-shaped (e.g., to enhance the crushing action), u-shaped, or otherwise shaped. Optionally, one or more protrusions/blades/sharpened portions can be positioned on the crush plate face, (e.g., with the cutting edge of the blade facing outwards) to better crush and/or cut the item being compacted. Optionally, the blade(s) or other protrusions relative to the plate face are removable and/or replaceable. For example, a blade can be removable mounted in a bracket coupled to the plate. Optionally, the blade(s) can be sharpened periodically. A crusher brace 406 is coupled to the crush arm 404 to maintain the crush plate 408 within a desired range of positions. The crush plate 408 moves with the area defined by the crusher brace 406. A stop 402 (e.g., a rubber stop) is provided on the metal frame.

10050J Optionally, one or more shock absorbers/stops can be positioned on the metal frame or otherwise to prevent the pedal from striking the frame itself when the user pushes all the way down on the pedal and/or to slow the descent of the pedal when the pedal is being depressed by a user. For example, the shock absorber can be an air or hydraulic shock with one end coupled to the pedal lever and one end coupled to the frame. The shock absorber can be a rubber stop positioned so that the pedal or pedal lever will strike the stop when fully depressed. A stop (e.g., a rubber stop) can be positioned on the metal frame or otherwise to prevent the pedal from striking the frame itself when the pedal is in the undepressed, at rest position.

[0051 J A frame back 414, coupled to the bottom shell 210 and/or other frame components, is provided that least partly supports the crush arm 404. A link is coupled to the crush plate and to a pedal brace 416. A pedal spring 412 (e.g., a helical spring) or other elastic device is coupled to the pedal brace 416 (e.g., by having one end inserted into a hole in the pedal brace) and the crush plate 408. The pedal 106 is coupled to the pedal brace 416. An end portion of the pedal is pivotally coupled to the frame back 414. Optionally, a cam gear mechanism is provided to further reduce the force needed to operate the compactor mechanism. .

[0052] When a user drops an item into the compactor unit 314, it will fall into the area defined by the crush plate 408 and the crush arm 404, where the intersection of the crush arm 404 and plate 408 stops the item from falling further. When the user depresses the pedal 106, the crush plate 408 is pivotally urged towards the crush arm 404, compressing and compacting the item. When the user releases the pedal 106, the spring 412 urges the crush plate 408 back to the rest position, allowing the compacted item to fall down a chute into the container 1 12, which is located lower than, and optionally offset from the compactor crush plate 408.

|0053] Optionally, the frame back 414, crush plate 408, crush arm 404, link 410, pedal brace 416 are plated (e.g., bright zinc plated or using other plating). Optionally, one or more other parts are powder coated or otherwise finished.

[0054] Figure 5 illustrates a bottom view of the top shell panel 128. The spring loaded safety door/lid 126 is provided to close an opening to the compactor mechanism.

10055) Figure 6 illustrates a side perspective cut away view of the example compactor unit.

[0056] Figure 7 illustrates a rear cut away view of the example compactor unit.

[0057] Figure 8A illustrates an example stackable container used to receive compacted items in the compactor unit. This example embodiment includes two integral handles for lifting the container. By way of example and not limitation, the container can be in the range of 2-5 gallons or 5-10 gallons in size/capacity. For example, the container can be 2, 3, 4, 4.9, 5, 6, 7, 8, 9, or 10 gallons in size/capacity. Figure 8B illustrates an example lid for the container illustrated in Figure 8A. Fig. 8C illustrates an example of the containers for items that are not being compacted. By way of example and not limitation, the larger of the containers is sized to receive bottles, such as glass bottles. By way of further illustration, the larger of the containers can be 1-5 gallons (e.g., I ₅ 2, 2.9, 3, 4, 5 gallons) or larger. In an example embodiment, the larger of the containers is 10"W x 6.5"L, although wider, narrower, longer, or shorter dimensions can be used as well. By way of further illustration, the smaller of the containers can be configured to receive bags, such as plastic bags. The smaller container, by way of example, can be 0.25-2 gallons (e.g., 0.5, 1, 1.5, 2, gallons) or larger or smaller. The containers may optionally be translucent. Figure 8D illustrates an

example snap-on container cover including a logo/trademark. Figure 8E illustrates example containers 206, 208.

[00581 Figure 9 illustrates an example process of using the compactor unit. At state 1 , a user inserts an item into a compactor lid opening. At state 2, the user depresses the compactor foot pedal. At state 3, the user opens the compactor unit door. At state 4, the user opens the compactor door to remove the container from the compactor unit. The user can then take the compacted items to a recycling/redemption location.

(00591 At state 5, the user opens the compactor lid. At state 6, the user stores one or more items in one or more receiving areas in the compactor unit.

|0060] The following lists example assembly steps, however, fewer, additional, or different steps can be used. In addition, that steps do not necessarily have to be performed in the order discussed below.

ASSEMBLY STEPS

1 Assemble Frame

2 Insert rubber pad/feet into base

3 Assemble frame - bottom shell - base assembly

4 Assemble top shell - top lid sub-assembly

5 Assemble door-front panel sub-assembly

6 Attach front panel assembly to frame (e.g., with pop rivets or screws)

7 Attach pedal to frame through front panel

8 Attach pedal spring to frame

9 Attach top shell assembly to frame (e.g., with pop rivets or screws)

11 Install handles

10 Attach outer skin

12 Install pods

[00611 While the foregoing detailed description discloses several embodiments of the present invention, it should be understood that this disclosure is illustrative only and is not limiting of the present invention. It should be appreciated that the specific configurations and operations disclosed can differ from those described above.