Vending machines have been known for a number of years in which the vending machine dispenses a prepackaged solid food product in response to a selection entered by a user.

However, presently, it is only possible for vending machines to dispense prepackaged solid food products which are loaded into the vending machine already prepackaged.

Hence, the user's selection of a food item is limited to the prepackaged food products which are within the vending machine, as the vending machines are not capable of making a food item in response to a user selection.

In accordance with the present invention, a vending machine comprises a housing, an outlet in the housing for dispensing a prepared solid food product, a selection input device located on the housing, the selection input device permitting a user to select ingredients from a number of different ingredients, and a number of ingredient holders, a preparation mechanism and a processing unit located within the housing; the processing unit dispensing the selected ingredients from the ingredient holders to the preparation mechanism in response to an input signal received from the selection input device, and the processing unit controlling preparation of a solid food product from the selected ingredients and dispensing the prepared solid food product to the outlet.

An advantage of the invention is that by having a number of ingredient holders within the vending machine and a preparation mechanism both controlled by a processing unit, a product such as a food item, can be prepared in the vending machine in response to a selection input by a user.

Preferably, the product prepared and dispensed by the vending machine is a sandwich or another form of food item with a filling located between two pieces of a bread item such as a roll or other form of bread product. However, typically, the bread items are slices of bread.

An example of a vending machine in accordance with the invention will now be described with reference to the accompanying drawings, in which:- Figure 1 is a schematic block diagram showing a vending machine for dispensing sandwiches; Figure 2 is a schematic diagram showing some of the main components within the vending machine; Figure 3 is a cross-sectional side view of the vending machine; Figure 4 is a perspective view of a bread dispenser for use in the vending machine; Figure 5 is a cross-sectional view of a bread dispenser for use in the vending machine; Figure 6 is a cross-sectional view of the vending machine on the line AA of Figure 3; Figure 7 is a detailed plan view of one pair of preparation plates on the preparation mechanism; Figures 8 and 9 each shows an ingredient holder and dispenser attached with a type of nozzle for use with the vending machine; Figures 10,11 and 12 show nozzle attachments for use with the ingredient holder and dispenser shown in Figures 8 and 9; and Figure 13 is a plan view along the line BB of ingredient holders and dispensers located in the vending machine.

Figure 1 shows a schematic block diagram of a vending machine 1 which includes an outer housing 2. The outer housing 2 includes a front display selection panel 3, a window 4 (optional) which permits viewing of a preparation compartment 11, a dispensing bin 5 and a coin entry mechanism and a cash card, credit card or charge card reader 6.

The vending machine 1 prepares and dispenses sandwiches from a mix of menu items selected by a customer by means of the front selection panel 3. The vending machine may be similar in size to an average free standing vending machine and the typical dimensions may be 36"to 40"wide, 36"to 40"deep and 72"high.

The vending machine 1 includes control circuitry which comprises a side circuitry 7, a top circuitry 8 and a base circuitry 9. The top circuitry 8 controls the temperature of an ingredient compartment 10, controls dispensing of the ingredients from the ingredient compartment 10 and also controls a preparation mechanism 30 within the preparation compartment 11. The side circuitry 7 couples the top circuitry 8 and the base circuitry 9 together and also facilitates reading of a credit card, cash card, charge card or ATM card to facilitate payment, and payment by bank notes or coins. In addition, the side circuitry 7 relays instructions to the various components within the vending machine 1 to control and execute making of a sandwich based on a selection of a customer made via the front selection panel 3. The side circuitry 7 also controls the temperature of a bread storage compartment 12 and the front toasting panel 57.

The bread storage compartment 12 is located in the lower area of the vending machine 1. A refrigeration unit 14 is located immediately above the bread compartment 12. The temperature of the refrigeration unit 14 is controlled by the side circuitry 7 and is optimised to maintain bread within the bread compartment 12 fresh for as long as possible.

An upper refrigeration unit 15 is controlled by the top circuitry 8 and controls the temperature of the ingredient compartment 10.

The vending machine 1 also includes a modem (not shown) for online communications with remote locations, for example, a central control operations unit. The modem also permits the vending machine to communicate with a bank or other clearing centre for authorising various modes of payment, for instance, a credit card, a charge card or an ATM card.

The base circuitry 9 controls dispensing of bread slices to a toaster unit 13, the temperature of the back panel 56 of the toaster unit 13 and the toasting process. The base circuitry 9 also controls the callipers arms (not shown) to pick up the toasted bread slices and place them onto the preparation platform.

In addition, the vending machine 1 also includes a wrapper storage compartment 16 which dispenses a wrapping material, for example, a plastic lined paper for wrapping the sandwiches prior to them being dispensed by the vending machine 1 to the dispensing bin 5.

A schematic diagram of the vending machine 1 is shown in Figure 2 and a cross-sectional side view of the vending machine 1 in Figure 3 shows the primary components used in the sandwich making process. The primary components are bread storage sub-compartments 20 located in the bread compartment 12, the toaster unit 13, the preparation mechanism 30 located within the preparation compartment 11 and ingredient holders and dispensers 22 located in the ingredient compartment 10. The toaster unit 13 comprises a back panel 56 with a"L-shaped"rack which can move vertically and a front panel 57 which is fixed at the top of the toasting unit compartment. Twelve bread storage sub- compartments 20 are arranged in two layers with six sub- compartments in each layer. Typically, the bread slices within the sub-compartments 20 are approximately 4"square by "thick. The bread slices are held within the sub- compartments 20 as shown in Figure 5. The twelve bread sub- compartments 20 are held with a drawer-like rack which can be removed to facilitate replacement of the containers during maintenance. One sub-compartment 20 is shown in Figure 4.

Each sub-compartment 20 comprises a square cross-sectional stainless steel housing 26 which is open at both ends and a stainless steel back plate 27 which is slidable within the housings 26 by means of an extendable rod 28 attached to the stainless steel back plates 27. The housings 26 have an open end 29 opposite to the end through which the stainless steel plates enter the housing 26. The stainless steel back plate 27 can move towards the open end 29 to dispense bread slices from within the containers 200. There are two four-vane rotary blades 60 shown in Figure 5, one each at the top and bottom of each bread storage container which, with their synchronised rotation, prevent the bread slices from falling out at the back and guide the bread slices into L-shaped toasting rack attached to the back panel 56 of the toaster for toasting.

The preparation mechanism 30 is shown schematically in Figures 2 and 3 and in more detail in Figures 6 and 7. The preparation mechanism 30 comprises a number of preparation plates 21a, 21b which are coupled together in pairs. Each plate is about 5.5" square size. Each pair comprises a fixed plate 21a and a movable plate 21b. Each pair is attached to a central axle 31 by an arm 32 such that the plates 21a, 21b are arranged in four pairs of plates 21a, 21b around the central axle 31 and each pair is equi-spaced circumferentially from the adjacent pairs. The central axle 31 is rotatable and rotation of the axle 31 is controlled by the top circuitry 8 so as to rotate the plates 21a, 21b about the central axle 31 by means of the arms 32. Each pair of plates 21a, 21b is connected by a hinge element which is normally held in the open position so that the plates 21a, 21b are in the position shown in Figure 7.

The ingredient compartment 10 is divided into four sections each of which holds six ingredient holders and dispensers 22, as shown in Figure 2. Two ingredient holders and dispensers 22 attached with different nozzles are shown in more detail in Figures 8 and 9 where it can be seen that each of the ingredient holders and dispensers 22 includes a rotatable outer cylinder 40 within which is located a circular plate 41 which can be moved within the inner cylinder 47 by means of an extendable rod 42. Each holder and dispenser 22 has a dispensing nozzle 43 at its lower end through which an ingredient located within the inner cylinder 47 is dispensed by the plate 41 pushing the ingredient towards and through the dispensing nozzle 43 while the outer cylinder 40 is rotated in either a clockwise or anti-clockwise direction.

Possible configurations of a dispensing nozzle are shown in Figures 10,11 and 12.

Figure 10 shows a dispensing nozzle 43a which comprises a number of apertures through which a semi-liquid or spreadable ingredient (such as butter, mayonnaise, peanut butter, various jams, herb butter or tartar sauce) may be dispensed.

Figure 11 shows a dispensing nozzle 43b which includes a number of bladed slots 44 which can be used to dispense solid food products, such as meat or vegetables by slicing. This is enabled by rotation of the outer cylinder 40, to which the dispensing nozzle 43b is attached, relative to the ingredient within the inner cylinder 47. Figure 12 shows a dispensing nozzle 43c which has a number of triangular shaped slits 46.

The dispensing nozzle 43c may be used to dispense semi- solids, such as egg mayonnaise or tuna mayonnaise. The dispensing nozzle 43c is used in pairs, one of which is attached to the inner cylinder 47 and the second one is attached to the outer rotatable cylinder 40. The two nozzles are positioned in such a way that the triangular apertures alternate with each other so that the apertures in each nozzle 43c are obturated by the other nozzle 43c. To dispense the semi-solid ingredient, the outer cylinder 40 is rotated to align the triangular apertures so that the ingredient may be dispensed through the aligned apertures.

Figure 13 shows how six ingredient holders and dispensers 22 are located in each of the four sections of the ingredient compartment 10. Each of the ingredient holders and dispensers 22 is attached at its upper end to a circular rotatable rack 50 which connects the ingredient holders and dispensers 22 to a central axle 51 which is also rotatable.

The ingredient holders and dispensers 22 are arranged in a circular frame 52.

Each circular rotatable rack 50 of six ingredient holders and dispensers are connected to a central circular rotatable rack 53. The central circular rotatable rack 53 can be rotated 90 degrees clockwise or anti-clockwise to facilitate changing the back ingredient holders and dispensers from the front of the machine so as to replace the expired or finished ingredients during maintenance. The circular rotatable racks 50 are hollow tubes to allow cabling and wires to be run on the inside to facilitate the connection of the circuitries.

A drip plate 55 as shown in Figure 3 is suspended beneath the nozzles of the six ingredient holders and dispensers to prevent drips from falling onto the parts below them and to collect the drips in a drip container 58 which is formed by the lower end of the tube 59. The drip plates 55 are in two semi-circular pieces and slope gently toward the central axle 51. The drip plates 55 and drip containers 58 can be detached for cleaning or replaced with clean ones. When an ingredient is being applied, the semi-circular drip plates 55 slides under or above the other one so that the nozzle can apply the ingredients onto the bread slices.

The toaster unit 13 includes three separate toasters 63 which are located at the back of the bread storage compartment 12 and wrapper storage compartment 16. Each toaster 63 includes a back panel 56 and a front panel 57 to toast each slice of bread simultaneously on both sides. The front panel 57 is located behind the wrapper storage compartment 16 while the back panels 56 can move vertically between the top and bottom layers of the bread storage compartment 12 and the front toasting panel 57. In the toasting process, the back panel 56 with a rack will move to the bread sub-compartment 26 to receive the selected bread slices. The back panel 56 with the bread slices in the rack will then move to the top where the front panel 57 is for the toasting process to start.

In addition, the toaster unit 13 includes a mechanism, such as two rotatable and two extendable arms with callipers (not shown) which can slide along the three toasters and remove each toasted bread slice from the toaster unit 13 and place them on the appropriate plates 21a, 21b in the preparation compartment 11.

A flow chart of a user's selection process is shown in detail in Figure 14. At the start of the selection process at stage 100, the user has three choices-to insert a cash card, smart card or other money holding device, or bank notes or coins into an appropriate slot in the coin entry mechanism or card reader 6.

If at stage 100 the user chooses to use cash 101, a standard sandwich will be displayed at stage 153. The user has three standard spread/salad/filling/topping combinations A, B and C at stage 104 and it will be fixed pricing for the standard sandwiches. After making a selection at stage 104, the user proceeds to stage 105 where he has three bread choices A, B and C. Next at stage 154, the user has to decide"yes"or "no"as to whether he wants his bread toasted or non-toasted.

The selection is then finished and the preparation process begins at stage 106. The preparation process is shown in Figure 15.

However, if at stage 100 the user chooses to use a smart card 102, he has to decide at stage 107"yes"or"no"as to whether he wants a new sandwich. If he chooses to select a completely new sandwich at stage 107, the price of the sandwich will depend on the actual fillings selected and he proceeds to stage 117. If he chooses"no"and he has made selections previously, his last three most frequently selected sandwich selections will be displayed on the front display selection panel 3 as"old favourites"OF1, OF2 and OF3 at stage 108 since the sandwich choice (s) may be stored in the smart card by the vending machine 1. Therefore, if the user wants one of his old favourite choices, it is not necessary for him to select all the individual ingredients again. After choosing one of his old favourites, he has a choice of whether he wants to confirm his order at stage 113.

If he decides"yes"confirming his order, the preparation process begins and his smart card is ejected at stage 114.

If he decides"no", that he does not want to confirm his order, the preparation process will not begin and his smart card will be ejected at stage 110.

When the user chooses to use a cash card 103 or a smart card 102 in which he has also chosen"yes"at stage 107 to select a new sandwich, the front display selection panel 3 displays a choice of three types of bread A, B and C at stage 117.

After he has made his bread choice which may include white, wholemeal or cornbread, he proceeds to stage 118 where he decides"yes"or"no"as to whether he wants his bread toasted or non-toasted. At the next stage 119, the cost of his sandwich will be displayed. At stage 109, a check is conducted by a processing unit (not shown) within the circuitry 7,8 and 9 as to whether or not the cost of the sandwich selected exceeds the cash value stored in the card.

If the cost of the sandwich shown at stage 119 displays an amount which, according to the processing unit at stage 109 exceeds the cash value stored in the card, the selection terminates at stage 120 and his card is ejected at stage 121.

If the cost of the sandwich which is displayed at stage 119 does not exceed the cash value stored in the card according to the processing unit at stage 109, he can then proceed to select his spread at stage 122.

At stage 122, he has the choice of whether he wants a spread or not. If he chooses"no"at stage 122, he proceeds to stage 123. If he decides that he wants a spread, he can choose from six types of spreads A to F which may include butter, mayonnaise, peanut butter, various fruit jams, tartar sauce and herb butter. After choosing his spread, he is given the choice of selecting single portion (lx) or double portion (2x) of the spread at stage 126. An update of the cost of his sandwich will be displayed at stage 127.

At stage 111, a check is conducted by the processing unit as to whether the cost of the sandwich selected exceeds the cash value stored in the card. If the updated cost of the sandwich shown at stage 127 displays an amount which, according to the processing unit at stage 111 exceeds the cash value stored in the card, the selection terminates at stage 128. The user's sandwich choice will then be displayed at stage 129 and he proceeds to stage 130.

At stage 130, he chooses"yes"or"no"as to whether he wants to confirm his sandwich selection. If he confirms positively at stage 130, the preparation process begins and his card is ejected at stage 131. If he confirms negatively, his previous selections are cancelled at stage 132 and at stage 133, his card is ejected.

At stage 123, he has a choice of whether he wants a salad or not. If he has chosen not to have a salad at stage 123, he will proceed to stage 124 where he is given the choice of whether to select a filling for his sandwich or not. If he decides that he wants a salad at stage 123, he can choose from six types of salads A to F which may include lettuce, tomato, avocado, cucumber, onions, mango and pineapple.

After choosing his salad, he is given the choice at stage 134 to select a single portion (lx) or a double portion (2x) of the salad. An update of the cost of his sandwich will be displayed at stage 135. At stage 112, a check is conducted by the processing unit as to whether or not the cost of the sandwich selected exceeds the cash value stored in the card.

If the updated cost of the sandwich shown at stage 135 displays an amount which, according to the processing unit at stage 112 exceeds the cash value stored in the card, the selection terminates at stage 136. The user's sandwich choice will then be displayed at stage 137. The user then proceeds to decide whether or not to confirm his sandwich selection at stage 130. If he confirms positively, the preparation process begins and his card is ejected at stage 131. If he confirms negatively, his previous selections are cancelled at stage 132 and at stage 133, his card is ejected.

If at stage 112 the processing unit calculates that the cost of the sandwich does not exceed the cash value stored in the card, the user proceeds to stage 138 where the processing unit checks whether he has made up to a total of three salad selections. The user has a maximum of three types of salads for his sandwich and this is monitored at stage 138. If he has not made a total of three salad selections, he proceeds to stage 139 where he decides"yes"or"no"as to whether or he wants another salad selection.

If he wishes not to have another salad at stage 139, he proceeds to stage 124 to begin his filling selection. On the other hand, if he indicates at stage 139 on the front display selection panel 3 his preference to have another salad, he returns to stage 123 to select another salad. If at stage 138, the processing unit checks that a total of three salads have been selected, the user proceeds to stage 124 to select his filling.

At stage 124, he has the choice to have a filling or not to have a filling. If he decides"no", that he is not having a filling at all, he proceeds to stage 125. On the other hand, if he wants a filling, he can choose from six types of fillings A to F which may include chicken, tuna, turkey, beef, chicken floss and sambal shrimps. After making his choice, he proceeds to select a single portion (lx) or a double portion (2x) of the filling at stage 140. Next at stage 141, an update of the cost of his sandwich is displayed. At stage 115, a check is conducted by the processing unit as to whether or not the cost of the sandwich selected exceeds the cash value stored in the card.

If the updated cost of the sandwich shown at stage 141 displays an amount that, according to the processing unit at stage 115, exceeds the cash value stored in the card, the selection terminates at stage 142. The user's sandwich choice will then be displayed at stage 143. The user proceeds to confirm his sandwich selection at stage 130. If he confirms positively at stage 131, the preparation process begins and his card is ejected. If he confirms negatively, his previous selections are cancelled at stage 132 and his card is ejected at stage 133.

If, according to the processing unit at stage 115, the cost of the sandwich which he has so far selected does not exceed the cash value stored in the card, the user proceeds to stage 144 where the processing unit checks whether he has made up to a total of two fillings selections. The user has a maximum of two types of fillings for his sandwich and this is monitored at stage 144. If the processing unit calculates at stage 144 that the user has not made a total of two fillings selections, he proceeds to stage 145 where he decides"yes" or"no"as to whether he wants another filling selection. If he chooses"yes", he returns to stage 124 for a selection of the filling. If he chooses"no", that he does not want another filling, he proceeds to stage 125 to select his topping. If the processing unit at stage 144 checks that the user has selected a total of two types of filling, the user proceeds to stage 125 to select his topping.

At stage 125, the user decides whether or not he wants a topping on his sandwich. If he chooses"no", that he does not want a topping on his sandwich, he proceeds to stage 152 where the front display selection panel 3 displays his sandwich choice. If he wishes to have a topping on his sandwich, he has six topping choices A to F which may include mustard, chilli sauce, tomato sauce, BBQ sauce, mushroom sauce and rendang sauce. After choosing the type of topping, he proceeds to stage 146 where he has a choice of whether to have a single portion (lx) or a double portion (2x) of the topping. Next at stage 147, the front display selection panel 3 shows an update of the sandwich cost. At stage 116, a check is conducted by the processing unit as to whether or not the cost of the sandwich selected exceeds the cash value stored in the card.

If, according to the processing unit, the cost of the sandwich displays an amount that exceeds the cash value stored in the card, the selection terminates at stage 148.

The user's sandwich choice will then be displayed at stage 149 and he proceeds to stage 130.

At stage 130, he chooses whether or not to confirm his sandwich selection. If he confirms positively at stage 131, the preparation process begins and his card is ejected. If he confirms negatively, his previous selections are cancelled at stage 132 and at stage 133, his card is ejected.

If the processing unit at stage 116 calculates that the updated sandwich cost does not exceed the cash value stored in the card, the user proceeds to stage 150 where the processing unit checks whether he has made up to a total of two toppings selections. Altogether, the user has a maximum of two types of toppings for his sandwich and this is monitored at stage 150. If the maximum of two toppings is not reached, the user proceeds to stage 151 where he can further select another topping. If he chooses"yes", that he wants another topping, he returns to stage 125. If he chooses"no", that he does not want another topping at stage 151, his sandwich choice would be displayed at stage 152 and he proceeds to stage 130. If the processing unit at stage 150 checks that the user has chosen a total of two toppings, his sandwich choice will be displayed at stage 152 and he proceeds to stage 130.

At stage 130, he chooses whether or not to confirm his sandwich selection. If he confirms positively, the preparation process begins and his card is ejected at stage 131. If he confirms negatively, his previous selections are cancelled at stage 132 and at stage 133, his card is ejected.

A flow chart of the preparation process is shown in detail in Figure 15. At stage 200, the selection process is completed and the preparation process begins.

Stage 201 relates to the process of toasting the bread. The bread can either be toasted or non-toasted. If toasting is required, the toasting time is set to a standard time at stage 202. If toasting is not required, the toasting time is set to zero at stage 203. Next, the preparation process proceeds to stage 204 where the back panel 56 move vertically between the top and bottom layers of the bread storage compartment 12 to receive bread slices.

Stage 205 relates to the selected bread type (Type 1, Type 2 and Type 3 which may include white, wholemeal and cornbread.

Two selected bread containers 200 dispense one bread slice each to the back panel 56 at stage 206.

Upon completion of stages 204 and 206, the back panel 56 moves to the front panel 57 for the toasting process to start at stage 207.

At stage 208, the preparation plates 21a, 21b in position"1" move down towards the wrapper storage compartment 16. The preparation plates 21a, 21b charge up and pick up a wrapping material from the wrapper storage compartment 16 to their surfaces at stage 209. The preparation plates 21a, 21b then rotate 180 degrees with the wrapping material firmly held by static at stage 210.

After the stages 207 and 210 are completed, a pair of calliper arms (not shown) in the toaster unit 13 then transfers the bread slices to the wrapping material on the preparation plates 21a, 21b at stage 211.

At the next stage 212, the preparation plates 21a, 21b discharge the static. The preparation plates 21a, 21b move up to the ingredient holders and dispensers 22 at level"1" at stage 213. The processing unit controls the dispensing of the ingredients. The selected ingredient holder and dispenser 22 dispenses selected spread onto the bread slice on the fixed preparation plate 21a at stage 214. The preparation plates 21a, 21b then move to position"2"at stage 215. This time, the selected spread is dispensed onto the bread slice on the movable preparation plate 21b at stage 216. The selected ingredient holder and dispenser 22 then dispenses selected salad (s) onto the bread slice on the fixed preparation plate 21a at stage 217. After the dispensing of the selected spread and salad is completed, the preparation plates 21a, 21b move to position"3"at stage 218. At this position"3", the selected ingredient holder and dispenser 22 dispenses selected filling (s) onto the bread slice on the fixed preparation plate 21a at stage 219. Next the preparation plates 21a, 21b move to position"4"at stage 220 where the selected ingredient holder and dispenser 22 dispenses selected topping (s) onto the bread slice on the fixed preparation plate 21a at stage 221.

After all the ingredients have been dispensed onto the slice of bread on the fixed preparation plate 21a, the preparation plates 21a, 21b move down away from the ingredient holders and dispensers 22 at stage 222. The spring/rod which attaches the movable plate 21b releases and the movable plate 21b flips over to place its bread slice and spread on top of the ingredients and bread slice on the fixed plate 21a at stage 223. The outer rim of the movable plate 21b clams shut over the outer rim of the fixed plate 21a.

Next at stage 224, an electric current passes through heating elements in the rims of the preparation plates and seals the wrapping material into a package around the sandwich. At stage 225, the spring/rod attached to the movable plate 21b pulls back and the plate 21b flips to return to its open position.

When the movable plate 21b is at this open position, the plates 21a, 21b invert at stage 226 and the wrapped sandwich falls off the fixed plate 21a into the chute leading to the dispensing bin 5 which slopes down from the back right up to the front opening which has a transparent window flap through which the user can collect the wrapped sandwich. The plates 21a, 21b remain inverted and ready for the next sandwich preparation.

The preparation process ends at stage 227. The front display selection panel 3 may comprise a touch sensitive screen and have push-button options to enable a customer to select a sandwich and ingredients.

The invention has the advantage that it permits a customer to select the desired ingredients and to prepare a sandwich having the ingredients in accordance with the customer's selection and does not rely on prepackaged food over which the customer has no control of the ingredients. The circuitry 7,8,9 can also be programmed to give discounts to certain groups of users, for example, smart card users, or for certain events like low usage period, or to encourage certain behaviour like speedier selection during high usage periods.