CUTLERY DISPENSER AND METHOD OF DISPENSING CUTLERY

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 60/864,636 filed November 7, 2006, which is herein incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to dispensers for cutlery, and more particularly to an automated cutlery dispenser and methods of dispensing cutlery therefrom.

BACKGROUND OF THE INVENTION

Disposable cutlery, for example, plastic spoons, forks, knives and "sporks," (e.g., a combination of a spoon and a fork), are frequently used in informal restaurant settings and are provided for use with "take out" restaurant food. To ensure that this cutlery is provided in a hygienic form, it is often purchased by a restaurant or other facility pre- sealed in a pouch. A napkin and condiments i.e., salt and pepper, may be included in the pouch. Such pouches are generally more expensive than the individual utensils due to the processing and materials necessary to form the pouches. Also, these pouches may provide more cutlery or condiments than the user needs and, as such, may be wasteful.

An alternative to such prepared pouches is the presentation of cutlery for use in an unwrapped form, for example, in a bin or cup. As would be recognized, this allows the customer to select only the utensils desired. However, this form of dispensing can be considered by customers to be unsanitary and can indeed be unsanitary if a previous customer does not take a utensil she touched. This method of providing cutlery for use by a consumer can also be unsanitary if a restaurant worker does not conform to the recommended hygiene standards of using gloves when contacting utensils for use by a consumer. The unregulated dispensing of the cutlery in this form also permits the user to take more utensils than intended, thus resulting in less profit for the establishment.

A variety of dispensers have been proposed as an alternative to loose or pouch- packaged cutlery. Previously known dispensers, however, suffer at least the perception of sanitary and hygienic concerns by many users. For example, when cutlery is dispensed into a collection tray, the tray of the dispenser may become soiled as users repeatedly touch the tray while collecting dispensed cutlery. Also, the handles, knobs or other actuators of manually operated dispensers are touched by user after user, causing concern among some individuals. Previously known dispensers also often lack the degree of convenience and economy in operation that would be desirable.

Accordingly, a continual need exists for improved cutlery dispensers that are particularly useful in dispensing disposable cutlery in a hygienic, convenient, economical and non- wasteful manner.

SUMMARY OF THE INVENTION

The present invention relates to dispensers for disposable cutlery and method of dispensing cutlery.

In one embodiment, a cutlery dispenser comprises a storage chamber adapted to retain a plurality of cutlery therein; an ejector for sequentially ejecting the plurality of cutlery from the storage chamber; an actuator for driving the ejector; and a sensor for triggering the actuator in response to an event.

In one embodiment, a cutlery dispenser comprises a storage chamber adapted to retain a plurality of cutlery therein, the storage chamber comprising a storage chute for retaining the plurality of cutlery in a stacked array; a touchless sensor for generating a signal in response to a user; an electronic controller adapted to receive the signal from the touchless sensor and trigger the automated dispenser mechanism in response thereto; and an automated dispense mechanism in operative communication with the electronic controller, the automated dispense mechanism adapted to discharge at least a portion of one of the plurality of cutlery pieces from the storage chute upon triggering by the electronic controller.

In one embodiment, a cutlery dispenser comprises a storage chute for containing a plurality of cutlery, each piece of cutlery having a handle end and a food-contact end; and a dispense mechanism for sequentially dispensing the cutlery one at a time from the storage chute, by presenting the handle end of a dispensed cutlery for retrieval by a user and retaining the food-contact end of the dispensed cutlery until released upon retrieval by the user.

In one embodiment, a cutlery dispenser comprises a storage chamber adapted to retain a plurality of cutlery therein; an ejector for sequentially ejecting the plurality of cutlery from the storage chamber; an actuator for driving the ejector; and an ultraviolet lamp for anti-microbial effect disposed within the storage chamber.

In one embodiment, a method of dispensing pieces of cutlery comprises sensing an input; and automatically dispensing one of a plurality of pieces of cutlery from the dispenser in response to the input.

The above described and other features are exemplified by the following Figures and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a front perspective view of an automated dispenser according to an exemplary embodiment of the present invention.

Figure 2 is a rear perspective view of the automated dispenser shown in Figure 1.

Figure 3 shows the automated dispenser of Figure 1 with its restocking door removed to better show internal components.

Figure 4 shows the automated dispenser of Figure 1 with additional components removed to better show automated dispensing components thereof.

Figure 5 is a detailed view of the automated dispensing components of the dispenser of Figure 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention may be understood more readily by reference to the following detailed description of the invention and the Figures provided herein. It is to be understood that this invention is not limited to the specific methods, arrangements and conditions described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. For example, reference is made throughout this disclosure to disposable cutlery for ease in discussion with the understanding that non-disposable cutlery (e.g., silverware and flatware) may be used in various embodiments.

In this disclosure and in the claims that follow, reference will be made to a number of terms, which shall be defined to have the following meanings.

The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

Ranges may be expressed herein as from "about" one particular value and/or to "about" or another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another aspect.

"Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event or circumstance occurs and instances where it does not. For example, the phrase "cutlery optionally comprises a stack lug" means that the lug may or may not be present on the cutlery and that the description includes both cutlery having the lug and cutlery not having the lug.

"Disposable cutlery" means any cutlery intended for about one use by the provider thereof although the cutlery can be used more times as desired by the end user. Such cutlery can be comprised totally or substantially totally from polymeric materials, such as polystyrene. The cutlery can comprise fillers, as would be known to one of

ordinary skill in the art. Methods of making disposable cutlery are known and are not described in detail herein. Disposable cutlery can also be prepared from filled polypropylene as described in U.S. patent application Ser. No. 10/227,977 (U.S. patent publication No. 2003/0015824), the disclosure of which is incorporated herein in its entirety by this reference.

"Packet" is used to denote a confined arrangement of a plurality of cutlery pieces, where the confined arrangement is suitable for use in a cutlery dispenser, and where the confining medium allows the cutlery to be aligned in the dispenser so that the cutlery can be reliably presented for use. The packet can be a banded stack of cutlery. Alternatively, the packet can be a stack of cutlery where the individual pieces of cutlery are connected together in stack form by, for example, adhesive or tabs or other means for placement within the cutlery dispenser.

"Stack" refers either to a confined configuration of cutlery or an unbound (e.g. unconfmed) arrangement of cutlery suitably aligned within a cutlery dispenser as indicated by the context.

Unless the context clearly indicates otherwise, the terms "cutlery" and "utensil" are used herein interchangeably to mean a fork, knife, spoon (including a soup spoon), or spork or other types of cutlery intended to be disposable.

Figures 1-5 show an example embodiment of a cutlery dispenser 10 according to the present invention. The cutlery dispenser 10 comprises a housing 12 formed of a back panel 14 and an access door or panel 16 connected to the back panel by one or more hinges 18, or that is removable, for access to internal components thereof. The access door or panel 16 is optionally formed from, in whole or in part, from a transparent or translucent material allowing external visual observation of the internal contents, to monitor the need for restocking of cutlery. The back panel 14 optionally includes one or more mounts or openings 20 for affixing the dispenser 10 to a support or mounting structure, and/or removable panel for accessing internal components. As depicted, the cutlery dispenser 10 is suitable for standalone positioning, as in the serving area of a food court or restaurant; and/or for positioning of multiple dispensers adjacent one

another in a side-by-side or top-to-bottom array, with each dispenser distributing a different type of cutlery utensil. Indicia such as graphics and/or text may be provided on the access door 16 or elsewhere, to indicate which type of cutlery utensil is dispensed by which dispenser.

The dispenser 10 is optionally mounted to a support surface by a pivotal coupling, whereby the dispenser can be turned toward a customer area for use and turned away from the customer area for refilling, service, or to prevent pilferage when the establishment is closed. In alternate forms of the invention, the cutlery dispenser 10 is a component subassembly of another apparatus, such as a vending machine for food or beverages incorporating a cutlery dispenser, and the housing or portions thereof may be omitted from the cutlery dispenser itself.

As seen best with reference to Figure 3, the cutlery dispenser 10 further comprises a storage chamber in the form of a chute 30 for receiving a plurality of cutlery utensils. The interior profile geometry of the storage chute 30 may be configured to closely match or generally correspond to the exterior profile of a particular type of disposable cutlery utensil, or may be configured for universal use with multiple types of utensils. The rails or channels comprising the storage chute are optionally somewhat flexible and/or are mounted to the housing with some play in their coupling, in order to minimize the incidence of cutlery jamming during dispensing. The storage chute 30 includes a receiver 32 at an upper portion thereof, into which the cutlery is loaded and replenished. In alternate embodiments, the receiver is positioned for loading cutlery from the side, bottom, or other location into the storage chamber. In the depicted embodiment, on or more stacked arrays of cutlery are loaded into the storage chute 3, forming an aligned stack of disposable cutlery in substantial contact with the interior of the storage chute around a perimeter of each cutlery piece. By "in substantial contact" it is meant that the cutlery is not present in the storage chute in a cartridge. The one or more stacked arrays of cutlery can be provided in the form of banded packets of cutlery utensils forming modular units. U.S. Patent Application No. 11/556,808, filed November 6, 2006, in incorporated herein by reference in its entirety for further understanding of example forms of banded packets of cutlery and

dispenser configurations suitable for use in connection with the automated dispenser of the present invention.

The storage chute 30 preferably has a capacity of at least one, and more preferably two or more, of the banded packets or other arrays of cutlery intended to be loaded therein. In alternate embodiments, the storage area or chamber of the cutlery dispenser 10 receives a stack or array of cutlery in a cartridge or other form of container or restraint, or is loaded with individual cutlery utensils in loose quantity.

With reference no to Figures 4 and 5, the cutlery dispenser 10 further comprises an automated dispense mechanism 40 for sequentially discharging cutlery utensils one at a time from the storage chute 30 to users. In the depicted embodiment, an ejector comprising one or more cams 42 (first and second cams 42a, 42b are depicted) having lateral displacement steps or surfaces 44 is positioned beneath the discharge opening of the storage chute 30. Cutlery housed in the storage chute 30 is fed to the ejector under the influence of gravity and/or other biasing means such as one or more springs or pistons, and with each operation of the cutlery dispenser 10, the ejector sequentially engages and at least partially discharges the bottom-most piece of cutlery from the storage chute.

Optionally, the proximal end or handle portion of the discharged piece of cutlery is presented to the user and the distal end is loosely held in the dispenser for removal by the user. For example, the lateral displacement surface 44a of the first cam 42a may be offset forwardly or rearwardly in the direction of rotation of the ejector relative to the lateral displacement surface 44b of the second cam 42b, to discharge one end or the other of the discharged piece of cutlery to a greater extent. In this manner, sanitation and hygiene concerns are avoided because users need only touch their selected utensil, which has not previously been exposed to contact by others, and need not touch the dispenser itself. In alternate embodiments, the automated dispense mechanism sequentially discharges the utensils into a collection tray or receptacle 46 optionally mounted to the housing 12 or other structure beneath the ejector. The cam(s) 42 of the ejector optionally comprise one or more eccentric surfaces 48 for jostling the stack of cutlery in the above storage chute 30 upon each operation of the

dispenser, to assist in alignment and efficient dispensing. A variety of cam face and lateral displacement surface configurations may be provided within the scope of the invention, each for example adapted for more efficient discharge of a particular cutlery type. In other alternate forms, the ejector may include one or more fingers, lobes, or other ejection members in place of the depicted cams 42.

The one or more cam(s) 42 are mounted to or integrally formed with a driveshaft 50, which in turn is rotationally mounted within a bore or channel through one or more clamps 52 affixed to the housing or other supporting structure. The bearing surfaces of the driveshaft 50 and the bore of the clamps 52 preferably define a close or medium running fit, to maintain accurate positional alignment but allow free and smooth rotation of the shaft. The driveshaft 50 is coupled to a motor 54, which is powered by one or more DC batteries 56, and/or by an external AC power source through a power cord 58 and an AC/DC power converter 60 to actuate the ejector. While a motor is utilized as the actuator in the depicted embodiment, one or more other types of linear or rotary actuators may drive the ejector within the scope of the invention, including without limitation solenoids, electronic actuators, piezoelectric actuators, magnetic actuators, and/or pneumatic or hydraulic actuators.

The motor or other actuator of the cutlery dispenser 10 is triggered to drive the ejector to automatically dispense cutlery in response to a signal generated by a sensor 70 upon recognition by the sensor or an input or event. In example forms of the invention, the sensor 70 is a motion or proximity sensor such as, for example, an infrared or ultrasonic motion detector or a capacitive proximity sensor. A variety of commercially available or specially designed sensor devices may be adapted for use in connection with the dispenser 10, including for example a photodiode having Part No. BCS100C05 manufactured and sold by Sharp Corp. In alternate embodiments, the sensor can be sound transducer for voice or sound actuation, a temperature sensor, a vibration sensor, a light sensor, or other form of sensor or switch for generating a signal in response to an input.

In example forms of the invention, the sensor 70 is a "touchless" or "touch-free" sensor not requiring physical contact by the user to recognize the input and generate a

triggering signal in response thereto, thereby further avoiding sanitary and hygiene concerns among users. The range of the sensor 70 can vary depending upon the intended application and the expected proximity of the dispenser 10 to other dispensers or objects, but in example forms will recognize an event or input such as a user passing their hand in front of the dispenser at a distance of about 0.25 inches to about 6 inches away. The sensor is preferably positioned at or near the point of discharge of cutlery from the ejector, which may be located at the front, side, bottom or elsewhere on the housing 12, but alternatively can be located remotely from the discharge. An indicator 72, such as an arrow, a flashing light, text, and/or other indicia can optionally be provided to indicate the sensor location and the manner of operation of the dispenser to a user.

In alternate forms of the invention, the sensor 70 is in communication with a vending machine or other device (of which the cutlery dispenser 10 may or may not be a part), and the dispenser is triggered to dispense cutlery in response to the vending of a product. For example, a cutlery dispenser 10 according to the present invention may be operatively associated with one or more vending machines for dispensing coffee, soup or other food or beverage, and a spoon or other utensil is automatically dispensed upon each sale from the vending machine or only upon sale of specified items requiring a specified type of utensil. In still other forms of the invention, the sensor comprises a contact or non-contact switch activated by a user or by an external device.

The sensor 70 communicates an analog or digital signal by way of a wire, conductor or other electrical, optical, magnetic or electromagnetic communication means, to a processor 80 for controlling the operation of the cutlery dispenser 10. The processor 80 may be any type of computational device including, for example, a microprocessor, a microprocessor, a microcontroller, a programmable logic array, a programmable gate array, an application specific integrated circuit (ASIC), and the like. The control of the cutlery dispenser 10 may be implemented solely in hardware, or in a combination of hardware, software and/or firmware associated with the processor 80. The processor is typically a microcontroller that performs the control algorithm in software, which may be stored in on-board memory in the

microcontroller, or in external memory. The memory may be any type of computer- readable medium including, for example, random access memory (RAM), read only memory (ROM), flash memory, compact disks (CDs), digital video disks (DVDs), magnetic disks, magnetic tapes, etc. Signal output from the processor 80 is communicated to a motor controller 90, or alternatively the motor control is integrated in to the processor. The motor controller 90, in turn, delivers power to the motor 54 to drive the cutlery ejector according to a prescribed mode of operation. In the depicted embodiment, the motor 54 actuates the driveshaft 50 and its associated cams 42 in a rocking or pivotal manner, back and forth between a loading position and a discharge position for engaging and discharging sequential pieces of cutlery one at a time from the storage chute 30 upon each operation of the dispenser. A return spring 94 is optionally provided to toggle the ejector back into the loading position. In alternate embodiments, the driveshaft 50 is rotationally driven in a single direction, with each rotation dispensing a single cutlery utensil, or with stepwise rotational increments each dispensing a cutlery utensil such that a single rotation of the driveshaft dispenses two or more utensils.

In an example method of operation, a plurality of disposable cutlery is loaded into the storage chute of an automated cutlery dispenser, or an automated cutlery dispenser is provided already loaded with a plurality of disposable cutlery. To load the dispenser, a door or access panel may be opened or removed, and one or more banded backs of cutlery inserted through a receiver into the storage area of the dispenser. Optionally, the automated dispense mechanism of the dispenser is disabled when the door or access panel is opened or removed, to prevent malfunction and/or waste due to unintended dispensing of cutlery. For example, a positional sensor or relay adjacent the door or access panel may signal the processor to deactivate the actuator when an open position is indicated. Once loaded, the door or access panel is closed and optionally locked using a key or electronic lock, or a hidden release mechanism is provided to prevent unauthorized access to the interior of the dispenser. If the dispenser's power source is not already connected, it is connected at this time. The dispenser may optionally comprise a power switch and/or manual or electronic lockout to prevent unauthorized use, which are activated when ready for use.

When a user needs a piece of cutlery, the dispenser is operated, for example by passing a hand in front of the motion or proximity sensor. The sensor communicates a signal to the processor, which in turn outputs one or more control signals to actuate the automated dispense mechanism and discharge at least a portion of one of the cutlery pieces from the storage chute to be collected by the user. For example, the processor signals the motor controller to operate the motor or other actuator to drive the cam assembly or other ejector through a controlled stroke or motion to eject a handle portion of a utensil for the user to grasp and remove from the dispenser for use.

An interlock may be provided to prevent further operation of the automated dispense mechanism until the previously dispensed utensil is removed by the user, in order to reduce the incidence of jamming. A timer is optionally incorporated into the processor to induce a delay between subsequent operations of the dispenser, to reduce waste. Subsequent users will activate the dispenser in a similar manner, and the dispenser sequentially dispenses cutlery one piece at a time from the storage chute. A refill indicator or alarm is optionally provided to notify service personnel when the sock of cutlery in the storage chute is low and in need of replenishing. Other optional features that may be included in embodiments of the cutlery dispenser within the scope of the invention include lighted marketing or other signage that illuminates when the dispenser is used, and the provision of ultraviolet lamps for anti-microbial effect within the storage and/or dispensing areas.

While the disclosure has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.