Abstract:
A sanitizer assembly for foot wear is provided that includes a base platform, a plurality of nozzles and an activation pump. The base platform includes a grate upon which footwear can be placed. The plurality of nozzles are positioned under the grate. The nozzles are configured and arranged to dispense a fine mist of alcohol-based sanitizer on the footwear. The activation pump is in fluid communication with the plurality of nozzles. The activation pump is further in fluid communication with a supply of alcohol-based sanitizer. In addition, the activation pump is configured and arranged to pump the alcohol-based sanitizer to the nozzles.

Description:
BACKGROUND 
       [0001]    In food processing plants, keeping a sanitary environment is imperative to prevent the food from becoming contaminated. One method used to maintain a sanitary environment is by sanitizing footwear of workers as they enter the plant. A typical footwear sanitizing system is done with the use of brush scrubbers or a sprayed foam solution. However, in dry powder production facilities, it is desirable to minimize moisture on the plant production floor and on the footwear. The use of a boot scrubber system or foam solutions introduce unwanted moisture on the plant production floor and on the footwear and hence are undesirable in a dry powder production facility. 
         [0002]    For the reasons stated above and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for a sanitary foot sprayer system that does not introduce significant moisture in a dry powder plant. 
       SUMMARY OF INVENTION 
       [0003]    The above-mentioned problems of current systems are addressed by embodiments of the present invention and will be understood by reading and studying the following specification. The following summary is made by way of example and not by way of limitation. It is merely provided to aid the reader in understanding some of the aspects of the invention. 
         [0004]    In one embodiment, a sanitizer assembly is provided. In one embodiment, the sanitizer system includes a base platform, a plurality of nozzles and an activation pump. The base platform includes a grate upon which footwear can be placed. The plurality of nozzles are positioned under the grate. The nozzles are configured and arranged to dispense a fine mist of alcohol-based sanitizer on the footwear. The activation pump is in fluid communication with the plurality of nozzles. The activation pump is further in fluid communication with a supply of alcohol-based sanitizer. In addition, the activation pump is configured and arranged to pump the alcohol-based sanitizer to the nozzles. 
         [0005]    In another embodiment, a footwear sanitizer system is provided. The system includes a sanitizer assembly, a first mat and a second mat. The sanitizer assembly includes a base platform, a plurality of nozzles and an activation pump. The base platform includes a grate upon which the footwear can be placed. The plurality of nozzles are positioned under the grate. The activation pump is in fluid communication with the plurality of nozzles. The activation pump is further in fluid communication with a supply of alcohol-based sanitizer. The activation pump is configured and arranged to pump the alcohol-based sanitizer to the nozzles. The nozzles are further configured to dispense a fine mist of the alcohol-based sanitizer on the footwear. The first mat is positioned near the sanitizer assembly. The first mat contains dry crystal powder to be applied to the footwear after the sanitizer has been applied. The second mat is positioned near the first mat. The second mat is configured and arranged to remove any dry crystal powder from the footwear. 
         [0006]    In yet another embodiment, a method of sanitizing footwear is provided. The method includes: dispensing a mist of alcohol-based sanitizer on footwear; placing the footwear in dry crystal powder; and removing dry crystal powder attached to the footwear. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The present invention can be more easily understood and further advantages and uses thereof will be more readily apparent, when considered in view of the detailed description and the following figures in which: 
           [0008]      FIG. 1  is a side perspective view of a footwear sanitizer system of one embodiment of the present invention that includes a sprayer assembly; 
           [0009]      FIG. 2  is a top view of the sprayer assembly of the footwear sanitizer system of  FIG. 1 ; 
           [0010]      FIG. 3  is a side view of the sprayer assembly of the footwear sanitizer system of  FIG. 1 ; 
           [0011]      FIG. 4  is an unassembled side perspective view of the sprayer assembly of the footwear sanitizer system of  FIG. 1 ; 
           [0012]      FIG. 5  is a block diagram of a sprayer assembly of one embodiment of the present invention; and 
           [0013]      FIG. 6  is a footwear sanitizer flow diagram of one embodiment of the present invention. 
       
    
    
       [0014]    In accordance with common practice, the various described features are not drawn to scale but are drawn to emphasize specific features relevant to the present invention. Reference characters denote like elements throughout Figures and text. 
       DETAILED DESCRIPTION 
       [0015]    In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the inventions may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the claims and equivalents thereof. 
         [0016]    Embodiments of the present invention provide a footwear sanitizer system that includes an automatic dispensing of an alcohol-based sanitizer on the bottom of footwear. The alcohol-based sanitizer dries quickly eliminating the moisture challenges experienced with other footwear cleaning methods. Referring to  FIG. 1 , a side perspective view of a footwear sanitizer system  100  of one embodiment is illustrated. The footwear sanitizer system  100  includes a sprayer assembly  200 , a first mat  300  and a second mat  400 . The sprayer assembly  100  selectively applies an alcohol-based sanitizer to a user&#39;s footwear. An example of alcohol-based sanitizer is Alpet D2 alcohol sanitizer, however, other types of alcohol-based sanitizers can be used. The first mat  300  includes a housing  302  (or mat base) which contains dry crystal powder  304  (such as, but not limited to, hydrogen peroxide crystals or quaternary ammonia-based crystals). As discussed further below, a user will step on the first mat  300  after the sprayer assembly  200  selectively applies the alcohol-based sanitizer to the user&#39;s footwear. The dry crystal powder will dry any remaining sanitizer on the user&#39;s footwear. The user will then step on the second mat  400 . The second mat  400  includes a housing (or second mat base)  402  which and a surface  404  that is designed to remove any remaining dry crystals from the user&#39;s footwear. 
         [0017]    The sprayer assembly  200  is now described in view of  FIGS. 1 through 4 . Referring to  FIG. 4 , a side view of the sprayer assembly  200  in an unassembled configuration is presented. As illustrated, the sprayer assembly  200  includes a base platform  202 . The base platform  202  includes a first side  202   a  and an opposed second side  202   b.  A first side wall  204  is coupled to the first side  202   a  of the base platform  202 . A second side wall  206  is coupled to the second side  202   b  of the base platform  202  in an opposed fashion to the first side wall  204 . This configuration provides a pathway through the sprayer assembly  200  for the user. The base platform  202  includes a grate  270 . The grate  270  allows for the sanitizer to be sprayed onto the user&#39;s footwear from under the base platform  202 . The grate  270  is designed also to provide a no slip surface and in one embodiment is made from stainless steel. Referring to the top view in  FIG. 2 , the grate  270  in this embodiment has left and right footprints  270   r  and  270   l  designs. The designs indicate to the user where they are to place their footwear. Also illustrated in  FIG. 2 , under the respective left and right footprints  270   r  and  270   l  of the grate  270 , are strategically placed dispensing manifolds  264  and  266 . Nozzles  260   a,    260   b,    260   c,    262   a,    262   b  and  262   c,  illustrated in  FIG. 4 , are in fluid communication with the respective dispensing manifolds  264  and  266 . The nozzles  260   a,    260   b,    260   c,    262   a,    262   b  and  262   c  direct a fine mist on the bottom of the user&#39;s footwear when the footwear are at the designated locations. The embodiment of  FIG. 4 , illustrates the use of three nozzles for each dispensing manifolds. That is, nozzles  260   a,    260   b  and  260   c  are in fluid communication with dispensing manifolds  264  and nozzles  262   a,    262   b,  and  262   c  are in fluid communication with dispensing manifolds  266 . Other numbers of nozzles per dispensing manifold could be used and hence the present invention is not limited to three nozzles per dispensing manifold. An example of a nozzle that provides mist droplets in the preferred range is Model No. 11907 1/8PJ20 from the BETE Corporation of Greenfield Mass. An underside  202   c  of the base platform  202  includes opposed rails  202   d  and  202   e  as illustrated in  FIG. 4 . A drip pan  208  designed to collect excess sanitizer is designed to be slidably received in the opposed rails  202   d  and  202   e  in the underside  202   c  of the base platform  202 . The drip pan  208  includes a drain  307  that can be used to remove excess sanitizer collected in the drip pan  208 . 
         [0018]    As illustrated in  FIG. 4 , the first side wall  204  includes a top edge  204   a  that is opposed to a bottom edge  204   b.  The base platform  202  is coupled proximate the bottom edge  204   b  of the first side wall  204 . Also illustrated in  FIG. 4  is a top edge  206   a  and an opposed bottom edge  206   b  of the second side wall  206 . The base platform  202  is coupled proximate the bottom edge  206   b  of the second side wall  206 . The first side wall  204  further includes a first side edge  204   c  and an opposed second side edge  204   d.  Similarly, the second side wall  206  also includes a first side edge  206   c  and an opposed second side edge  206   d.  Attached to each of the first and second side walls  204  and  206  are a pair of gate assemblies  210   a,    210   b,    210   c  and  210   d.  In particular, a first gate assembly  210   a  is coupled proximate the first side edge  204   c  and the top edge  204   a  of the first side wall  204  and the second gate assembly  210   b  is coupled proximate the second side edge  204   d  and the top edge  204   a  of the first side wall  204 . A third gate assembly  210   c  is coupled proximate the first side edge  206   c  and the top edge  206   a  of the second side wall  206  and a fourth gate assembly  210   d  is coupled proximate the second side edge  206   d  and the top edge  206   a  of the second side wall  206 . Each gate assembly  210   a,    210   b,    210   c  and  210   d  includes a gate bracket  252  that is coupled to an outer surface  204   e  and  206   e  of a respective side wall  204  and  206 . A gate  250  is pivotally coupled to the gate bracket  252  via pivot connection  251 . An actuator (generally designated as  254 ) is coupled between the gate bracket  252  and the gate  250  to selectively position the gate  252  to at least partially block the passageway formed by the base platform  202  and the side walls  204  and  206 . Further description of the operation of the actuator  254  and the actuators  254   a,    254   b,    254   c  and  254   d  of the gate assemblies  210   a,    210   b,    210   c  and  210   d  is discussed below. Also illustrated in  FIGS. 3 and 4  are adjustable feet  228  that are coupled to the respective bottom edges  204   b  and  206   b  of the respective first and second side walls  204  and  206 . The feet members  228  are held in place via nuts  230 . The first side wall  204  further includes a first handrail  224  that is coupled along the top edge  204  of the first side wall. Similarly, the second side wall  206  includes a second handrail  226  that is coupled along the top edge  206   a  of the second side wall  206 . The handrails  224  and  226  provide a stable structure to grasp when stepping onto, standing on and stepping off of the base platform  202 . 
         [0019]    The components that control the operation of the sprayer assembly  200  are coupled to the outer surface  206   e  of the second side wall  206 . The control components contain a controller  502  (illustrated in  FIG. 5 ) that is housed in a control housing  212  that is coupled to the second side wall  206  as illustrated in  FIG. 4 . Operation of the controller  502  is described in detail below. The control components further include a filter/lockout assembly  225  that is coupled to an external system air supply pump (system pump  220 ). The system pump  220  is shown in  FIG. 5 . In one embodiment, the filer portion of the filter/lockout assembly  225  is a pneumatic filter that filters out moisture from the air supplied by the system pump  220 . The lockout portion of the filter/lockout assembly includes a value that shuts down the system for system maintenance. The system pump  220  provides air to the activation pump  222 , which in one embodiment is a diaphragm pump. The control components further include first and second solenoid valves  216  and  214  and regulators  217  and  221  and at least one sensor  218  which in one embodiment is a photo eye sensor known in the art. How the control components work together to control operations of the sprayer assembly is described below in regards to  FIG. 5  and  FIG. 6 . 
         [0020]      FIG. 5  illustrates a block diagram of elements of the sprayer assemble  200 .  FIG. 5  further illustrates the connections between the components. Operation of the sprayer assembly  200  is controlled by the controller  502 . The controller  502  can be a digital or an analog device capable of generating logic decisions to control operations of the sprayer assembly  200 . The controller  502  is coupled to receive signals from at least one position sensor  218 . In an embodiment illustrated in  FIG. 5 , more than one sensor is used. In this embodiment, three photo eye sensors  218   a,    218   b  and  218   c  are used. The sensors  218   a,    218   b  and  218   c  sense the position of the user and provide signals to the controller  502 . Hence, the controller  502  uses the signals from the sensors  218   a,    218   b  and  218   c  to, at least in part, determine a user position within the sprayer assembly  200  to start a sanitizing cycle. The embodiment of  FIG. 5  also includes a user input  532  that is in communication with the controller  502 . The user input  532  allows the user to communicate to controller  502 . Example communications include an indication that a longer spray time is needed, or that operations should cease. The controller  502  is in communication with a timer  530 . The controller  502  uses the timer  530 , at least in part, to time the duration of the spray. This embodiment further includes a status indicator  508  that is in communication with the controller  502 . In one embodiment, the status indicator  508  provides an indication of the status of operations of the sprayer assembly  200 . For example, the status indicator  508  may be a light or an audible alarm that indicates to the user that the user can enter the sprayer assembly  200  or leave the spray assembly when the cleaning cycle is over. 
         [0021]    As further illustrated in  FIG. 5 , a power supply  525  is coupled to supply power to the controller  502 . The system pump  220  in this embodiment is external to the sprayer assembly  100 . That is, in an embodiment, an air pump from the plant the sprayer assembly  200  is located, is used to supply an air flow to the filter/lockout assembly  225 . The controller  502  selectively activates the first and second valves  216  and  214  to allow the air supplied by the system pump  220  to activate functions of the sprayer assembly  100 . For example, valve  214  is selectively opened and closed to control the gate actuators  254   a,    254   b,    254   c  and  254   d  of the respective gate assemblies  210   a,    210   b,    210   c  and  210   d  and valve  216  is selective turned open and closed to activate the activation pump  222 . As illustrated, the filter/lockout assembly  225  is coupled to supply air to the activation pump  222  via tubing  512 . The coupling passes through the first valve  216  and a first regulator  217 . The first valve  216  is a solenoid and as discussed above, is controlled by the controller  502 . The regulator  217  is an air regulator in one embodiment. Hence, when the controller  502  wants to activate the activation pump  222  (the diaphragm pump) to deliver the spray to footwear of the user, the controller  502  opens the first valve  216 . With the first valve  216  open, the air flow from the system pump  220  causes the activation pump  222  to pump out a solution from the solution storage container  504  through tubing  510 . In one embodiment, solution filter  506  is used to filter the solution before it is delivered to the nozzles  262   a,    262   b,    262   c,    264   a,    264   b  and  264   c  so the nozzles do not become plugged with debris. 
         [0022]    When the controller  502  wants to activate the actuators  254   a,    254   b,    254   c  and  254   d  of the gate assemblies  210   a,    210   b,    210   c  and  210   d,  the controller  502  opens up the second valve  214 . This delivers a flow of air, from the system pump  220 , through tubes  512  to activate the actuators  254   a,    254   b,    254   c  and  254   d  of the gate assemblies  210   a,    210   b,    210   c  and  210   d.  The bock diagram of  FIG. 5 , illustrates the gates actuators  254   a,    254   b,    254   c  and  254   d  being activated at the same time by a single valve-regulator line coupled to each of the actuators  254   a,    254   b,    254   c  and  254   d  of the gate assemblies  210   a,    210   b,    210   c  and  210   d.  This does not have to be the case. Separate valve-regulator lines could be coupled to operate the actuators of the gate assemblies separately. For example, gate assemblies  210   b  and  210   d  could be activated together to allow the user to step into the sprayer assembly  200  and gate assemblies  210   a  and  210   c  could be activated together to direct the user out of the sprayer assembly  200  to the first and second mats  300  and  400  after the footwear spraying is done. Hence, the present invention is not limited to a configuration that activates all of the gate assemblies  210   a,    210   b,    210   c  and  210   d  simultaneously. Moreover, in one embodiment, only one pair of gate assemblies  210   a  and  210   c  are used. In this embodiment, the gates  250  of gates assemblies  210   a  and  210   c  are opened after the sanitation cycle is complete. Moreover, in an embodiment, the side walls  204  and  206  are generally identically machined so that the control components and the gates can be mounted on either side wall  204  or  206  depending on the desired orientation and configuration desired by a customer. 
         [0023]      FIG. 6  illustrates a footwear sanitizer flow diagram  600  of one embodiment of the present invention. In the embodiment shown, the process starts with the controller  502  having the gates  250  of the spraying assembly  200  in an open position ( 602 ). In an embodiment, with only two gates to control the exit of the spraying assembly, the process would start with the gates in the closed position. A user then enters the spray assembly  200  placing the user&#39;s footwear in the designated position on the grate  270  of the base platform  202  ( 604 ). The controller  502  monitors the output of the at least one sensor  218  to determine if a user is in the select location ( 606 ). If it is determined that a user has not been detected in the select location at step ( 608 ), monitoring continues at step ( 606 ). If it is determined that a user has been detected at the select location at step ( 608 ), the gates are closed ( 610 ). The controller  502  then dispenses the mist of sanitizer  503  on the user&#39;s footwear for a select amount of time ( 612 ). As discussed above, in one embodiment, the user can request additional dispensing time if they feel it is needed. Once the sanitizer  503  has been dispensed for the allotted time, the controller opens the gates  250  to allow the user to exit the spraying assembly  200 . The user then steps into the first mat  300  that contains dry crystal powder  304  ( 616 ). The dry crystal powder  304  helps dry the sanitizer. The user then steps into the second mat  400  which contains a surface designed to remove any dry crystal powder  304  that attached to the footwear of the user ( 618 ). When the user steps off the second mat  400  the sanitizing cycle is complete. 
         [0024]    Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof.