Distributable container and system and method using distributable container

A container, method and system for dispensing a solid product held in a distributable container having an opening. A mechanical interlock secures the opening of the container preventing contact with the solid product by a user. A dispenser, fixed at a dispensing location, is adapted to receive the mechanical interlock of the container. A power source is operatively coupled to the dispenser and adapted to power the mechanical interlock allowing dispensing of the solid product from the container.

TECHNICAL FIELD

This invention relates to a system for dispensing an active ingredient using a dispensable tablet, the dispensable tablet and a container for holding such dispensable tablets.

BACKGROUND

Automated machines are often used for cleaning dishes, utensils, kitchen items, pots and pans, etc. These automated machines, commonly called warewashing machines, are often used by commercial establishments such as restaurants. A typical warewashing machine may use an active ingredient found in a detergent, rinse aid or sanitizer.

For a sanitizer, an active ingredient, such as chlorine, may be supplied in powdered or solid block form. A warewashing machine presents an adverse environment for such powdered or solid active ingredients. Since the active ingredient must react and dissolve quickly in water used in the warewashing machine, the solid or powdered active ingredients should be formulated to easily dissolve. However, this desired ability to dissolve quickly when used is a liability while the solid or powdered active ingredient has not yet been dispensed. The very wet and high temperature environment of the warewashing machine can degrade the solid or powdered active ingredients. If such wet and/or high temperature environment should come into contact with the active ingredient before being dispensed into the warewashing machine deleterious effects may result.

A relatively large, e.g., 600 gram, solid block can be utilized with a flood-type dispenser. As the ingredient in the solid is needed, the dispenser floods the solid block for a specified period of time with water. As water floods the solid block, the solid block erodes providing an ingredient/water solution using a portion of the solid block that has been eroded. Some, perhaps much, of the solid block remains for use in subsequent cycles of the machine to which the dispenser operates. During subsequent cycles, the solid block may again be flooded with water and the process is repeated.

However, some problems exist with this arrangement. Because of variations in water temperature, more or less of the active ingredient, e.g., chlorine, can be eroded from the solid block. For example, a lower water temperature will erode less chlorine from the solid block in the predetermined period of time allotted. However, a higher water temperature will erode more chlorine from the solid block in the same predetermined period of time. Depending upon the water temperature, either too much or too little chlorine may be used to produce a desired sanitizing solution.

Other forms of active ingredient dispensers also exist in the warewashing machine environment.

Powdered detergent is typically individually manually metered or poured into the warewashing machine. This, however, results in the non-uniform dose of detergent for the warewashing machine which is highly variable based upon the person performing the manual dispensing operation. Further, it is possible that the user could come into contact with the active ingredient which could raise a safety issue.

Alternatively, a tablet of detergent may be manually placed into a warewashing machine. While placing a tablet of detergent into the warewashing machine does provide a uniform dose, this dispensing system also requires the user to handle a tablet in order to manually place the tablet into the warewashing machine.

Another technique for dispensing an ingredient is known in the industry as a blister pack. A blister pack, well known in the industry, consists of a plastic top, typically clear, formed with indentations with each indentation capable of holding an individual dose of tablet or tablets. A backing sheet is adhered over the plastic top to secure the tablets in the indentations. A user may then take the blister pack and, pushing on the plastic top at an indentation, push an individual tablet or tablets contained in an indentation through the backing sheet, perforating the backing sheet, and releasing the tablet or tablets. While this technique also provides for uniform dose, it also could allow the user to come in contact with the tablet being dispensed. Most importantly, dispensing of tablets with a blister pack is an intensely manual operation.

PCT International Publication Number WO 02/058528, Hindustan Lever Limited, Detergent Dispenser System, describes a removable cartridge for a detergent dispensing system for a dishwasher. A storage unit contains a plurality of cylindrical or spherical detergent tablets arranged in two or more rows with curved surfaces of adjacent tablets touching such that when the cartridge is upright that tablets will move under gravity towards the transfer station. The transfer station has an ejection means to eject a tablet from the transfer station through a transfer port to prevent ingress of moisture into the cartridge. The dispensing system of Hindustan recognizes the problem of moisture contamination. Hindustan attempts to have the dispensing mechanism handle all of the responsibility of preventing the moisture from contaminating the dispensing container. However, Hindustan does not solve the problem because even a little moisture or extreme humidity can then contaminate not only the tablet being dispensed but literally the whole cartridge (container) of tablets.

Some tablets being dispensed may be fragile or the active ingredient may be toxic to a user. In this case, allowing a user to contact or directly interact with solid product, including tablets, can be a significant disadvantage.

Further, some tablets and some active ingredients may contaminate the dispenser over time. Continued dispensing of multiple containers of solid product can, especially over time, cause significant contamination of the dispensing mechanism and can lead to deleterious operation including decreased reliability.

SUMMARY OF THE INVENTION

In one embodiment, the present invention provides a system for dispensing a solid product held in a distributable container having an opening. A mechanical interlock secures the opening of the container preventing contact with the solid product by a user. A dispenser, fixed at a dispensing location, is adapted to receive the mechanical interlock of the container. A power source is operatively coupled to the dispenser and adapted to power the mechanical interlock allowing dispensing of the solid product from the container.

In a preferred embodiment, the invention further provides a cleaning machine operatively coupled to the dispenser and adapted to receive the solid product dispensed from the dispenser.

In a preferred embodiment, the opening of the container is circular. A circular cap is adapted to fit over and secure the opening of the container, the circular cap having a central axis and having an opening therein positioned off-center from the central axis. A shaft operatively cooperates with the circular cap and is adapted to be coupled to the power source. A disc is rotatably coupled with the shaft positioned adjacent the circular cap nearest the solid product in the container. The disc has at least one opening therein cooperating with the opening of the circular cap at an angular position upon rotation of the disc.

In another embodiment, the present invention provides a distributable container for holding a solid product and adapted to mate with a dispenser fixed at a dispensing location and having a power source. A receptacle having an opening holding the solid product. A mechanical interlock secures the opening of the receptacle preventing contact with the solid product by a user. The mechanical interlock is adapted to mate with the dispenser and dispense the solid product using the power source.

In another embodiment, the present invention provides a method of dispensing a solid product from a distributable container having a mechanical interlock preventing contact with the solid product by a user to a dispenser fixed at a dispensing location. The container holding the solid product is distributed to the dispensing location. The mechanical interlock of the container is mated with the dispenser. Power from the dispenser is provided to the mechanical interlock to controllably dispense the solid product allowing the dispenser to dispense a predetermined amount of the solid product from the container without allowing contact of the solid product with the user.

In a preferred embodiment, the mechanical interlock substantially prevents moisture from the dispenser from affecting the solid product.

In a preferred embodiment, the solid product is a plurality of tablets.

In a preferred embodiment, the plurality of tablets can be dispensed one at a time.

In a preferred embodiment, the mechanical interlock is fixedly secured to the container.

In a preferred embodiment, the power source provides rotary motion to the mechanical interlock.

In a preferred embodiment, the solid product is bleach.

In a preferred embodiment, the solid product is rinse aid.

In a preferred embodiment, the solid product is detergent.

DETAILED DESCRIPTION

The present invention uses granular chlorine in a commercial warewashing environment. The preferred ingredients are sodium dichloro-s-triazinetrione dihydrate or sodium dichloroisocyanurate dihydrate.

In a preferred embodiment, the active ingredient, in this example, chlorine, is contained in dispensable tablet10, shown in cross-sectional view inFIG. 1. In order to avoid the problem of how much active ingredient to dispense into the warewashing machine, dispensable tablet10can be constructed to contain exactly the unit dose desired for optimum operation of the warewashing machine. Thus, when an operation of the warewashing machine needs an optimum dose of the active ingredient a single dispensable tablet10may be dispensed to the warewashing machine ensuring the proper dosage.

Alternatively, the unit dose desired for optimum operation of the warewashing machine can be contained in two or more of dispensable tablets10as long as an integral number of dispensable tablets10contain the intended dose for the warewashing machine. For example, if the intended dose for the warewashing machine is contained in two of dispensable tablets10, then two dispensable tablets10can be dispensed when required. Of course, reasonableness is preferred in the number of dispensable tablets10the intended dose for the warewashing machine. As the number of dispensable tablets10over which the intended dose for the warewashing machine is spread, the more difficult it is to count the number of dispensable tablets10which must be dispensed and to actually dispense that number of dispensable tablets10. For this reason, it is preferred that the number of dispensable tablets10over which the intended dose for the warewashing machine is spread be limited to not more than ten.

It is recognized that while it is preferred that a unit dose for the warewashing machine be contained in a single dispensable tablet10, or in a plurality of dispensable tablets10, that the warewashing machine could require differing amounts of the active ingredient during different cycles or with different options of single cycle. For example, the warewashing machine could require a single dispensable tablet10when operating in a normal mode and could require two or more dispensable tablets10when operating in a heavy duty mode. Nevertheless, at least one cycle of the warewashing machine in at least one mode operates with an intended dose of the active ingredient contained in a plurality of dispensable tablets10, preferably not more than ten dispensable tablets10.

Dispensable tablet10illustrated inFIG. 1is spherical in shape. Other generally rounded shapes for dispensable tablet10are also contemplated. For example, dispensable tablet10′ illustrated inFIG. 2is of a generally disc shape, preferably with slightly rounded edges. This shape can also be compared to the common shape of medicinal tablet, such as an aspirin tablet. Dispensable tablet10and10′ have generally rounded shapes in order that dispensable tablets10and10′ may be more easily dispensed through automated dispensing equipment. It is also desirable that dispensable tablets10and10′ have generally rounded shapes so that dispensable tablets10and10′ do not have sharp corners, e.g., ninety degree three dimensional corners, which are subject to breakage as dispensable tablets10and10′ are handled, both manually and with automated equipment but especially with automated equipment.

The preferred size for dispensable tablet10′ is an approximately 0.7 gram tablet, plus or minus 0.5 grams, having a diameter of approximately 0.3750 inches (9.52 millimeters with a height of approximately 0.2205 inches (5.59 millimeters).

While dispensable tablet of the present invention may be any of a variety of shapes, two of the preferred shapes are illustrated inFIG. 1as dispensable tablet10and inFIG. 2as dispensable tablets10′. It is to be recognized and understood that other shapes are possible. The remainder of the discussion in this disclosure will be made to dispensable tablet10but applies equally well to dispensable tablet10′ and to a variety of shapes not specifically illustrated, for example elliptical shapes.

Since dispensable tablet10is a tablet, the active ingredient contained in dispensable tablet10is in solid form. In order that the active ingredient in dispensable tablet10can be utilized in the warewashing machine, dispensable tablet10should be readily dissolvable in the solution operatively utilized during operation of the warewashing machine. It is desirable that dispensable tablet10dissolve quickly in water so that the active ingredient can be effectively utilized by the warewashing machine. Dispensable tablet10should also be food contact safe.

However, since a warewashing machine often utilizes very hot water in order to accomplish its washing and/or sterilizing functions, the environment of the warewashing machine often contains very high humidities and, often, high temperatures. While this environment is conducive to effective washing and even to effective dissolving of dispensable tablet10once dispensed into the warewashing machine, such environment must be prevented from adversely affecting dispensable tablets10which have not yet been dispensed into the warewashing machine. As will be seen, part of the function of preventing moisture and, preferably, heat from affecting the supply of non-dispensed dispensable tablets10is accomplished in the dispensing apparatus. It is, however, also desirable that additional protection be taken to prevent the adverse effect of moisture and, preferably, heat on dispensable tablets10which have not yet been dispensed.

FIG. 3is a cross-sectional view of dispensable tablet10. The active ingredient is contained in the interior portion12of dispensable tablet10. In a preferred embodiment, interior portion12of dispensable tablet10is a 0.7 gram spherical ball having a concentration of 70 parts per million consisting of fifty-six percent (56%) chlorine dry bleach for a tank size of the warewashing machine of approximately two (2) gallons (7.6 liters).

Other examples of active ingredients are pH modifiers, surfactants, enzymes, builders, lime away products, coupling agents, metal salts and components of rinse aids, detergents and sanitizers.

Dispensable tablet10also may have protective coating14surrounding the exterior of interior portion12. Protective coating14can be made of a number of materials which can protect dispensable tablet from moisture, e.g., high humidity, and, preferably, heat when dispensable tablet is not yet dispensed. However, protective coating14can not be so protective that dispensable tablet10does not readily dissolve when dispensed into the warewashing machine. Protective coating14also protects dispensable tablet from mechanical breakage during shipping and dispensing. An example of a protective coating14is titanium dioxide coated from enzymes having an approximate thickness of the human hair, or approximately 0.1 millimeter. It is preferred that protecting be applied either by spraying or dipping.

It is also possible that interior portion12of dispensable tablet10could be in liquid or semi-liquid form with protective coating14forming a dissolvable shell around interior portion12. This is similar to a paintball or bath beads in construction (although, obviously, paint is not utilized in a warewashing environment). In this embodiment, a liquid detergent or a liquid sanitizer could be used as the active ingredient. Once dispensed, again protective coating14would dissolve in the warewashing machine and the active ingredient contained in interior portion12would be released into the warewashing machine. Other examples of alternative forms of dispensable tablets10include gel tabs, a liquid or semi-liquid active ingredient contained in a water soluble film and a powder containing an active ingredient contained in a water soluble film. Other forms of packaging an active ingredient, e.g., a liquid or a powder, in a packet or other individualized container are also contemplated.

FIG. 4illustrates container16holding a plurality of dispensable tablets10. Container16has a relatively narrow opening18, preferably sealed, for example with foil20. With dispensable tablets10held in container16, especially with foil20sealing opening18, a user of the warewashing machine is protected from contacting dispensable tablets10. Since the active ingredient contained in dispensable tablets10can be caustic to humans, preventing a user or another person coming into contact with tablets10in container16, e.g., a child, is desirable. Sealing container16with foil20also prevents an unskillful user from inadvertently coming into contact with dispensable tablets10as, for example, by simply unscrewing a screw-on lid. Container16has a relatively narrow neck22which allows container16to be inserted into a dispenser. Container16also has sloping side walls24which assist in enabling dispensable tablets10to flow toward opening18when container16is inverted and inserted into a dispenser.

FIG. 5shows dispenser26adapted to dispense dispensable tablets10. Dispenser26has sloping walls28adapted to mate with sloping side walls24of container16. Neck22of container16is accommodated with a corresponding receptacle30in dispenser26. Projection32is adapted to penetrate foil20seal of container16and release dispensable tablets10from container16. Restriction section34funnels dispensable tablets10so that, at the lower end of restriction34only a single dispensable tablet10is allowed to pass at a time. Restriction34has an opening36adapted to mate with rotatable disc38. Rotatable disc38rotates in a housing of dispenser26just slightly larger than rotatable disc26. Rotatable disc38has at least one, and in this example, three, openings40sized to allow a single dispensable tablet10to fall from container16through restriction34into one of openings40. A rotatable disc rotates a single dispensable tablet10accompanies each opening40. As an opening40reaches the bottom of rotatable disc40, a dispensable tablet10is released into passage42which is adapted to communicate with the warewashing machine into which dispensable tablet10is to be dispensed.

FIG. 6shows container16having been inverted and inserted into dispenser26. Dispenser26has mating sloping walls28adapted to facilitate the insertion of and support of sloping side walls24of container16. Neck22of container16is accommodated with a corresponding receptacle30in dispenser26. As neck22of container16is inserted into receptacle30of dispenser26, projection32penetrates foil20of container16puncturing foil20and releasing dispensable tablets10from container16. Dispensable tablets10are funneled in restriction section34so that, at the lower end of restriction34only a single dispensable tablet10is allowed to pass at a time. Restriction34has an opening36adapted to mate with rotatable disc38. Rotatable disc38rotates in a housing of dispenser26just slightly larger than rotatable disc26. Rotatable disc38has at least one, and in this example, three, openings40sized to allow a single dispensable tablet10to fall from container16through restriction34into one of openings40. A rotatable disc rotates a single dispensable tablet10accompanies each opening40. As an opening40reaches the bottom of rotatable disc40, a dispensable tablet10is released into passage42which is adapted to communicate with the warewashing machine into which dispensable tablet10is to be dispensed.

Thus, as rotatable disc38is rotated so that the next opening40in rotatable disc reaches the bottom another dispensable tablet10is released into the warewashing machine through passage42. Since dispensable tablets10still being held in container16are physically remote from passage42, which may be contaminated with moisture from the warewashing machine, for example, and because any moisture laden air is prevented from directly being passed into container16by rotatable disc38, dispenser16aids in preventing dispensable tablets10still being held in container16from being affected by the adverse high moisture content of the warewashing machine to which dispenser26is adapted to be utilized.

Of course, it is to be recognized and understood that if the intended dose for the warewashing machine calls for more than one dispensable ball10, that rotatable discs is rotated through exactly the number of openings40for which the intended dose calls.

Rotatable disc38may be operated automatically through any number of commonly available and readily understood automated mechanical turning mechanisms. Alternatively, rotatable disc38may also be operated manually by the user.

FIG. 7,FIG. 8,FIG. 9andFIG. 10illustrate an embodiment of a closure44for container16holding solid product, e.g., dispensable tablets10. Cap46is secured to opening18of container16by any suitable means, such as by screw threads. Preferably, cap46is fixedly secured, meaning that cap46is secured to container16in a way which would make it difficult for a user to remove cap46. An example of being fixedly secured would be by press fitting grooves or ridges in cap46with corresponding ridges or grooves, respectively, in container16. Preferably, such ridges and grooves would be back angled, or under cut, to allow cap46to snap onto container16but make it difficult to remove cap46from container16. Another example would be by use of an adhesive. Preferably, although cap46would be fixedly secured to container16making it difficult for a user to remove cap46from container16, cap46would be secured in a way that would allow a qualified service provider, maintenance person or factory refiller to remove cap46with proper tools, perhaps tools not readily available to a user.

Cap46has at least one off-center opening48appropriately sized to allow passage of a tablet10. Internal disk50is adapted to be mounted on rotatable shaft52co-axially with cap46. Internal disk50has at least one off-center opening52appropriately sized to allow passage of a tablet10. In this embodiment, internal disk50has three openings52.

In operation, rotatable shaft52of closure44can be mated to a power source in a dispenser with opening18of container16, and hence closure44, being oriented generally downwardly with respect to container16. While container16does not need to be directly inverted with opening18on the bottom of container, it is desired that container16be oriented such that gravity will allow tablets10to be dispensed from container16. For example, opening18of container16need only be lower than some of tablets10contained in container16.

As rotatable shaft52is rotated, one of openings54of internal disk50will align with opening48in cap46which will allow a tablet10to fall by gravity through the combined openings and be dispensed from container16. Preferably, each time one of openings54of internal disk50align with opening48in cap46, a tablet10will be dispensed. Of course, if the rotation of rotatable shaft52, and hence the rotation of internal disk50, is slow enough then more than one tablet10may be dispensed each time one of openings54of internal disk50aligns with opening48in cap46. The number of tablets dispensed can be controlled by varying the rotational speed of rotatable shaft52and internal disk52. The number of rotations, or partial rotations, of rotatable shaft52and internal disk50determines the number of tablets10dispensed. When rotation stops, dispensing will stop. Care should be taken, of course, to stop the rotation of rotatable shaft52when one of openings54in internal disk do not align with opening48of cap46.

FIG. 11illustrates an assembled closure44with one of openings54of internal disk50aligned with opening48in cap46with a tablet10shown positioned for dispensing through the aligned openings48,54.

Closure44forms a mechanical interlock which allows tablets10to be dispensed from container16without allowing a user the ability to contact tablets10. This may be desirable, for example, is tablets10are fragile or are constructed from a material which may be toxic when contacted by a user. This is especially true if cap46is fixedly secured over opening18of container16.

While closure44forms a mechanical interlock allowing dispensing while preventing contact between a user and tablets10, power to perform the dispensing operation remains in the dispenser. Rotatable shaft52is adapted to mate with a rotatable power source in dispenser26′ to selectively and controllably rotate rotatable shaft52enabling the dispensing operation to be performed. Control over rotation enables, for example, one tablet10to be dispensed at a time.

In an embodiment, container16may be distributed to a user containing tablets10with opening18secured by closure44. Closure44provides a mechanical interlock preventing the dispensing of tablets10until dispensing is desired. At the same, power to do dispensing is obtained from dispenser26′. Thus, the mechanical interlock of closure44and the power to dispense functions are separated, the former residing with container16and the latter residing with dispenser26′. The power to dispense does not have to be supplied with the distributable container16even though container16provides the mechanical interlock of closure44.

Since closure44is associated with container16, a new mechanical interlock can be used each time container16is replaced. Such replacement will help prevent possible contamination of the mechanical interlock over time since this mechanism is replaced with a clean interlock mechanism each time container16is replaced. Further, modifications and improvements in the mechanical interlock can be accomplished over time without the necessity of updating dispenser26′.

An additional security closure, for example, a security film or adhesive tab, may be employed to cover cap46during shipment or distribution of container16. Alternatively, container16may be secured for premature dispensing of tablets10during distribution by positioning disk50so that none of openings54are aligned with opening48and mechanically securing that position, for example, by a pin which can be removed by a user prior, preferably just prior, to insertion of container16into dispenser26′. After such security closure is removed, if applicable, container16may be mated to dispenser26′ with the power source of dispenser26′ engaging rotatable shaft52.

FIGS. 12,13and14illustrate another alternative embodiment of the present invention.FIG. 12illustrates cap46′ which is very similar to cap46illustrated inFIG. 8. Cap46′ has a central axis hole56and off-center opening48. Opening48in cap46′ performs the same function as opening48in cap46. Cap46′ has ridges and grooves for mating with grooves and ridges around the edge of opening18in container16′. Rotary disk58, illustrated inFIGS. 13 and 14, has a central shaft60for rotatably mounting of rotary disk58at groove62in central axis hole56of cap46′ such that rotary disk58is interior of cap46′ when cap46′ is installed on container16′. Rotary disk has a plurality of fins64positioned between a plurality of openings54. As can be seen by reference toFIG. 15, which show container16′ with cap46′ and rotary disk58positioned for dispensing. Tabs66, protruding from cap46′, provide mechanical support for rotary disk58from the weight of tablets10.

Central shaft60of rotary disk58has a opening adapted to mate (FIG. 16) with a power source68when container16′ is inserted into dispenser26′. Central shaft60has an opening configured to mate with a complementary portion of power source68. Preferably, power source68provides rotary motion to rotary disk58. Power source68can be controlled by motor70, for example. Dispenser26′ is operatively coupled via passage72to cleaning machine74which can any of a variety of machines available in marketplace, such as warewashing machine. Solenoid76optionally can be used to seal off vapors from cleaning machine74when dispensing is not occurring.

Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention. It should be understood that this invention is not limited to the illustrative embodiments set forth above.