Coin pad for coin processing system

According to some embodiments of the present disclosure, a resilient coin sorting pad for imparting motion to a plurality of coins is provided, the resilient pad designed to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge. The resilient pad comprises a lower foam layer having a top surface, an upper skin layer coupled to the top surface of the foam layer, and a layer of mesh material. According to some embodiments, the upper skin layer comprises at least one layer of nitrile rubber and the layer of mesh material is nylon fiber mesh. According to some embodiments, the upper skin layer comprises at least two layers of nitrile rubber and the layer of mesh material is positioned between the at least two layers of nitrile rubber.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to coin sorting devices and, more particularly, to coin sorters of the type which use a coin-driving member and a coin-guiding member or sorting head for sorting coins of mixed diameters.

BACKGROUND OF THE DISCLOSURE

Generally, disc-type coin sorters sort coins according to the diameter of each coin. Typically, in a given coin set such as the United States coin set, each coin denomination has a different diameter. Thus, sorting coins by diameter effectively sorts the coins according to denomination.

Disc-type coin sorters typically include a resilient pad (disposed on a rotating disc) that rotates beneath a stationary sorting head having a lower surface positioned parallel to the upper surface of the resilient pad and spaced slightly therefrom. The rotating, resilient pad presses coins upward against the sorting head as the pad rotates. The lower surface of sorting head includes a plurality of shaped regions including exit slots for manipulating and controlling the movement of the coins. Each of the exit slots is dimensioned to accommodate coins of a different diameter for sorting the coins based on diameter size. As coins are discharged from the sorting head via the exit slots, the sorted coins may follow respective coin paths to, for example, sorted coin receptacles where the sorted coins are stored.

Although coin sorters have been used for a number of years, problems are still encountered in this technology. For example, as coins are guided by the sorting head, portions of the sorting head and/or pad become worn due to friction between the stationary sorting head and the moving coins.

SUMMARY

According to some embodiments of the present disclosure, a resilient coin sorting pad for imparting motion to a plurality of coins is provided, the resilient pad designed to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge. The resilient pad comprises a lower foam layer having a top surface, an upper skin layer coupled to the top surface of the foam layer, and a layer of mesh material. According to some embodiments, the upper skin layer comprises at least one layer of nitrile rubber and the layer of mesh material is Kevlar® fiber mesh. According to some embodiments, the upper skin layer comprises at least one layer of nitrile rubber and the layer of mesh material is nylon fiber mesh having woven pattern such as a leno or a triaxial weave pattern. According to some embodiments, the upper skin layer comprises at least two layers of nitrile rubber and the layer of mesh material is positioned between the at least two layers of nitrile rubber.

The above summary of the present disclosure is not intended to represent each embodiment, or every aspect, of the present disclosure. Additional features and benefits of the present disclosure will become apparent from the detailed description, figures, and claims set forth below.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments will be shown by way of example in the drawings and will be desired in detail herein. It should be understood, however, that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the inventions as defined by the appended claims.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Turning now to the drawings and referring first toFIG. 1A, a disc-type coin processing system or coin sorter100according to some embodiments of the present disclosure is shown.FIG. 1Ais a perspective view of a coin processing system or coin sorter, according to some embodiments of the present disclosure, with portions thereof broken away to show the internal structure. The coin processing system100includes a hopper110for receiving coins of, for example, mixed denominations that feeds the coins through a central opening in an annular sorting head112. As the coins pass through this opening, they are deposited on the top surface of a rotatable disc114. This rotatable disc114is mounted for rotation on a shaft (not shown) and driven by an electric motor116. The disc114typically comprises a resilient pad118, preferably made of a resilient rubber or polymeric material, bonded to the top surface of a solid disc120. While the solid disc120is often made of metal, it can also be made of a rigid polymeric material.

According to some embodiments, coins are initially deposited by a user or operator in a coin tray (not shown) disposed above the coin processing system100shown inFIG. 1A. The user lifts the coin tray which funnels the coins into the hopper110. A coin tray suitable for use in connection with the coin processing system100is described in detail in U.S. Pat. No. 4,964,495 entitled “Pivoting Tray For Coin Sorter,” which is incorporated herein by reference in its entirety.

As the disc114is rotated, the coins deposited on the resilient pad118tend to slide outwardly over the surface of the pad118due to centrifugal force. As the coins move outwardly, those coins which are lying flat on the pad118enter a gap between the surface of the pad118and the sorting head112because the underside of the inner periphery of the sorting head112is spaced above the pad118by a distance which is about the same as the thickness of the thickest coin the coin sorter100is designed to sort. The coins are processed and sent to exit stations or channels where they are discharged. The coin exit stations or channels may sort the coins into their respective denominations and discharge the coins from the sorting head112corresponding to their denominations.

FIG. 1Bis a functional block diagram of a control system for the coin processing system100shown inFIG. 1Awhich may be employed with the sorting heads112,212,312to be subsequently described.FIG. 1Billustrates a system controller180and its relationship to the other components in the coin processing system100. More details regarding a system controller180and its relationship to the other components in the coin processing system100are described in U.S. Pat. No. 7,743,902, which is incorporated herein by reference in its entirety. But briefly, an operator of system100communicates with the coin processing system100via an operator interface182which is configured to receive information from the operator and display information to the operator about the functions and operation of the coin processing system100. The controller180monitors the angular position of the disc114via an encoder184which sends an encoder count to the controller180upon each incremental movement of the disc114. Based on input from the encoder184, the controller180determines the angular velocity at which the disc114is rotating as well as the change in angular velocity, that is, the acceleration and deceleration, of the disc114. The encoder184allows the controller180to track the position of coins on the sorting head112,212or312after being sensed. According to some embodiments of the coin processing system100, the encoder has a resolution of 40,000 pulses per revolution of the disc114.

The controller180also controls the power supplied to the motor116which drives the rotatable disc114. When the motor116is a DC motor, the controller180can reverse the current to the motor116to cause the rotatable disc114to decelerate. Thus, the controller180can control the speed of the rotatable disc114without the need for a braking mechanism. If a braking mechanism186is used, the controller180also controls the braking mechanism186. Because the amount of power applied is proportional to the braking force, the controller180has the ability to alter the deceleration of the disc114by varying the power applied to the braking mechanism186.

FIG. 2is a bottom plan view of a first exemplary sorting head for use with the system ofFIGS. 1A and 1BandFIG. 3is a bottom plan view of a second exemplary sorting head for use with the system ofFIGS. 1A and 1B. The sorting heads212and312and the operation of system ofFIGS. 1A and 1Bemploying these sorting heads are described in more detail in U.S. patent application Ser. No. 15/782,343 filed Oct. 12, 2017, now issued as U.S. Pat. No. 10,181,234, each of which is incorporated herein by reference in its entirety.

InFIGS. 2-3, the underside of sorting heads212,312are shown. The coin sets for any given country are sorted by the sorting heads212,312due to variations in the diameter size. The coins circulate between the sorting head212,312and the pad118(FIG. 1A) on the rotatable disc114(FIG. 1A). The pad118has a circular surface with a center at C. The sorting head212,312has a circular portion centered at point C2, C3which corresponds with the center C of pad118. The coins are deposited on the pad118via a central opening202,302and initially enter an entry area204,304formed in the underside of the sorting head212,312. It should be kept in mind that the circulation of the coins inFIGS. 2-3appear counterclockwise asFIGS. 2-3are views of the underside of the sorting heads212,312.

The sorting heads212,312may include a cutout for a discrimination sensor234,334. The discrimination sensor234,334may be disposed flush with a flat surface239,339of a discrimination region230,330or recessed slightly within the sorting head just above the flat surface239,339of the discrimination region230,330. Likewise, a coin trigger sensor236,336is disposed just upstream of the discrimination sensor234,334for detecting the presence of a coin. Coins first move over the coin trigger sensor236,336(e.g., a photo detector or a metal proximity detector) which sends a signal to a controller (e.g., controller180) indicating that a coin is approaching the coin discrimination sensor234. According to some embodiments, the sensor236,336is an optical sensor which may employ a laser to measure a chord of passing coins and/or the length of time it takes the coin to traverse the sensor236,336and this information along with the information from the coin discrimination sensor is used to determine the diameter, denomination, and validity of a passing coin. Additional description of such embodiments may be found in U.S. Pat. No. 7,743,902, incorporated herein by reference in its entirety.

According to some embodiments, the coin discrimination sensor234,334is adapted to discriminate between valid and invalid coins. Use of the term “valid coin” refers to coins of the type the sorting head is designed or configured to sort. Use of the term “invalid coin” refers to items being circulated on the rotating disc that are not one of the coins the sorting head is designed to sort. Any truly counterfeit coins (i.e., a slug) are always considered “invalid.” According to another alternative embodiment of the present disclosure, the coin discriminator sensor234,334is adapted to identify the denomination of the coins and discriminate between valid and invalid coins.

Some coin discrimination sensors suitable for use with the disc-type coin sorter100shown inFIGS. 1A-3are described in detail in U.S. Pat. Nos. 7,743,902; 5,630,494; and 5,743,373, each of which is incorporated herein by reference in its entirety. Another coin discrimination sensor suitable for use with the present disclosure is described in detail in U.S. Pat. No. 6,892,871, which is incorporated herein by reference in its entirety. Other coin discrimination sensors suitable for use with the present disclosure are described in detail in U.S. Pat. Nos. 9,430,893; 9,508,208; 9,870,668; 10,068,406; 9,501,885; 9,916,713 and U.S. patent application Ser. No. 15/461,046 filed on Mar. 16, 2017.

In disc-type coin processing systems or coin sorters100such as those shown inFIGS. 1A, 1B, 2 and 3, processing of coins without errors or interruptions and/or preventing interference can be very important. In many applications such as in self-service coin applications in which a customer deposits coins into a coin sorter system or sorter100(as opposed to an employee depositing coins into the coin sorter system or sorter100), maintaining uptime may be important as these machines are a source of revenue for their owner. Component failures can result in costly service calls. One particular high frequency of failure component is the coin sorting pad118.

In some environments or applications, such as for example, in some self-service applications, bulk coin that is received from users (patrons or customers) can contain non-coin materials. Although coin processing systems or sorters100may employ one or more methods of debris management to remove, cull or minimize debris getting onto the pad118, debris, particularly sharp objects (screws, paperclips, nails, etc.), that, nonetheless, makes its way to the sort pad118can stall, tear, rip, ripple, puncture, and/or stretch, etc. the pad118. Resulting damage to the pad118can affect the processing capabilities of the coin processing system or sorter100and/or interfere with accurate authentication, counting, sorting and general processing of coins, and/or may ultimately result in the coin processing system or sorter100being unusable, forcing a service call where a technician would repair the coin processing system or sorter100by replacing the pad118.

Coin processing in the coin processing system or sorter100relies on the pad118to drive the coins under the sort head212,312past a series of grooves and undulations in a predetermined method to authenticate, count and/or direct coins into one or more coin receptacles such as mixed denomination or denomination-specific containers. The process relies on a good quality flat pad to ensure control of the coins. When debris and other non-coin materials enter the system, the pad118can tear, rip, gouge, ripple, and/or stretch, affecting the accuracy of the coin processing system or sorter100. The damage to the pad118can cause problems in the ability to process the coins.

Some coin processing systems or coin sorters100employ a pad118made from a nitrile rubber rubber-based material. While such material may provide good coin sorting performance, it may also be very susceptible to tears, gouges, rips, punctures, stretching, etc., when debris (sharp debris) is deposited onto the pad118. As a result, such pad material, when punctured, may tear very easily, propagating the puncture to the point that the coin processing system or sorter100is quickly rendered un-usable. Some exemplary damage to coin sorter pads118caused by non-coin sharp objects is illustrated inFIGS. 4A-4J. More particularly,FIGS. 4A-4Cillustrate examples of damage such as gouges or tears DA, DB, DCnear an edge118aof a pad118;FIGS. 4D-4Gillustrate examples of damage such as tears or gouges DD, DE, DFto a center portion118cof a pad118; andFIGS. 4H-4Jillustrate examples of damage such as tears to portions118hof a pad118under a sorting head such as sorting head212,312. InFIG. 4E, coins CN have accumulated under the center portion118cof the pad118after a top portion of the center portion118chas been torn away from a bottom portion of the pad118. InFIG. 4F, a gouged-out area DFis illustrated along with a tear extending from the gouged-out area DF toward the center of the pad118. InFIG. 4G, a gouged-out area DG2is illustrated along with a tear DG3extending from a damaged area DG1toward the center of the pad118. InFIG. 4H, gouged-out areas DH1, DH2are illustrated along with a bent-shaped tear DH3extending from the gouged-out area DH2toward the edge of the pad118and having a top portion or layer of the pad near the gouged-out area DH2that has separated from a bottom portion or layer of the pad. InFIG. 4I, a gouged-out area DIis illustrated along with a tear extending from an edge of the gouged-out area DI. InFIG. 4J, a gouged-out area DJis illustrated.

In some environments or applications, such as for example, in some self-service applications, failures caused by pad damage from non-coin, sharp objects may typically occur within 400,000 coins processed on average. In some environments, such as for example, in some self-service applications, failures caused by pad damage from non-coin, sharp objects may occur within the processing of 100,000-800,000 coins. In contrast, in some environments, such as, for example, in some attended applications in which a trained operator feeds coins into a coin hopper110, failures caused by pad damage from non-coin, sharp objects may be much rarer and coin pad118may last for the processing of as many as 4-6 million coins, with typical pad life ranging from 1.5 million coins to 4 million coins. A typical service interval for the coin processing systems or coin sorters100where a technician visits to perform routine maintenance, including a pad118replacement, may occur at an average interval of approximately 1.5 million coins processed by the coin processing systems or coin sorters100. Having to visit a coin processing system or coin sorter100between regular service intervals, such as, for example, every 400,000 coins processed on average in, for example, some self-serve applications, increases the cost of maintenance by nearly a factor of four (4), and decreases coin processing system or coin sorter100uptime resulting in lost revenue.

According to some embodiments, a need exists for a solution that results in an average service life of the coin pad118of approximately 1.5 million coins processed and/or for the ability for an untrained user to replace the pad118without a service call in the event of early failure, thereby avoiding an unplanned service call. According to some embodiments, it has been found that it would be desirable if the pad118were made from a material that was puncture resistant and/or from a material if punctured that would resist propagation on the puncture, thus, resisting the formation of a tear and/or gouged-out area. Furthermore, it has also been found that it would be desirable if a pad118were constructed so as to prevent and/or minimize the extent of tears, rips, ripples, stretch, gouges, and/or punctures of or in the pad118and/or for a system for detecting the existence of damage to a pad118and annunciating and/or alerting an operator of or owner of or maintenance personnel for a coin processing system or coin sorter100of damage to a pad118when it occurs, before the damage to the pad118compromises the counting/sorting function of the coin processing system or coin sorter100.

Often the pad surface, or skin, material can be fabricated in different ways such as Calendaring or coating techniques.

The present disclosure provides several improvements to increase pad118resilience and operating life and/or to detect the existence of damage to a pad118and annunciate and/or alert an operator of or owner of or maintenance personnel for a coin processing system or coin sorter100of damage to a pad118when it occurs, before the damage to the pad118compromises the counting/sorting function of the coin processing system or coin sorter100and/or to reduce downtime of a coin processing system or coin sorter100by facilitating pad118replacement by an unskilled person as opposed to a trained service technician. These improvements include (1) a debris-resilient pad skin having a mesh layer; (2) a pad skin that is machined to achieve tight pad tolerances; (3) a coin pad118having detectable coin pad layers; (4) a system for detecting pad118damage; (5) a composite differential adhesive for adhering a coin pad118to disc120; and/or (6) a twist-lock debris blade or cone. According to some embodiments, one or more or all of these improvements may be employed with a coin processing system or coin sorter100. According to some embodiments, one or more or all of these improvements may be employed in a self-service coin processing system or coin sorter100and/or an attended coin processing system or coin sorter100.

(1) Debris-Resilient Pad Skin Having a Mesh Layer

FIG. 5AandFIG. 5Bare top views of a mesh material501that may comprise a layer of coin pad118. According to some embodiments, the mesh material501is made of Kevlar® fiber made by DuPont, nylon, or other material. Bench testing has shown little to no stretch of pads118made using a Kevlar® fiber mesh501and/or the prevention of or the resistance to puncture of the skin118sof a pad118made using a Kevlar® fiber mesh501.

FIG. 5Fa top view of an exemplary leno weave pattern for a mesh layer501according to some embodiments. Such a leno weave pattern is also illustrated inFIG. 5A. According to some embodiments, the leno weave pattern is achieved when parallel sets of twisted pairs of fibers WARP are oriented generally orthogonal to a set of single fibers WEFT, wherein the single fibers WEFT are woven through adjacent twists of the twisted pairs of the fibers WARP. According to some embodiments, 4.1 ounce (116 g) nylon leno mesh is employed. According to some embodiments, the mesh material501is made of Kevlar® fibers. According to some embodiments, the use of a leno weave pattern increases the stability (e.g., tear resistance, stretch resistance) of the mesh materials and the NBR diagonally between the orthogonal sets of fibers. According to some embodiments, the use of leno nylon mesh in combination with nitrile rubber inhibits, reduces, or prevents stretching of the pad118in a diagonal direction D5F(see.FIG. 5F) with respect to the leno weave pattern.

FIG. 5Gis a top view of an exemplary triaxial weave pattern for a mesh layer501′ according to some embodiments. According to some embodiments, three sets of parallel threads are oriented at about 60° from each other and are interwoven in an alternating over one, under one pattern with respect to the threads of the non-parallel sets of threads. According to some embodiments, the mesh material501′ is made of Kevlar® fibers. According to some embodiments, the mesh material501′ is made of nylon fibers. According to some embodiments, the use of a triaxial weave pattern provides better stability (e.g., tear resistance, stretch resistance) in all directions. According to some embodiments, the use of a triaxial weave pattern provides three dimensional (3D) stretch resistance and may reduce or minimize the “rebounding” or “slingshot” effect as the pressure on the top of the pad generating a “plowing” effect otherwise exhibited by some pads when pad pressure on a coin is released, such as in a re-gauging area, such as described in U.S. patent application Ser. No. 16/224,246 filed Dec. 18, 2018, herein incorporated by reference in its entirety. According to some embodiments, use of pads without a mesh layer or without a mesh layer employing a triaxial weave pattern, may result in a “rebounding” or “slingshot” effect as the pressure on the top of the pad generating the “plowing” effect is relieved such as when the coins move downstream of the re-gauging wall252and/or the re-gauging block254whereby the top of the pad118which has been pushed radially inward by a coin moving along re-gauging wall252moves or rebounds radially outward as a coin moves past the downstream end of the gauging block254and/or along the re-gauging wall252and/or the downstream end of the re-gauging wall252.

According to some embodiments, alternative weave patterns are employed for mesh material501,501′ such as, for example, two sets of parallel threads oriented orthogonal to each other and interwoven in an alternating one over, one under pattern.

According to some embodiments, a layer of mesh501,501′ made of Kevlar®, nylon, and/or other material is incorporated into a pad118and the layer of mesh enhances tensile strength, dimensional stability, puncture/cut resistance, impact resistance, stretch resistance, and overall longevity. According to some embodiments, a layer of mesh501,501′ having a leno weave pattern or triaxial weave pattern and made of Kevlar®, nylon, and/or other material is incorporated into a pad118and the layer of mesh enhances tensile strength, dimensional stability, puncture/cut resistance, impact resistance, stretch resistance, and overall longevity.

According to some embodiments, the layer of mesh501,501′ is imbedded and/or fabricated within a pad118such as a pad118made of nitrile rubber.FIG. 5Dis a partial cross-sectional view of a portion of a sorting head312illustrating an exemplary coin C50 (US 50¢ coin) pressing a portion of pad118downward. In some embodiments, the pad118may comprise a lower foam layer118fand an upper skin layer118scoupled to the lower foam layer118fsuch as with adhesive. According to some embodiments, a layer of mesh material501,501′ is contained within the skin layer118sof the pad118. Fabricating such a pad skin118scan be accomplished in several ways such as, for example, calendaring and coating approaches.FIG. 5Cis a side view of a skin layer118shaving a layer of mesh material501(or501′) embedded therein.

Turning toFIG. 5E, the mesh layer501,501′ can be positioned and controlled in any position (distance) within the thickness of the skin118s.FIG. 5Eillustrates three exemplary options for placement of a mesh layer501,501′ within a skin layer118sof a pad118(not to scale). According to Option #1 and Option #2, a skin layer118shas an overall thickness of 0.043 inches (1.1 mm). In the illustrated example in Option #1, a 0.005 inch (0.1 mm) thick mesh layer501,501′ is positioned above a bottom 0.010 inch (0.25 mm) thick nitrile rubber layer and below a top 0.028 inch (0.71 mm) thick nitrile rubber layer. In Option #2, the mesh layer501,501′ is positioned closer to the middle of the skin layer188s, with a 0.005 inch (0.1 mm) thick mesh layer501,501′ positioned between a bottom 0.019 inch (0.48 mm) thick nitrile rubber layer and below a top 0.019 inch (0.48 mm) thick nitrile rubber layer. According to Option #3, a skin layer118shas an overall thickness of 0.068 inches (1.7 mm) and comprises a 0.005 inch (0.1 mm) thick mesh layer501,501′ positioned between a bottom 0.010 inch (0.25 mm) thick nitrile rubber layer and below a top 0.053 inch (1.3 mm) thick nitrile rubber layer. According to some embodiments, the nitrile rubber layers are made from WARCO 80-P-987 material.

According to some embodiments, pads118incorporating such a layer of mesh501,501′ have prevented or inhibited the occurrence of tears, rips, gouges, stretching, ripples, stretch etc. According to some embodiments, embedding a mesh layer501,501′ between two layers of rubber such as nitrile rubber or other material allows for any final surface finish, such as a mesh finish.

While nitrile rubber has been described as a material from which the skin118sof a pad118may be made, other materials additionally or alternatively be used, such as, for example, Neoprene, urethane, composite urethane, polymers, rubber, or rubber products, leather, or a spongy, compliant material.

Likewise, while layer501,501′ has been described as a mesh, other configurations and/or materials may be used according to some embodiments, such as, for example, a solid layer of support material, loose fibers in spoke or overlapping material, a layer of urethane, spray on materials, embedded materials, gold specs, or a pad skin made from a slurry of materials cured into a pad skin. The materials may include, for example, Kevlar® fiber, nylon, urethane, metal, etc.

Likewise, while pads118in the present disclosure have been and/or are later described as a having a bottom foam layer, the bottom layer may be made out of other material such as, for example, nitrile rubber, Neoprene, urethane, composite urethane, polymers, rubber, or rubber products, leather, or a spongy, compliant material.

Finally, while the pads118in the present disclosure have been and/or are later described as having separate skin118sand bottom118flayers, a pad without separate layers may also be used according to some embodiments, such as, for example, a pad118with an embedded mesh or stiffening materials without separate skin and foam layers, e.g., a single type of material throughout the pad and/or such a single type of material with a layer of mesh or other strengthening layer therein.

(2) Machine Skin to Achieve Tight Pad Tolerances

In Options #1 and #3 ofFIG. 5E, the mesh layer501,501′ is positioned closer to the bottom of the skin layer118s, leaving more nitrile rubber material on top to enhance the wear life of the pad118, allowing the completed pad118to be post-processed, by machining the thicker side of the skin top surface to control the overall thickness of the pad118with great accuracy. According to some embodiments, the mesh layer501,501′ is positioned in the lower 50% of the skin thickness. According to some embodiments, the mesh layer501,501′ is positioned in the lower 40% of the skin thickness. According to some embodiments, the mesh layer501,501′ is positioned in about the lower 33%-35% of the skin thickness. According to some embodiments, the mesh layer501,501′ is positioned in the lower 25% of the skin thickness.

According to some embodiments, it can be desirable to maintain a tight tolerance on the height or thickness of coin pads118. In disc-type coin processing systems100such as coin sorters or coin counters or coin sorters, an air gap exists between the top of the sort pad118and the underside of the sorting head112. The height of the air gap will vary based on the country set of coins to be processed by the system100and whether the system100is a coin counter or a coin sorter. For example, a properly adjusted machine100may be set with an air gap range of 0.005″-0.008″ (a 0.003″ range) [0.13 mm-0.020 mm (a 0.07-0.08 mm range)]. This air gap is set once a new sort pad118is installed in the machine100. Setting/adjusting the air gap is performed by a trained technician. When the pad118needs to be replaced, a new pad118will be installed. Coin pads118could have a height or thickness tolerance of +/−0.003″ (0.08 mm). Thus, if, for example, the original pad118that was installed had a thickness on the low end of the tolerance range (−0.003″) [−0.08 mm] and the new pad118being installed has a thickness on the high end of the tolerance range (+0.003″) [+0.08 mm], the 0.006″ [0.15 mm] increase in height/thickness of the pad could eliminate the intended air gap or cause it to fall outside an acceptable range. As a result, a trained technician or trained attendant installing the new pad118would need to adjust air gap so it was within an acceptable range, e.g., by adjusting the height of the sorting head112.

Sort pads118used on attended machines100typically have a life expectancy of 4-6 million coins. However, sort pads118used on self-service machines100typically have a much shorter life expectancy of under 1 million coins. The shorter lifespan in self-service machines100can be attributed to several factors, such as, for example, coin condition and/or user training but is mainly due debris and non-coin objects (nails, screws, keys, etc.) that are deposited into the machine100by a customer. The shorter coin pad life expectancy and the lack of trained personnel to change coin pads and adjust the air gap in self-service applications can result in more downtime for a self-service machine100and/or higher maintenance costs.

According to some embodiments, coin pads118are manufactured to tighter height/thickness tolerances so as to obviate or reduce the need to adjust the machines100to obtain an air gap within a desired range (e.g., by adjusting the height of the sorting head112). To remove the need to adjust the air gap after each sort pad change, the tolerance range of the coin sort pad118overall thickness is made tighter than the allowable air gap range. Therefore, according to some embodiments, coin pads118are made with a height/thickness tolerance range for a finished pad118of about +/−0.0015″ (about +/−38 μm).

According to some embodiments, in order to achieve this tolerance range, a face grinding process is performed following the final assembly process of a sorting pad118. The desired pad thickness tolerance is achieved by grinding the top skin118sof a pad118. According to some embodiments, an assembled sorting pad118is mounted to a vacuum chuck in a lathe. Then using a tool post grinder and grinding wheel, the face (top skin)118sof the pad118is ground so as to bring the coin pad118to a desired or target finish dimension/thickness within a tolerance of about +/−0.0015″ (about +/−38 μm).

According to some embodiments, one or more coatings of detectable material is/are applied to the top surface of the coin pad skin118s. According to some embodiments, the presence and/or thickness or level of the coating(s) is detected using one or more sensors such as, for example, a discrimination sensor234,334. According to some embodiments, one or more sensors such as, for example, a discrimination sensor234,334are employed to determine or measure: (a) coin thickness, (b) pad wear levels, (c) coin spacing (if the coating is eddy current detectable and distinguishable from the coins), (d) basic imaging of coins (and/or distinguishing between the presence and absence of a coin under the sensor(s)), such as, for example, if an infrared (IR) coating is used, and/or (e) diameter of coin such as, for example, if an infrared (IR) coating is used.

FIG. 6Ais a schematic view of a sensor600for detecting characteristics of pad118and/or a coin positioned on the pad such as within a monitored path604and/or area603located within an annular region604of the pad118. According to some embodiments, the sensor600comprises one or more emitters601and one or more detectors602. According to some embodiments, a plurality of emitters601are positioned about or around the one or more detectors602. According to some embodiments, the emitters601emit ultraviolet (UV) and/or infrared (IR) light and the detectors602sense reflected or emitted ultraviolet (UV) and/or infrared (IR) and/or visible light. According to some embodiments, the sensor600is mounted in the sorting head212,312such as, for example, in the location of discrimination sensor234,334and may be mounted in the sorting head212,312so as to be in close proximity to the top surface of the skin118s.

FIG. 6Bis a side sectional view of a portion of a pad118comprising a lower foam layer118fand an upper skin layer118s. According to some embodiments, a coating605of detectable material is applied on the surface of the coin pad skin118s. Alternatively, according to some embodiments, detectable elements606are applied on the surface of the coin pad skin118s. Alternatively, according to some embodiments, both a coating605of detectable material and detectable elements606are applied on the surface of the coin pad skin118s. One or more of the sensors600are configured to detect the detectable material of the coating605and/or the detectable elements606. The coating605and/or the detectable elements606have a thickness of D6. According to some embodiments, the coating605(and/or the detectable elements606) are applied across the entire surface of the pad118. According to some embodiments, the coating605(and/or the detectable elements606) are applied across only select portions of the surface of the pad118such as, for example, near the perimeter of the pad118, e.g., within annular region604.

According to some embodiments, the sorting head assembly including the sorting head212,312and pad118are manufactured to a high degree of precision. As a result, the location and relative proximities of pad surface features are known with a high degree of accuracy. According to such embodiments, the sensor(s)600can be calibrated to detect the distance between an upper surface of a new coin pad118and the sensor(s)600and set the detected distance as corresponding to a pad life of 100%, e.g., a processor such as controller180may store an initial detected distance in a memory such as memory188, and associate that detected distance with a pad life of 100%. Then as coins wear away the top surface of the pad118, the distance between the sensor(s)600and the top surface of the pad118will increase and the increase in distance can be associated with a detected degree of wear, and a processor such as controller180may receive periodic distance measurements from a corresponding sensor such as sensor600and compare those measurements with the initial detected distance and detect any change and/or the degree of change in the measured distance and take appropriate action or actions as the measured distance satisfies one or more predetermined thresholds, such as, sending or displaying a warning to change the pad shortly when a first threshold is met (e.g., associated with 10% remaining pad life) and/or stop the operation of the coin sorter or counter100and send or display a message to change the pad when a second threshold is met (e.g., when 0% pad life remains).

For example, according to some embodiments, when a new pad is installed on rotatable solid disc120, using average distance or specific location distance (such as by employing disc encoder184to associate a measured distance with a specific location on the surface of the pad118), a location specific distance and/or average distance “X” between one or more sensor(s)600and the top surface of the pad118is measured. For example, the initial distance may be detected to be 0.25 inches (6.3 mm), e.g., 0.21″ (5.3 mm) recess depth between the bottom of sensor600and the lowermost surface210/310of the sorting head212/312plus a 0.04″ (1.0 mm) gap between the lowermost surface210/310of the sorting head212/312and the top of the pad118such as the level of the top of coating605. The height of the level of the top of the coating605(and/or the detectable elements606) and/or pad118is then repeatedly monitored and the level of wear of the coating605(and/or the detectable elements606) and/or pad118is repeatedly determined. For example, when a new coin pad118is installed, the distance between the sensor(s)600and the coating level605is detected, e.g., by sensor600, and the measured distance is set or associated with a pad life of 100%, e.g., a processor such as controller180communicatively coupled to an associated distance sensor, e.g., sensor600, may store an initial measured distance in a memory such as memory188, and associate that measured distance with a pad life of 100%. As the top surface of the coating605(and/or the detectable elements606) and/or pad118and/or pad skin118swears away, the measured distance increases and may increase proportionally. A processor such as controller180may receive periodic distance measurements from a corresponding sensor such as sensor600and compare those measurements with the initial measured distance and detect any change and/or the degree of change in the measured distance and take appropriate action or actions as the measured distance satisfies one or more predetermined thresholds. For example, when the measured distance reaches a predetermined amount, the controller180may generate a warning signal or message and, for example, alert an operator via operator interface182, to indicate that the coin pad118should be cleaned and/or replaced. For example, the controller180may generate such a warning signal when the measured distance increases to a distance associated with an expected remaining pad life of 10%-15% or 5%.

According to some embodiments, a gap between the lower surface of a sorting head such as the lowermost surface210/310of the sorting head212/312and the top of the pad118may change over time such as caused by pad wear or settling of the pad. According to some embodiments, when the measured gap distance exceeds of predetermined threshold, a processor such as controller180receiving periodic distance measurements from a corresponding sensor such as sensor600may send and/or display a message instructing an operator or service technician that the height of the sorting head relative to the top of the pad118needs to be manually adjusted, such as by lowering the sorting head.

According to some embodiments, the top of a pad118may have waves in it causing the measured gap between the lower surface of a sorting head such as the lowermost surface210/310of the sorting head212/312and the top of the pad118to vary by rotation of the pad. According to some such embodiments, one or more specific location distances (such as by employing disc encoder184to associate a measured distance with a specific location on the surface of the pad118) may be employed for distance measurements and decisions.

According to some embodiments, the sensor(s)600measure the amount of light (e.g., visible, infrared and/or ultraviolet light) reflected off or emitted by the coating605(and/or the detectable elements606) and the amount of detected light is used to measure pad wear. For example, according to some embodiments, when a new pad is installed on rotatable solid disc120, using average light intensity or specific location light intensity (such as by employing disc encoder184to associate a measured light intensity with a specific location on the surface of pad118), a location specific light intensity and/or average light intensity “Y” is measured, e.g., by sensor600, and a processor such as controller180communicatively coupled to an associated sensor may store an initial light intensity “Y” in a memory such as memory188, and associate that measured light intensity “Y” with a pad life of 100%. The light intensity received by the sensor(s)600from the coating605(and/or the detectable elements606) is then repeatedly monitored, e.g., by a processor such as controller180communicatively coupled to an associated light intensity sensor, e.g., sensor600, and the level of wear of the coating605is repeatedly determined. For example, when a new coin pad118is installed, the light intensity is detected and the measured light intensity is set or associated with a pad life of 100% e.g., a processor such as controller180communicatively coupled to an associated light intensity sensor may store an initial detected or measured light intensity in a memory such as memory188, and associate that detected light intensity with a pad life of 100%. A processor such as controller180may receive periodic light intensity measurements from a corresponding sensor such as sensor600and compare those measurements with the initial measured light intensity and detect any change and/or the degree of change in the measured light intensity and take appropriate action or actions as the measured light intensity satisfies one or more predetermined thresholds. As the top surface of the coating605(and/or the detectable elements606) wears away, the detectable coating605(and/or the detectable elements606) wears away such as by, for example, wearing away proportionally and the corresponding detected light intensity diminishes or increases such as by, for example, diminishing or increasing proportionally. When the detectable light intensity level reaches a predetermined amount, the controller180may generate a warning signal or message and, for example, alert an operator via operator interface182, to indicate that the coin pad118should be cleaned and/or replaced. For example, the controller180may generate such a warning signal when the measured light intensity decreases or increases to an intensity associated with an expected remaining pad life of 10%-15% or 5%. According to some embodiments, a deeper fabric finish or a thicker coating605(and/or thicker layer of the detectable elements606) is provided to allow for a longer coating wear life.

According to some embodiments, the coating605(and/or the detectable elements606) is IR (infrared) detectable and is used with a coin imaging sensor [see, e.g., U.S. Pat. Nos. 9,430,893; 9,508,208; 9,870,668; 10,068,406; 9,501,885; 9,916,713 and U.S. patent application Ser. No. 15/461,046 filed on Mar. 16, 2017, each incorporated by reference herein by its entirety] to discern whether a coin is present under the sensor or not (Coin/No Coin), and/or provide a high precision coin diameter measurement, including the ability to measure non-circular perimeters and internal voids in coins (e.g., holes, cutouts, etc.). According to some such embodiments, the IR coating605(and/or the IR detectable elements606) combined with the use of imaging sensor(s) enhances the contrast between a coin and the coin pad118hereby facilitating distinguishing a coin from the background coin pad118such as by a processor such as controller180communicatively coupled to an associated sensor wherein the processor is configured to receive data from the associated sensor and use the received data to distinguish a coin from the background coin pad118.

According to some embodiments, the coating605(and/or the detectable elements606) is eddy current detectable by an eddy current sensor (e.g., sensor600may be an eddy current sensor). According to such embodiments, the detection of such an eddy current coating605(and/or eddy current detectable elements606) is used to signal a break between closely spaced coins that would otherwise appear as overlapping signal patterns, particularly when the coins being processed are not eddy current detectable and the coating605(and/or elements606) are distinguishable from the coins such as by a processor such as controller180communicatively coupled to an associated sensor wherein the processor is configured to receive data or signal patterns from the associated sensor and use the received data or signal patterns to detect a spacing between coins and to distinguish one coin from an adjacent coin.

According to some embodiments, the distance a coin displaces the top of the coin pad118from the location it has been detected to be in the absence of a coin is measured and the increase in distance is used to measure the thickness of the coin displacing the top of the coin pad118. For example, using average distance or specific location distance (such as being employing disc encoder184to associate a measured distance with a specific location on the surface of pad118), a location specific distance and/or average distance “X” between one or more sensor(s)600and the top surface of the pad118is measured when no coins are present on the pad118. For example, the initial distance may be detected to be 0.25 inches (6.3 mm), e.g., 0.21″ (5.3 mm) recess depth between the bottom of sensor600and the lowermost surface210/310of the sorting head212/312plus a 0.04″ (1.0 mm) gap between the lowermost surface210/310of the sorting head212/312and the top of the pad118. With this known initial distance, a coin passing beneath the sensor600presses the upper pad surface further away by the difference between the coin thickness and distance “X”. The controller180receiving distance measurements from sensor606can then determine the thickness of the coin to a high degree of accuracy. Uses of coin thickness detection might include differentiating between two coins of identical or similar diameter but having different thicknesses, etc.

FIG. 7Ais a schematic top view of a coin pad118having a plurality of tear detectable elements701and/or702.FIG. 7Bis a schematic side view of a coin pad118having a tear detectable element701.FIG. 7Cis a schematic top view of exemplary tear detectable elements701that may be employed with a coin pad such as, for example, the coin pad illustrated inFIG. 7A. While only one detectable element701ais shown inFIG. 7A, according to some embodiments, a plurality of detectable elements701a,701e, and/or701fcan be positioned about the pad118such as, for example, 4-6 elements701a(and/or701eand/or701f) per quarter of the circular pad118. According to some embodiments, a plurality of detectable elements701a(and/or701eand/or701f) can be positioned about the pad118every certain number702dof degrees such as, for example, about every 18 degrees. The pad118has a center C. According to some embodiments, a pad118may have only a single detectable element such as detectable element701bor701d.

The shape of the detectable elements such as701a,701b,701e,701fmay take on different shapes such as, for example, arc-shaped configurations repeated in one or more or all of sectors702d.

According to some embodiments, each detectable element701a-701fcomprises a wire such as, for example, a thin copper wire, providing a continuity path monitored by a continuity sensor communicatively coupled to controller180. While continuity is maintained in each detectable element701a-701f, the pad integrity is indicated to be O.K. (e.g., the continuity detector(s) communicate maintained continuity to controller180. When the surface of the pad118is damaged, such as by a sharp non-coin object, a tear, rip, gouge, etc., and the damage in the pad118breaks one or more of the detectable elements, e.g., wires,701a-701f, the continuity of one or more of the detectable element(s) is broken, halting the flow of electricity through the one or more of the detectable elements, e.g., wires,701a-701f. When electricity no longer flows through the one or more of the detectable elements, e.g., wires,701a-701f, such condition is detected by one or more continuity detectors and communicated to a processor such as controller180which can then generate a stop signal to cause the rotatable disc120to stop rotating, e.g., by turning off or reversing motor116and/or applying braking mechanism186, and/or the controller180can generate an alert that the pad118has been damaged, such as, for example, via operator interface182. Accordingly, if a break in the continuity of the one or more detectable elements701a-701fis detected, this condition could be used to detect a deterioration of the pad (e.g., a tear or rip in the coin pad). According to some embodiments, when a break in continuity is detected, an emergency stop signal may be issued (e.g., by controller180) and the motor116driving the pad118may be stopped and/or an associated brake186may be activated to stop the rotation of the rotatable disc120and the pad118and/or the controller may annunciate and/or alert an operator of or owner of or maintenance personnel for a coin processing system or coin sorter100of damage to the pad118. According to some embodiments, the sensor(s) monitoring continuity communicates wirelessly with a processor such as the motor controller180and/or brake186.

According to some embodiments, magnetic detectors are employed instead of or in addition to continuity detectors to detect a break in one or more of the detectable elements701a-701f.

According to some embodiments, such as embodiments employing a plurality of detectable elements separately monitored, e.g., detectable elements701a,701c,701e,701f, the coin sorter or counter100may permit an operator to override (e.g., using operator interface182) a stop or halt command issued by a controller180upon the detection that one or more of the detectable elements has been broken in a particular one or more sectors702dif after inspection of the pad118, the operator believes the damage to the pad is not significant enough to warrant replacement of the pad.

According to some embodiments, the detectable elements701a-701fare printed on or inside the pad118using stretchable or flexible electronic technology (see, e.g., “Soft, Wearable Health Monitor with Stretchable Electronics,” by Georgia Institute of Technology, Tech Briefs, September 2019, pp. 35-36, www.techbriefs.com included as Exhibit 3 in the Appendix and/or “New conductive ink for electronic apparel,” Phys Org, Jun. 25, 2015, https://phys.org/news/2015-06-ink-electronic-apparel.html included as Exhibit 4 in the Appendix.

As shown inFIG. 7B, according to some embodiments, the detectable elements, e.g., wires,701a-701fare embedded within the pad118such as, for example, between the pad skin118sand the pad foam layer118f. In the example shown inFIG. 7B, layers of adhesive710are positioned on each side of the detectable elements, e.g., wires,701a-701fbetween the pad skin118sand the pad foam layer118f. According to some embodiments, a single layer of adhesive710positioned on one side of the detectable elements, e.g., wires,701a-701fbetween the pad skin118sand the pad foam layer118fcould be employed. According to some embodiments, the wires701are made of copper printed on a fabric sheet embedded within the pad118as described above.

Additionally or alternatively, the pad118may comprise a detectable element702which may comprise a thin sheet of copper such as, for example, printed copper on a fabric sheet embedded within the pad118such as, for example, between the pad skin118sand the pad foam layer118f, such as explained above with connection withFIG. 7B. According to some embodiments, the printed detectable element702which may take any of a variety of forms or patterns such as, for example, the annular star shape having an undulating outer edge defined by line701dand a central area (inside of line724) devoid of copper shown inFIG. 7A. According to some embodiments, the central area has perimeter724having a diameter of between about 5-6 inches (12.7-15 cm), e.g., about 5.38 inches (13.7 mm). According to some embodiments, the central area (and/or continuity line701d) is sized so that the detectable elements701a-701f,702are positioned below the sorting head212,312, and not within the central opening202,302of the annular sorting head212,312. According to some embodiments, the annular star shape of the detectable element702has a plurality of outward projections positioned about the pad118every certain number702dof degrees such as, for example, about every 18 degrees.

According to some embodiments, when the surface of the pad118is damaged, such as by a sharp non-coin object causing a tear, rip, gouge, etc., and the damage in the pad118results in a break in the detectable element702, resulting in the continuity of the detectable element(s) being broken, the halt of the flow of electricity through the detectable element702is detected by one or more continuity detectors. Such a condition is communicated by the one or more continuity detectors to a processor such as controller180which can then cause the rotatable disc120to stop rotating, e.g., by turning off or reversing motor116and/or applying braking mechanism186, and/or the controller180can generate an alert that the pad118has been damaged, such as, for example, via operator interface182. Accordingly, if a break in the continuity of the detectable element702is detected, this condition could be used to detect a deterioration of the pad (e.g., a tear or rip in the coin pad). According to some embodiments, when a break in continuity is detected, an emergency stop signal may be issued (e.g., by controller180) and the motor116driving the pad118may be stopped and/or an associated brake186may be activated to stop the rotation of the rotatable disc120and the pad118and/or the controller may annunciate and/or alert an operator of or owner of or maintenance personnel for a coin processing system or coin sorter100of damage to the pad118. According to some embodiments, the sensor(s) monitoring continuity communicates wirelessly with a processor such as the motor controller180and/or brake186.

According to some embodiments, a battery720supplies power to the detectable elements701a-701f,702and/or the continuity sensor(s). For example, as shown via dotted lines coupled to the ends of detectable element701a, the ends of the detectable elements701a-701fmay be connected to one or more power lines powered by battery720and monitored by one or more continuity sensors. According to some embodiments, kinetic energy is used to recharge the battery720(e.g., as done with some wrist watches). According to some embodiments, the battery720may be wirelessly charged, e.g., like some Samsung smartphones are charged. According to some embodiments, one or more transceivers are coupled to the continuity sensor(s) both of which may be located in an electronics area722. The one or more transceivers enable the continuity sensors to wirelessly communicate with a processor such as, for example, controller180. According to some embodiments, an external power source may be employed and fed to the electronics on the pad118such as the detectable elements701a-701f,702and/or the continuity sensor(s).

According to some embodiments, the pad118has an outer edge118ehaving a diameter of about 11 inches (28 cm). According to some embodiments, an electronics area722has a diameter of about 2-3 inches (5-8 cm), e.g., about 2.63 inches (6.68 cm) and fits under or in and/or is protected by a center cone801c, see, e.g.,FIGS. 4A, 4I, 8A, and 8B.

According to some embodiments, the battery720and electronic area(s)722are mounted on a removable pad interface728having. e.g., a circular shape and dimensioned to fit under or in and/or be protected by a center cone801c. During a pad change, the removable pad interface728may be decoupled from a pad118to be replaced and coupled to a new pad118to be or which has been coupled to the solid disc120. According to some embodiments, the removable pad interface728and/or the pad118have printing or other alignment indications thereon to facilitate the proper alignment of the removeable pad interface728with respect to the pad118. According to some embodiments, a bottom surface of the removeable pad interface728has a plurality of electrodes extending therefrom and which electrically couple the electronics on the removeable pad interface728to the detectable elements701a-701f,702when the removeable pad interface728is pressed into the top surface of the pad118.

(5) Composite Differential Adhesive

According to some embodiments, to facilitate the changing of a pad118, such as by an operator of the system100between visits of regular maintenance personnel and/or by maintenance personnel, an adhesive having a lower level of tackiness is used to couple a pad118to the rotatable disc120. According to some embodiments, due to the size and high surface energy of the turntable (e.g., a disc120having an 11″ (28 cm) diameter and being made of machined aluminum) a “low tack” adhesive is able to produce high amounts of strength in a shear direction (e.g., parallel to the surface of the disc120while allowing for very low force required while removing the pad when in tension (e.g., in a direction perpendicular and/or some other angle other than parallel to the surface of the disc120). Additionally or alternatively, according to some embodiments, a differential adhesive (different levels of adhesion on each side) is employed that will properly bond with the low surface energy of the machined pad and the high surface energy of the turntable platen/disc120. According to some such embodiments, an operator may peel off a pad118that needs to be replaced and couple a new pad118to the disc120in its place.

According to some embodiments, the differential adhesive is oriented with respect to the lower surface of the pad118such that the differential adhesive releases the bond between it and the disc120while remaining adhered to the old pad118so that when an old pad118is removed, all or most of the adhesive remains attached to the removed old pad118and the top surface of the rotatable disc120is substantially free of adhesive. Then an adhesive protective layer (e.g., film) may be removed from the bottom of a new pad118and then the pad118may be coupled to the top surface of the disc120.

According to some embodiments, the differential adhesive is made by adhering or laminating a “low tack” adhesive layer to a “high tack” or high-strength adhesive layer and adhering the “high tack” adhesive layer to the bottom surface of the pad118. A liner remains over the “low tack” adhesive layer until the pad118is to be adhered to a disc120. According to some embodiments, 3M Flexomount™ Solid Printing Tape 412DL is used as the “high tack” adhesive layer and 3M Repositionable Tape 9415PC tape is used as the “low tack” adhesive layer. “High tack” is a tackiness equal to or greater than the tackiness of 3M Flexomount™ Solid Printing Tape 412DL and “low tack” is a tackiness equal to or less than the tackiness of 3M Repositionable Tape 9415PC. The 3M Repositionable Tape 9415PC tape may be used on items that need to be repositioned easily and carries a very low adhesive bond similar to that of a 3M Post-It® note. More information about 3M Flexomount™ Solid Printing Tapes including 412DL is provided in the data sheet included as Exhibit 1 in the Appendix and more information about 3M Repositionable Taps including 9415PC is provided in the data sheet included as Exhibit 2 in the Appendix. According to some embodiments, 3M Flexomount™ Solid Printing Tape 412DL serves as a high strength adhesive that provides a good bond to a machined foam118fsurface of the sort pad118.

According to some embodiments, a sheet of differential adhesive is made beginning with a sheet of 3M Flexomount™ Solid Printing Tape 412DL and a sheet of 3M Repositionable Tape 9415PC tape, each having a paper or plastic liner on both opposing surfaces thereof. The liner on one surface of each of the 3M Flexomount™ Solid Printing Tape 412DL and 3M Repositionable Tape 9415PC tape is removed, and the exposed surfaces of the sheets of 3M Flexomount™ Solid Printing Tape 412DL and 3M Repositionable Tape 9415PC tape are adhered or laminated together to create a sheet of differential adhesive. The high tack side of the 3M Flexomount™ Solid Printing Tape 412DL is then attached or adhered to the foam118fside of a sort pad118(after removing the liner from that side of the sheet of differential adhesive) while the liner on the 9415PC side of the differential adhesive sheet remains on the sort pad118until the pad118ready to be installed on a disc120. At that time, the liner covering the 9415PC side of the differential adhesive sheet is removed, and the pad118via the differential adhesive is adhered to the disc120of a coin sorter100.

(6) Twist-Lock Debris Blade or Cone

According to some embodiments, to facilitate the changing of a pad118, such as by an operator of the system100between visits of regular maintenance personnel and/or by maintenance personnel, a twist-lock debris blade or cone801is employed.FIG. 8Ais a top perspective view andFIG. 8Bis a bottom perspective view of a twist-lock debris blade or cone801.FIG. 8Cis a bottom perspective view of a debris blade or cone post810and a retaining washer interface820andFIG. 8Dis a side perspective view of the debris blade or cone post810, the retaining washer interface820, and a coupler830.FIG. 8Eis a bottom perspective view of the retaining washer interface820.FIG. 8Fis an exploded, perspective view of some components of a twist-lock debris blade or cone assembly861and disc mounting assembly862according to some embodiments.FIG. 8Gillustrates perspective views of parts of a twist-lock debris blade assembly861and disc mounting assembly862and a post coupling tool870according to some embodiments.FIG. 8His a perspective view of a post coupling tool870engaged with a twist-lock debris blade assembly861according to some embodiments.

According to some embodiments, the debris blade801may have a relatively straight debris arm801acoupled to or integral with a center cone801cas illustrated inFIGS. 8A, 8B, 4A, and 4Bor a curved debris arm801bcoupled to or integral with a center cone801cas illustrated inFIG. 4E.

According to some embodiments, utilizing the spring force of the sorting pad118, the debris blade801incorporates a quarter turn, locking geometry to install and retain the debris blade while in use. To remove, the user depresses the debris blade post810using a post coupling tool (such as, for example, a 5/16 inch [8 mm] hex tool or key fitted into a tool interface810tlocated on the top of the debris blade post810) and rotates the debris blade post810a quarter turn in the counter-clockwise direction. The pad118is then removed by lifting on the outer edge of the pad118.

According to some embodiments, the debris blade post810has one or more retaining flanges812located near the bottom of the post810. The retaining washer interface820has a central generally circular opening or cylindrical aperture826slightly larger than the generally circular or cylindrical lower portion of the post810. The retainer washer interface820also has one or more retaining flange unlocked profiles824and one or more retaining flange locking profiles or surfaces822which may define one or more detents. In between the unlocked profiles824and the locking surfaces822, the interface820has one or more cam profiles or surfaces820c. To install the post810and couple it to the washer interface820, the generally circular or cylindrical lower portion of the post810is fitted through the central, generally circular opening826of the interface820with the retaining flanges812lined up with the unlocked profiles824. The post810is then turned a quarter turn in a clockwise direction (e.g., using the post coupling tool870) and the retaining flanges812travel under the cam surfaces820cand are retained by the locking surfaces822in the absence of downward pressure by the post coupling tool870. The pad118is made of a flexible, resilient material that permits the post810and the retaining flanges812thereof to be moved downward when the post810is pressed downward by a person. However, when the person no longer pushes downward on the post810, the pad118presses the post810and the retaining flanges812into locked engagement with the locking surfaces822.

To uncouple the post810from the interface820, the post is pressed downward and rotated a quarter-turn in the counter-clockwise direction, first moving the retaining flanges812out of locked engagement with the locking surfaces822, then moving the retaining flanges812over the cam surfaces820cand finally aligning the retaining flanges with the unlocked profiles824of the interface820. The generally circular or cylindrical lower portion of the post810is then removed from the central, generally circular opening826of the interface820with the retaining flanges812lined up with the unlocked profiles824.

Although not shown inFIGS. 8C and 8D, according to some embodiments, the debris blade801a,801band the associated center cone801cmay remain coupled to the post810during the process of coupling and decoupling the post810to the interface washer820.

According to some embodiments, the washer interface820is fixedly coupled to the rotatable disc120such as via one or more fasteners (e.g., screws) inserted through apertures828and coupled directly or indirectly to the rotatable disc. For example, according to some embodiments, the washer interface820is fixedly coupled to a disc coupler or debris cone base830which in turn is fixedly coupled to the rotatable disc120such as via a threaded post832.

Turning toFIG. 8F, some components of a twist-lock debris blade assembly861and disc mounting assembly862according to some embodiments are shown. As shown, the twist-lock debris blade assembly861comprises a stop841, a shim842, the center cone801chaving a debris blade801aformed integral therewith, a bearing housing843, a shim844, a washer845, an angled washer846, and the debris blade post810into which a dowel pin847is inserted above the stop841. A retaining ring848is also coupled to the debris blade post810. According to some embodiments, the several washers assist with allowing free rotation of the post810and/or reduce friction, etc., during the rotation of the post810. According to some embodiments, the bearing housing843may be a one-way bearing.

The disc mounting assembly862comprises the retainer washer interface820, two screws851and washers852used to secure the retaining washer interface820to the disc coupler or debris cone base830. The threaded post832is fitted through a central aperture in the base830and screwed into a corresponding threaded aperture in the center of the disc120(not shown inFIG. 8F). Referring toFIGS. 8D and 8F, the base830, also has one or more retaining tabs830twhich fit into matching depressions or holes in the surface of the disc120which keep the base830from rotating with respect to the disc120when the base830is secured to the disc120. When installed, a top surface830tsof the base830is flush with the top surface of the disc120according to some embodiments. Additionally, the base830may have a raised, circular, pad centering portion830d. During installation of a new pad118, the pad118may have a central aperture sized to accommodate the raised, circular, pad centering portion830dof the base830which assists with centering the pad118on the disc120.

According to some embodiments, the twist-lock debris blade assembly861is assembled during production and remains assembled during the processes of coupling and decoupling the debris blade post810to the retaining washer interface820. Rather, the twist-lock debris blade assembly861may be removed and installed as a unit during a pad change operation.

As shown inFIGS. 8G and 8H, according to some embodiments, the post coupling tool870may have a large handle at the top of the tool870to facilitate the ability of a person to press down on the tool870and rotate it during the process of uncoupling and/or coupling the post810from/to the retaining washer interface820. The lower end of the tool870is configured to mate with the tool interface810tlocated on the top of the debris blade post810, and may be, for example, a 5/16 inch (8 mm) hex tool or key. According to other embodiments, the tool870and the tool interface810tmay have other configurations such as, for example, an internal or external wrenching hex, flat head or cross recessed head, knurl, or other shape that provides adequate torque to the post810to get its retaining flanges812to engage and seat properly within the interface820.

WhileFIGS. 8A-8B and 8F-8Hillustrate a cone801chaving a debris blade or arm801a,801bextending therefrom, according to some such embodiments, a cone801cnot having a debris blade or arm801a,801bmay be used.

FIG. 9Ais a side perspective view;FIG. 9Bis a first side;FIG. 9Cis a second side view;FIG. 9Dis a top view; andFIG. 9Eis a cross-sectional side view of an alternative embodiment of a retaining washer interface920according to some embodiments. The second side view shown inFIG. 9Cis about 90° offset from the first side view shown inFIG. 9B. The cross-sectional view shown inFIG. 9Eis taken along line9E-9E shown inFIG. 9D.

10A is a perspective view;FIG. 10Bis a first side; andFIG. 10Cis a second side view of an alternative embodiment of a center cone retaining post1010according to some embodiments.FIG. 11is a perspective view of portions of a coin processing system100showing a center cone retaining post1010holding a center cone801cagainst the top of a pad118. The pad118is bonded or coupled to the top surface of a solid disc120. InFIG. 11, the retaining post1010is coupled to the retaining washer interface920which has been coupled to the solid disk120and/or other portion of a turntable such as by a threaded end932being screwed into a threaded aperture in the center of the solid disk120and/or turntable.

As shown inFIGS. 10A-10C, the center cone retaining post1010has a cylindrical post section1012having a high-friction handle1060near a first end and having retaining flanges1012near a second end. According to some embodiments, the high-friction handle1060has a knurled surface. When in an operative position, a bottom surface1062of the handle1060engages a top surface of a cone801cto bias the cone801cdownward into a pad118as shown inFIG. 11. According to some embodiments, the post may not have a handle and may have a cone engaging surface1062without having a handle1060.

Turning back toFIGS. 9A-9E, the retaining washer interface920may have a generally cylindrical shape and have a generally cylindrical central aperture926in a top end of the interface920and one or more side apertures924aand one or more pivot apertures927a. As illustrated, two side apertures have a generally vertical orientation and are defined by generally vertical internal side walls924extending from near the top of the interface920to a lower internal wall927. As illustrated, two pivot apertures927adefined by internal walls927extend generally horizontally from lower portions of side apertures924ain a common direction (clockwise inFIG. 9A) and terminate with a raised upper wall922. Although not visible inFIG. 9A, there is a second pivot aperture927aon the far side of the interface920having the same or similar shape as the visible aperture927a. The cylindrical center aperture926is sized to accommodate the cylindrical post section1012of the cone retaining post1010and the apertures924a,927aare sized to accommodate the retaining flanges1012of the cone retaining post1010. The interface920also has a threaded post932at a lower end that is configured to be screwed into a corresponding threaded aperture in the center of the disc120, thereby securely coupling the interface920to the disc120.

To assemble the arrangement shown inFIG. 11, the threaded post932of the interface920is screwed into a corresponding threaded aperture in the center of the disc120. Then a pad118is coupled to the disc120. According to some embodiments, the pad118has a central opening or aperture sized to just fit about the circumference of a bottom portion920Bof the interface920, thereby aiding in centering the pad118on the disc120. Once the pad118has been installed in the disc120, the cone801chaving a central opening in placed over the interface920.

Next, the center cone retaining post1010is coupled to the interface920. To accomplish this coupling, the lower end of the cone retaining post1010is inserted through the center opening in the cone and the retaining flanges1012on the post1010are aligned with the side apertures924aof the interface920. According to some embodiments, the center opening in the cone may have cut outs sized to permit the retaining flanges1012of the post1010to fit therethrough. Once the retaining flanges1012on the post1010are aligned with the side apertures924aof the interface920, the post1010is lowered within the interface920until the retaining flanges1012contact the lower internal walls927. The post1010is then rotated about its longitudinal axis (here, vertical axis) until the retaining flanges1012contact the walls at the end of the pivot apertures927a. To aid in the rotation of the post1010, the handle1060may have a high-friction surface such as a knurled surface. According to some embodiments, a user, operator, or technician may insert and rotate the post1010into and within the interface920by holding and squeezing the handle1060in his or her handle. According to some embodiments, while the post1010is being lowered vertically within the interface920with the retaining flanges aligned within the vertical apertures924a, the lower surface of1062of the handle contacts the top edge of the cone801c. To enable the post1010to travel further down into the interface920so that the retaining flanges1012may become aligned with the horizontal apertures927a, the user must press the handle1060downward, thereby pushing the cone801cinto the compressible pad118. While still pressing downward, the handle is then turned or rotated (clockwise inFIG. 9A) as the retaining flanges pass through the pivot apertures927a. Once the retaining flanges1012contact the walls at the end of the pivot apertures927aand the downward bias or pressure from a person installing the post1010within the interface920is removed, the resilient pad118biases the cone801cupward, thereby pressing upwardly into the lower surface1062of the handle1060and thereby biasing the post1010upward and raising the retaining flanges1012into the raised upper walls922and the corresponding rotation prevention notches or detents927b.

To remove the cone801cand pad118from the arrangement shown inFIG. 11, the above steps are followed in reverse order. A person presses the handle1060downward, thereby pushing the cone801cinto the compressible resilient pad118and moving the retaining flanges out of the rotation prevention notches or detents927b. While still pressing downward, the handle is then turned or rotated (counter-clockwise inFIG. 9A) as the retaining flanges pass through the pivot apertures927a. Once the retaining flanges1012contact the far interior walls924at the other end of the pivot apertures927aand/or the retaining flanges1012become aligned with the vertical side apertures924a, the post1010may be moved upward and out of the interface920. Next the cone801cmay be lifted over the interface920and removed. Next the pad118may be de-coupled from the disc120and, if desired, a new pad118may be coupled to the disc120and the cone801cand the post1010may be reinstalled.

According to some embodiments, the post1010may have a tool interface on the top of the post1010or handle1060. Such a tool interface may be the same or similar to tool interface810tdiscussed above and may be designed to work with tool870. According to some such embodiments, the high-friction area of the handle1060may be omitted.

While the cone801cshown inFIG. 11does not have a debris blade or arm801a,801bextending therefrom, according to some embodiments, it may have a debris blade or arm. Likewise, while some of the embodiments above utilize a cone801chaving a debris blade or arm801a,801bextending therefrom, according to some such embodiments, a cone801cnot having a debris blade or arm801a,801bmay be used.

Thus, employing one or more of the above improvements (1)-(6), a number of advantages may be achieved. For example, a pad118with a higher tensile strength may be provided; a pad118that is tear resistant may be provided; a pad118that is puncture resistant may be provided; a pad118exhibiting reduced stretch may be provided which can contribute to maintaining a coin on its desired path, the reduction of mis-sorts, and the ability to process coin sets that are otherwise more challenging; pad tears or damage may be detected and annunciated such as by notifying appropriate personnel and halting operation of the coin sorter100thereby minimizing sorting inaccuracies that may otherwise be caused by use of a damaged pad; pad wear detection and/or preventative measures may be provided and, for example, the detection of a certain level of pad wear may be used to prompt service or other personnel to change a worn pad before a catastrophic failure or mis-sorts due to a worn pad occur; and/or a coating that allows for improved coin authentication and/or coin discrimination may be provided.

When combined, improvements (2), (5) and/or (6) detailed above may provide an untrained user the ability to reliably repair the machine100in a situation where the sorting pad118is damaged due to unexpected debris. For example, the twist-lock debris blade801may be removed using a counter-clockwise quarter-turn motion such as with an appropriate tool (e.g., a 5/16″ (8 mm) Hex Key), and the pad118is then removed by lifting on the outer edge of the pad118. According to some embodiments, a compound differential adhesive (5) allows the pad118to be removed from the turntable120surface easily without any or minimal residue being left behind. With improvement (2), the tolerances held during the manufacturing of the pad118may eliminate the need for an attendant or operator to adjust the mechanical sorting gap desired for optimal machine operation. With a new pad118in place, the twist-lock debris blade801may be re-installed and the machine100may be placed back in operation.

ALTERNATIVE EMBODIMENTS

A resilient coin sorting pad for imparting motion to a plurality of coins, the resilient pad configured to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge, the resilient pad comprising:

a lower foam layer having a top surface;

an upper skin layer coupled to the top surface of the foam layer; and

a layer of mesh material.

The resilient pad of embodiment 1 wherein:

the upper skin layer comprises at least one layer of nitrile rubber; and

the layer of mesh material is Kevlar® fiber mesh.

The resilient pad of embodiment 1 wherein:

the upper skin layer comprises at least one layer of nitrile rubber; and

the layer of mesh material is nylon fiber mesh.

The resilient pad of embodiment 2 or embodiment 3 wherein:

the upper skin layer comprises at least two layers of nitrile rubber; and

the layer of mesh material is positioned between the at least two layers of nitrile rubber.

The resilient pad of embodiment 4 wherein:

the at least two layers of nitrile rubber comprise a first layer having a first thickness and a second layer having a second thickness, and the layer of mesh material has a third thickness, and the first thickness is larger than the combined thicknesses of the second and third thicknesses, and wherein the first, second, and third thicknesses contribute to a thickness of the skin layer.

The resilient pad of embodiment 5 wherein the first, second, and third thicknesses are such that the layer of mesh is positioned in about the lower 33%-35% of the thickness of the skin layer.

The resilient pad of embodiment 5 wherein the first, second, and third thicknesses are such that the layer of mesh is positioned in the lower 40% of the thickness of the skin layer.

The resilient pad of embodiment 5 wherein the first, second, and third thicknesses are such that the layer of mesh is positioned in the lower 20% of the thickness of the skin layer.

The resilient pad of embodiment 5 wherein the first, second, and third thicknesses are such that the layer of mesh is positioned in the lower 50% of the thickness of the skin layer.

The resilient pad of embodiment 5 wherein the first, second, and third thicknesses are such that the layer of mesh is positioned in the lower 70% of the thickness of the skin layer.

The resilient pad of according to any of embodiments 1-10 wherein the layer of mesh material has a leno weave pattern.

The resilient pad of according to any of embodiments 1-10 wherein the layer of mesh material has a triaxial weave pattern.

The resilient pad of according to any of embodiments 1-10 wherein the layer of mesh material comprises interwoven fibers.

A resilient coin sorting pad for imparting motion to a plurality of coins, the resilient pad designed to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge, the resilient pad comprising:

a lower foam layer having a top surface;

an upper skin layer coupled to the top surface of the foam layer; and

one or more coatings of detectable material applied to a top surface of the skin layer.

The resilient pad of embodiment 14 wherein:

the detectable material reflects or emits light responsive to infrared illumination.

The resilient pad of embodiment 15 wherein:

the detectable material emits visible light responsive to infrared illumination.

The resilient pad of according to any of embodiments 14-16 wherein:

the detectable material reflects or emits light responsive to ultraviolet illumination.

The resilient pad of any of embodiment 14-17 wherein:

the detectable material emits visible light responsive to ultraviolet illumination.

A resilient coin sorting pad for imparting motion to a plurality of coins, the resilient pad designed to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge, the resilient pad comprising:

a lower foam layer having a top surface;

an upper skin layer coupled to the top surface of the foam layer; and

one or more electrically conductive elements coupled to or embedded within the skin layer.

A coin processing system for processing a plurality of coins comprising:

a rotatable disc having a resilient coin sorting pad of embodiment 19 coupled thereto for imparting motion to the plurality of coins, the resilient pad being generally circular and having an outer periphery edge; and

one or more continuity sensors coupled to the one or more electrically conductive elements configured to sense when one or more of the electrically conductive elements have a break therein preventing the flow of electricity therethrough.

The coin processing system of embodiment 20 further comprising:

a processor communicatively coupled to the one or more continuity sensors;

a motor operatively coupled to the rotatable disc for causing the rotatable disc to rotate and the motor being communicatively coupled to the processor;

wherein upon sensing one or more of the electrically conductive elements have a break therein preventing the flow of electricity therethrough, the processor sends a signal to the motor to stop the rotation of the rotatable disc.

A coin processing system for processing a plurality of coins of a mixed plurality of denominations, the coins of the plurality of denominations having a plurality of diameters, comprising:

a rotatable disc having a resilient coin sorting pad according to any of embodiments 1-19 coupled thereto for imparting motion to the plurality of coins, the resilient pad being generally circular and having an outer periphery edge; and

a stationary sorting head having a lower surface generally parallel to and spaced slightly away from the resilient pad, the lower surface forming a coin path for directing the movement of each of the coins.

A disc-type coin processing system comprising:

a hopper for receiving coins;

an annular sorting head having a central opening;

a rotatable disc having a top surface; and

a resilient pad of according to any of embodiments 1-19 coupled to the top surface of the rotatable disc.

A coin processing system for processing a plurality of coins of a mixed plurality of denominations, the coins of the plurality of denominations having a plurality of diameters, comprising:

a rotatable disc having a resilient pad coupled thereto for imparting motion to the plurality of coins, the resilient pad being generally circular and having an outer periphery edge, the resilient pad comprising:

a lower foam layer having a top surface;

an upper skin layer coupled to the top surface of the foam layer; and

one or more electrically conductive elements coupled to or embedded within the skin layer, when unbroken the electrically conductive elements conducting electricity and completing one or more associated continuity paths;

a stationary sorting head having a lower surface generally parallel to and spaced slightly away from the resilient pad, the lower surface forming a coin path for directing the movement of each of the coins;

at least one continuity sensor communicatively coupled to a processor or controller, the continuity sensor monitoring whether the one or more electrically conductive elements continue to conduct electricity and complete the associated one or more associated continuity paths;

wherein when the sensor detects that one or more of the continuity paths have been disrupted and no longer conduct electricity, the processor or controller generates a stop signal to stop the rotation of the rotatable disc.

The coin processing system of embodiment 24 further comprising a motor driving the rotation of the rotatable disc and being communicatively coupled to the processor or controller; and wherein in response to the generation of a stop signal, the processor or controller halts the operation of the motor.

The coin processing system of embodiment 24 or embodiment 25 further comprising a rotatable disc brake communicatively coupled to the processor or controller; and wherein in response to the generation of a stop signal, the processor or controller initiates the operation of the brake to stop the rotation of the rotatable disc.

A twist-lock debris blade comprising:

a debris blade post; and

a retaining washer interface;

wherein the debris blade post comprises a generally circular lower portion and one or more retaining flanges located near a bottom of the post extending outward from the generally circular lower portion;

wherein the retaining washer interface comprises:

a central, generally circular opening,

one or more retaining flange unlocked profiles,

one or more retaining flange locking profiles or surfaces, and

one or more cam profiles or surfaces between the unlocked profiles and the locking surfaces;

wherein to couple the post to the washer interface, the generally circular lower portion of the post is fitted through the central, generally circular opening of the interface with the retaining flanges lined up with the unlocked profiles, the post is then turned a quarter turn so that the retaining flanges travel under the cam surfaces and are retained by the locking surfaces in the absence of downward pressure on the post;

wherein to uncouple the post from the washer interface, the post is pressed downward and rotated a quarter-turn so that the retaining flanges move out of locked engagement with the locking surfaces and then move over the cam surfaces and are finally aligned with the unlocked profiles of the washer interface, whereby the post may be moved upward and the generally circular lower portion of the post may be removed from the central, generally circular opening of the interface.

A twist-lock debris blade or cone comprising:

a post; and

a retaining washer interface;

wherein the post comprises a generally circular lower portion and one or more retaining flanges located near a bottom of the post extending outward from the generally circular lower portion;

wherein the retaining washer interface comprises:

a central, generally circular opening,

one or more retaining flange unlocked profiles,

one or more retaining flange locking profiles or surfaces, and

one or more cam profiles or surfaces between the unlocked profiles and the locking surfaces.

The twist-lock debris blade or cone of embodiment 28 wherein the generally circular lower portion of the post and the retaining flanges are sized to fit through the central, generally circular opening of the interface when the retaining flanges are lined up with the unlocked profiles and wherein the generally circular lower portion of the post and the retaining flanges are sized not to fit through the central, generally circular opening of the interface when the retaining flanges are lined up with flange locking profiles or surfaces.

The twist-lock debris blade or cone of embodiments 28 or 29 wherein the unlocked profiles and the flange locking profiles or surfaces of the retaining washer interface are displaced from each other by about 90° relative to the central, generally circular opening of the retaining washer interface.

A method of coupling the post of any of embodiments 28-30 to the retaining washer interface of any of embodiments 28-30 in a disc-type coin processing system comprising an annular sorting head having a central opening, a rotatable disc having a top surface, and a resilient pad coupled to the top surface of the rotatable disc, wherein the post has a longitudinal axis, wherein the retaining washer interface is coupled to the rotatable disc, the method comprising:

aligning the retaining flanges of the post with the unlocked profiles of the retaining washer interface;

fitting the generally circular lower portion of the post through the central, generally circular opening of the interface with the retaining flanges lined up with the unlocked profiles;

pressing downward on the post to overcome an upward bias asserted on the post by the resilient pad and turning the post about its longitudinal axis so that the retaining flanges travel under the cam surfaces of the interface move adjacent to locking surfaces;

removing the downward pressure on the post wherein the retaining flanges are biased upward by the resilient pad into engagement with the locking surfaces of the interface.

A method of decoupling the post of any of embodiments 28-30 from the retaining washer interface of any of embodiments 28-30 in a disc-type coin processing system comprising an annular sorting head having a central opening, a rotatable disc having a top surface, and a resilient pad coupled to the top surface of the rotatable disc, wherein the post has a longitudinal axis, wherein the retaining washer interface is coupled to the rotatable disc, and wherein the retaining flanges of the post are biased upward by the resilient pad into engagement with the locking surfaces of the interface, the method comprising:

pressing downward on the post to overcome the upward bias asserted on the post by the resilient pad and turning the post about its longitudinal axis so that the retaining flanges travel under the cam surfaces of the interface move into alignment with the unlocked profiles of the retaining washer interface;

lifting the post upward out of the interface by fitting the generally circular lower portion of the post through the central, generally circular opening of the interface with the retaining flanges aligned with the unlocked profiles.

The methods according to any of embodiments 31 or 32 wherein the act of turning the post comprises turning the post a quarter turn.

The methods according to any of embodiments 31-33 wherein the post comprises a tool interface located on a top of the post and wherein the acts of pressing downward on the post and turning the post are performed using a tool engaged with the tool interface.

A resilient coin sorting pad for imparting motion to a plurality of coins, the resilient pad designed to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge, the resilient pad comprising:

a foam layer having a bottom surface;

a differential adhesive coupled to the bottom surface of the foam layer, the differential adhesive comprising at least two adhesive layers, the adhesive layers having different degrees of tack.

The resilient coin sorting pad of embodiment 35 wherein the differential adhesive comprises a layer of high tack coupled to the bottom surface of the foam layer and a layer of lower tack coupled to the layer of high tack adhesive.

The resilient coin sorting pad of embodiment 35 or embodiment 36 wherein the differential adhesive comprises a layer of 3M Flexomount™ Solid Printing Tape 412DL coupled to the bottom surface of the foam layer and a layer of 3M Repositionable Tape 9415PC tape coupled to the layer of 3M Flexomount™ Solid Printing Tape 412DL.

A coin processing system for processing a plurality of coins of a mixed plurality of denominations, the coins of the plurality of denominations having a plurality of diameters, comprising:

a rotatable disc having a resilient coin sorting pad according to any of embodiments 35-37 coupled thereto for imparting motion to the plurality of coins, the resilient pad being generally circular and having an outer periphery edge, wherein the adhesive layer having the lower degree of tack contacts and couples the pad to the rotatable disc; and

a stationary sorting head having a lower surface generally parallel to and spaced slightly away from the resilient pad, the lower surface forming a coin path for directing the movement of each of the coins.

A disc-type coin processing system comprising:

a hopper for receiving coins;

an annular sorting head having a central opening;

a rotatable disc having a top surface; and

a resilient pad of according to any of embodiments 35-37 coupled to the top surface of the rotatable disc, wherein the adhesive layer having the lower degree of tack contacts and couples the pad to the rotatable disc.

A method of manufacturing a resilient coin sorting pad for imparting motion to a plurality of coins, the resilient pad designed to be coupled to a rotatable disc of a coin sorter, the resilient pad being generally circular and having an outer periphery edge, the pad comprising a foam layer and a skin layer, the method comprising:

a mounting an assembled sorting pad to a vacuum chuck in a lathe;

using a tool post grinder and grinding wheel, grinding the skin layer of the pad so as to bring the thickness of the coin pad to a desired thickness within a tolerance of about +/−0.0015″ (about +/−38 μm).

A twist-lock cone retaining assembly comprising:

a cone retaining post; and

a retaining washer interface;

wherein the cone retaining post comprises a generally circular lower portion and one or more retaining flanges located near a bottom of the post extending outward from the generally circular lower portion;

wherein the retaining washer interface comprises:

a central, generally circular opening in a top surface of the interface,

one or more elongated side apertures in communication with the circular opening and extending downward from the top surface of the interface,

one or more pivot apertures pivot apertures, a first end of each pivot aperture being in communication with a respective one of the side apertures near a lower end of the side apertures, each pivot aperture having an upper detent near a second end of each pivot aperture.

The twist-lock debris blade of embodiment 41 wherein the generally circular lower portion of the post and the retaining flanges are sized to fit through the central, generally circular opening of the interface when the retaining flanges are lined up with the elongated side apertures and wherein the generally circular lower portion of the post and the retaining flanges are sized not to fit through the central, generally circular opening of the interface when the retaining flanges are lined up with the one or more upper detents.

The twist-lock debris blade of embodiments 41 or 42 wherein the elongated side apertures and the upper detents of the retaining washer interface are displaced from each other by about 90° relative to the central, generally circular opening of the retaining washer interface.

A method of coupling the cone retaining post of any of embodiments 41-43 to the retaining washer interface of any of embodiments 41-43 in a disc-type coin processing system comprising an annular sorting head having a central opening, a rotatable disc having a top surface, and a resilient pad coupled to the top surface of the rotatable disc, wherein the post has a longitudinal axis, wherein the retaining washer interface is coupled to the rotatable disc, wherein the cone retaining post comprises a handle having a cone engaging surface configured to engage a post engaging surface of a cone, the cone having an upper central opening, the method comprising:

positioning the cone over retaining washer interface and over the pad so that the central opening of the cone is aligned with the central, generally circular opening in the top surface of the interface;

aligning the one or more retaining flanges of the cone retaining post with the one or more elongated side apertures of the retaining washer interface;

fitting the generally circular lower portion of the post through the central opening of the cone and the central, generally circular opening of the interface with the retaining flanges lined up with the elongated side apertures;

moving the post downward within the circular opening of the interface until the cone engaging surface of the handle of the post engages the post engaging surface of the cone;

pressing downward on the cone retaining post to overcome an upward bias asserted on the post by the resilient pad via the cone engaging with the cone engaging surface of the post so that the retaining flanges become aligned with the one or more pivot apertures and turning the post about its longitudinal axis so that the retaining flanges move through the pivot apertures until the retaining flanges move adjacent to the one or more detents;

removing the downward pressure on the cone retaining post wherein the retaining flanges are biased upward by the resilient pad into engagement with the detents of the interface.

A method of decoupling the cone retaining post of any of embodiments 41-43 from the retaining washer interface of any of embodiments 41-43 in a disc-type coin processing system comprising an annular sorting head having a central opening, a rotatable disc having a top surface, and a resilient pad coupled to the top surface of the rotatable disc, and a cone having an upper central opening, wherein the cone is positioned about the interface, wherein the post has a longitudinal axis, wherein the retaining washer interface is coupled to the rotatable disc, and wherein the retaining flanges of the cone retaining post are biased upward by the resilient pad into engagement with the detents of the interface, and wherein the cone retaining post comprises a cone engaging surface configured to engage a post engaging surface of a cone, the method comprising:

pressing downward on the cone retaining post to overcome the upward bias asserted on the post by the resilient pad and turning the post about its longitudinal axis so that the retaining flanges travel under the detents of the interface and move through the pivot apertures and come into alignment with the side apertures of the retaining washer interface;

lifting the cone retaining post upward out of the interface by fitting the generally circular lower portion of the post through the central, generally circular opening of the interface with the retaining flanges aligned with the side apertures and though the central opening of the cone.

The methods according to any of embodiments 44 or 45 wherein the act of turning the post comprises turning the post a quarter turn.

The methods according to any of embodiments 44-46 wherein the cone retaining post comprises a tool interface located on a top of the cone retaining post and wherein the acts of pressing downward on the cone retaining post and turning the post are performed using a tool engaged with the tool interface.

The methods according to any of embodiments 44-47 wherein the post has a high-friction handle having a knurled surface.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and described in detail herein. It should be understood, however, that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the disclosure is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the inventions as defined by the appended claims.