Abstract:
A system and apparatus for processing recyclable materials, including a header box, a plurality of routing channels connected to the header box, and a temporary storage container for each routing channel. During use, a user deposits one or more recyclable items into an intake header box, and the user then presses a selected button, corresponding to the material of the item, to control routing of the deposited item to a pre-sorted storage area. The header box includes a mirror, showing the routing channels, to allow a user to determine if the system is clear or blocked. The routing channels are made from modular units, so that the apparatus can be modified or adapted to meet the needs of different users, or the changing needs of a single user.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a system and apparatus for processing recyclable materials. More particularly, the present invention relates to a system and apparatus for sorting and temporarily storing recyclable materials, in which the apparatus includes an intake header box and a plurality of routing channels connected to the header box. During use, a user deposits one or more recyclable items into the intake header box, and the user then presses a selected button to control routing of the deposited item to a pre-sorted storage area. Even more particularly, the present invention relates to a system and apparatus of the type described in which the routing channels are made from modular units, so that the apparatus can be modified or adapted to meet the needs of different users, or the changing needs of a single user. 
         [0003]    2. Description of the Background Art 
         [0004]    Recycling of certain materials such as, for example, glass, cans, and plastics, among other materials, is becoming more popular in today&#39;s increasingly environmentally-conscious society. Many communities now have facilities and equipment to pick up recyclable materials at curbside. 
         [0005]    A number of different sorting and storage systems are known for processing recyclable materials. Examples of some of the known sorting and storage systems, for recycling used materials, include those described in U.S. Pat. No. 5,366,097 (Hazlewood), U.S. Pat. No. 5,425,458 (Gilcreest et al.), U.S. Pat. No. 5,447,017 (Becher et al.), U.S. Pat. No. 6,119,869 (Geiman), U.S. Pat. No. 6,141,945 (Becher), and U.S. Pat. No. 6,443,057 (Gazzoli). 
         [0006]    Although the known sorting and storage systems have some utility for their intended purposes, a need still exists in the art for an improved modular sorting and storage system and apparatus for processing recyclable materials in the home or in a small business environment. In particular, there is a need for an improved recyclable material processing system which will overcome difficulties encountered with the known art. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention provides an improved modular system, method and apparatus for processing recyclable materials. An apparatus according to the invention is usable to sort recyclable materials and to temporarily store recyclable materials in separate storage containers by material type, according to input from a user. In one embodiment, the apparatus includes an intake portion, which extends through an exterior building wall and into an interior room of the building, and a routing and storage portion which is disposed outside of the building. 
         [0008]    In a first illustrative embodiment of the present invention, a modular apparatus for receiving and sorting recyclable materials is provided, including a hollow intake header box having an inlet door and defining a temporary holding area therein, and a plurality of routing ducts operatively attached to, and extending away from the intake header box. The routing ducts may use passive gravity feed as a mechanism for moving an item therethrough. The apparatus also includes a distribution mechanism operatively connected to the header box. The distribution mechanism is either disposed inside of the header box, or is situated between the header box and the plurality of routing ducts. 
         [0009]    The apparatus for receiving and sorting recyclable materials according to the first illustrative embodiment also includes a plurality of selection buttons, either disposed on or operatively connected to the header box, for allowing a user to selectively indicate a material type corresponding to a recyclable item placed in the header box, and to control operation of the distribution mechanism for routing the item to the proper storage receptacle. 
         [0010]    The apparatus according to the present invention may also include a plurality of storage receptacles, with a respective one of the storage receptacles disposed at a lower end of each of the routing ducts. Optionally, the storage receptacles may be made substantially sealable, in order to inhibit entry of insects, rodents, and other animals. 
         [0011]    According to one embodiment of the present invention, a reflective mirror is mounted in the header box, in order to allow a user to view a reflected image therein of the sorting and distribution area of the system. The mirror enables the user to determine if there is any blockage or interference inside the system from inside a house without having to go outside of the house. 
         [0012]    The apparatus for receiving and sorting recyclable materials according to the first illustrative embodiment is constructed using a plurality of interchangeable modular components, so that the apparatus can be adjustably adapted to different applications, depending on the needs of different users, or on the changing needs of a single user. 
         [0013]    Many of the interchangeable modular components are made with a hinge-like structure, including a plate portion having a substantially straight peripheral edge, and a plurality of regularly spaced-apart cylindrical tube sections attached to the peripheral edge of the plate portion. Each of the tube sections has a longitudinal axis which is disposed substantially parallel to the peripheral edge to which it is attached. The spaced-apart cylindrical tube sections are adapted to cooperatively intermesh with the spaced-apart cylindrical tube sections of another adjacent modular component, at which point the adjacent modular sections can be interconnected as described below. 
         [0014]    When the tube sections of adjacent modular components are intermeshed and aligned with one another, the adjacent components can be connected in one of two ways. The first way of connecting the intermeshed tube sections is to slidably place a rod inside of the aligned tube sections, and the second, alternate way of connecting the intermeshed tube sections is to place an outer, external tube which has a longitudinal portion thereof removed, so that it has a C-shaped cross-section, over and partially covering a substantial exterior portion of the aligned tube sections. 
         [0015]    Selected components of the interchangeable modular components may include substantially rectangular plate portions. Other selected components of the interchangeable modular components may include substantially triangular plate portions, or other polygonal plate portions having flat edges. 
         [0016]    Optionally, some or all of the plate portions of the interchangeable modular sections may be formed from a translucent or transparent plastic material. 
         [0017]    For a more complete understanding of the present invention, the reader is referred to the following detailed description section, which should be read in conjunction with the accompanying drawings. Throughout the following detailed description and in the drawings, like numbers refer to like parts. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a perspective view of an apparatus for receiving and sorting recyclable materials according to a first illustrative embodiment of the present invention; 
           [0019]      FIG. 2  is a rear plan view of the apparatus of  FIG. 1 , modified to have an enlarged storage area at a central portion thereof; 
           [0020]      FIG. 3  is a side elevational view of the apparatus of  FIGS. 1-2 , also showing a wall of a building through which part of the apparatus extends; 
           [0021]      FIG. 4A  is a top plan view of a rectangular modular unit which is a component of the apparatus of  FIGS. 1-3 ; 
           [0022]      FIG. 4B  is a side plan view of the rectangular modular unit of  FIG. 4A ; 
           [0023]      FIG. 4C  is an enlarged detail view of an edge portion of the rectangular modular unit of  FIG. 4B ; 
           [0024]      FIG. 5  is a top plan view of a pair of modular units of  FIG. 4A  placed side by side; 
           [0025]      FIG. 6  is a top plan view of the modular units of  FIG. 4B , moved into an aligned configuration, and also showing a connecting rod for joining the modular units together; 
           [0026]      FIG. 7  is a top plan view of two right triangular modular sections which are also components of the apparatus of  FIGS. 1-3 ; 
           [0027]      FIG. 8  is a top plan view of an equilateral triangular modular section which is another component of the apparatus of  FIGS. 1-3 ; 
           [0028]      FIG. 9A  is a side plan detail view of an intake header, including an angled mirror, which is another component of the apparatus of  FIGS. 1-3 ; 
           [0029]      FIG. 9B  is a front plan detail view of the intake header box of  FIG. 9A ; 
           [0030]      FIG. 10  is a rear plan view of an apparatus for receiving and sorting recyclable materials according to a second illustrative embodiment of the present invention; 
           [0031]      FIG. 11  is a perspective view of a storage container which is a component part of the apparatus of  FIGS. 1-3 , shown with a cover thereof in a closed position; 
           [0032]      FIG. 12  is a second perspective view of the storage container of  FIG. 11 , with a handle depressed in order to release a latching assembly for the cover; 
           [0033]      FIG. 13  is a third perspective view of the storage container of  FIGS. 11-12 , with the cover being pivotally lifted away from a main body of the container; and 
           [0034]      FIG. 14  is a detail view of the handle and latching mechanism of the storage container of  FIGS. 11-13 . 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    It should be understood that only structures considered necessary for clarifying the present invention are described herein. Other conventional structures, and those of ancillary and auxiliary components of the system, are assumed to be known and understood by those skilled in the related art. 
         [0036]    The present invention provides an improved modular system, method and apparatus for processing recyclable materials. An apparatus according to the invention is usable to sort and separate recyclable materials according to input from a user, and to temporarily store the sorted recyclable materials in separate storage containers by material type. 
         [0037]    Referring now to  FIGS. 1-3  of the drawings, a first illustrative embodiment of an apparatus for processing recyclable materials is shown generally at  20 . In the embodiment of  FIGS. 1-3 , the apparatus  20  includes an intake portion  22 , part of which is adapted to extend through a building wall W ( FIG. 3 ) and into an interior room of a building, such as a single family home, small business, or similar application. The apparatus  20  also includes a routing and storage portion  24  which is adapted to be disposed outside of the building. 
         [0038]    In an alternative application of the apparatus  20 , it could be free standing and not associated with a building or other structure. Due to the modular nature of the components making up the apparatus  20 , it may be made large or small, wide or narrow, short or tall, etc, to conform to the environment in which it is used. In addition, after installation in a setting, it may easily be modified, as needed, to fit changing requirements of a user. 
         [0039]    In the embodiment of  FIGS. 1-3 , the apparatus  20  is usable for receiving, sorting and temporarily storing recyclable materials, such as glass (sorted by color), plastic of different grades, metal cans, etc. The apparatus  20  includes a hollow intake header box  25 , having an inlet door  27  and defining a temporary holding area therein, and a plurality of routing ducts  26 ,  28 , and  30 , operatively attached to, and extending away from the intake header box  25 . Within header box  25  is a mirror  29  pivotally mounted by a hinge  14  to the rear wall  25   b  of the header box  25  and adjustably supported by a chain  15  attached to the rear wall  25   b  of the header box  25 . The mirror  29  has a reflective surface  29   a  such that reflective surface  29   a  provides a user with a reflected view of the routing ducts  26 ,  28 , and  30  and distribution mechanism  32 , from inside the house upon which the system  20  is mounted, without having to go outside to view the entire system  20 . 
         [0040]    The routing ducts  26 ,  28 , and  30  may use passive gravity feed as a mechanism for moving an item therethrough. Each of the routing ducts  26 ,  28 ,  30  may have a door  31  formed in a lower section thereof to provide access to a storage receptacle  44  ( FIG. 3 ) disposed therein, and this door  31  may be provided with a unique handle and latch mechanism  33 , as discussed further below. 
         [0041]    The storage receptacles  44  may be formed in different sizes, if desired, to accommodate expected storage needs for different materials. As an example of this,  FIG. 2  illustrates that a central routing duct  28  may be made larger at the bottom end thereof than adjacent routing ducts  26 ,  30  if it is anticipated that there will be a need for a larger storage receptacle  44  therein. This is just one example of how the modular nature of the apparatus  20  allows it to be made adaptable to accommodate the needs of different users, or the changing needs of a single user. 
         [0042]    The apparatus  20  for receiving and sorting recyclable materials according to the first illustrative embodiment also includes a distribution mechanism  32  operatively connected to the header box  25 . The distribution mechanism  32  may be disposed inside of the header box, or alternatively, the distribution mechanism  32  may be situated between the header box and the plurality of routing ducts. The distribution mechanism  32  may include mechanical and/or electromechanical components, and includes at least one movable routing gate. Optionally, the distribution mechanism  32  may include an optical scanner for reading a code on a recyclable item, to indicate the type of material in the header box  25 . 
         [0043]    As seen best in  FIG. 9B , the apparatus  20  for receiving and sorting recyclable materials according to the first illustrative embodiment also includes a plurality of selection buttons such as those shown at  34 - 41 , operatively connected to the header box  25 , for allowing a user to selectively indicate a material type corresponding to a recyclable item  45  placed in the header box, and thereby to control operation of the distribution mechanism  32  for routing the item to the proper storage receptacle  44 . The mirror  29  with reflective surface  29   a  provides a user with a reflected view of the routing ducts  26 ,  28  and  30  allowing a user to view any obstruction within the routing ducts  26 ,  28  and  30  and the distribution mechanism  32 . 
         [0044]    The apparatus according to the present invention may also include a plurality of storage receptacles  44 , with a respective one of the storage receptacles disposed at a lower end of each of the routing ducts  26 ,  28 ,  30 . Optionally, the storage receptacles  44  may be made substantially sealable, in order to exclude insects, rodents, and other animals. 
         [0045]    The apparatus  20  for receiving and sorting recyclable materials according to the first illustrative embodiment is constructed using a plurality of interchangeable modular components, so that the apparatus can be adjustably adapted to different applications, depending on the needs of different users, or on the changing needs of a single user. Examples of some illustrative modular components include a square component  46 , as shown in  FIGS. 4A-4C , and a plurality of triangular components such as those shown at  48  and  50  in  FIGS. 7-8 . 
         [0046]    Many of the interchangeable modular components are made with a hinge-like structure, and this structure will now be discussed in relation to the square component of  FIGS. 4A-4C  and  5 - 6 . The hinge-like structure of each modular component, as illustrated by the square component  46 , includes a plate portion  52  having a substantially straight peripheral edge  54 , and a plurality of regularly spaced-apart cylindrical tube sections  56  attached to the peripheral edge of the plate portion. Each of the tube sections  56  has a longitudinal axis, such as that shown at  58  in  FIG. 4A , which is disposed substantially parallel to the peripheral edge  54  to which it is attached. 
         [0047]    Referring now to  FIGS. 5-6 , it will be seen that the spaced-apart cylindrical tube sections  56  along a straight edge portion of the modular component  46  are adapted to cooperatively intermesh with another plurality of spaced-apart cylindrical tube sections  56 ′ of another adjacent modular component  46 ′, at which point the adjacent modular sections  46 ,  46 ′ can be interconnected. This can be done repeatedly to create appropriate three-dimensional structures which, in turn, can be joined together to form the apparatus  20 . 
         [0048]    When the tube sections of adjacent modular components  46 ,  46 ′ are intermeshed and aligned with one another, the adjacent components can be connected in one of two ways. The first way of connecting the intermeshed tube sections  46 ,  46 ′ is to slidably place a rod  60  inside of the aligned tube sections, as shown in  FIG. 6 . A second, alternate way of connecting the intermeshed tube sections is to place an outer, external tube  62  ( FIG. 4C ) which has a longitudinal portion thereof removed, so that it has a C-shaped cross-section, over and partially covering a substantial exterior part of the aligned tube sections  56 ,  56 ′. 
         [0049]    As previously noted, some selected components of the interchangeable modular components may include square or substantially rectangular plate portions. Other selected components of the interchangeable modular components may include substantially triangular plate portions. 
         [0050]    Optionally, some or all of the plate portions  52  of the interchangeable modular sections may be formed from a translucent or transparent plastic material. If desired, the tube sections  56  may also be formed of plastic. 
         [0051]    Referring now to  FIGS. 11-13 , a storage receptacle  44  is shown having a removable cover  64 , where the cover includes a main plate  66 , and a handle and latch mechanism  33  connected to the main plate. The handle and latch mechanism  33  on the cover  64  of the storage receptacle  44  shown in  FIGS. 11-13  is substantially similar to the handle and latch mechanism used on the access doors  31  of the apparatus  20 , and shown in  FIG. 1 . 
         [0052]    The handle and latch mechanism  33  includes a hollow support member  65 , which is provided as a three-sided rectangular box rigidly affixed on top of the main plate  66  of the cover  64 . The support member  65  has a hollow cutout formed in the top thereof to provide clearance for the handle  67 , and is also open on the side thereof facing away from the handle. 
         [0053]    The handle  67  is pivotally attached to the support member  65  at a pivot connection  70 , which may be provided as a rivet, or as a nut and bolt connection. The handle  67  is a generally L-shaped member, which includes a handgrip portion  68  extending outwardly away from the support member  65 , and a connecting arm  72 , integrally attached to the handgrip portion  88  and extending inwardly inside of the support member  65 . A spring  74  is provided extending between the handle  67  and a movable plate  69  of the handle and latch mechanism  33 . An innermost end of the connecting arm  72  is, in turn, pivotally attached to a linking member  75 , and this linking member is affixed to the movable plate  69 . 
         [0054]    An arcuate locking lip  76  is integrally affixed to an outermost portion of the movable plate  69 , and this locking lip extends around an edge of a plurality of tube sections  56  at an edge of a side panel of the container  44 . The arcuate locking lip  76  is sufficiently rounded that when it is in abutting contact with the tube sections  56 , the cover  64  is temporarily locked in a closed position over the top of the container  44 , as illustrated in  FIG. 11 . 
         [0055]    However, as illustrated in  FIG. 12 , when the handgrip portion  68  of the handle  67  is pressed inwardly, that pushes the linking member  75  outwardly and causes the movable plate  69  and the attached locking lip  76  to also move outwardly, away from the tube sections  56 . This disengages the locking lip  76  from the side wall of the container  44 , and permits the cover  64  to be pivotally lifted away from the main body of the container  44 , thus opening the container. 
         [0056]    An advantage of the above-described design for the handle and latch mechanism  33  is that when the gripping section  68  of the handle  67  is used to lift and carry the entire storage container  44 , the upward lifting motion on the handle  67 , coupled with the natural downward pull of gravity on the container, tends to pull the movable plate  69  and attached locking lip  76  inwardly, and to easily keep the cover  64  in locked engagement with the main body of the container  44 . 
         [0057]    Referring now to  FIG. 10  of the drawings, a second illustrative embodiment of an apparatus for processing recyclable materials is shown generally at  120 . The apparatus  120  according to the second embodiment is substantially similar to the apparatus  20  according to the first embodiment as previously described, except as specifically described as different herein. 
         [0058]    In the embodiment of  FIG. 10 , the apparatus  120  includes an intake portion  122 , part of which is adapted to extend through a building wall W ( FIG. 3 ) and into an interior room of a building, such as a single family home, small business, or similar application. The apparatus  120  also includes a routing and storage portion  124  which is adapted to be disposed outside of the building. 
         [0059]    In the embodiment of  FIG. 10 , the apparatus  120  for is usable for receiving, sorting and temporarily storing recyclable materials, such as glass (sorted by color), plastic of different grades, metal cans, etc. The apparatus  120  includes a hollow intake header box  125 , having an inlet door (similar to that shown at  27  in  FIG. 9B ) and defining a temporary holding area therein, and a plurality of routing ducts  126 - 130 , operatively attached to, and extending away from the intake header box  125 . The routing ducts  126 - 130  may use passive gravity feed as a mechanism for moving an item therethrough. Each of the routing ducts  126 - 130  may have a door formed in a lower section thereof to provide access to a storage receptacle  44  ( FIG. 3 ) disposed therein. 
         [0060]    The apparatus  120  for receiving and sorting recyclable materials according to the second illustrative embodiment also includes a distribution mechanism  132  operatively connected to the header box  125 . The distribution mechanism  132  may be disposed inside of the header box  125 , or alternatively, the distribution mechanism  132  may be situated between the header box and the plurality of routing ducts  126 - 130 . The distribution mechanism  132  may include mechanical and/or electromechanical components, and includes at least one movable routing gate. Optionally, the distribution mechanism  132  may include an optical scanner for reading a code on a recyclable item, to indicate the type of material in the header box  125 . 
         [0061]    Although the present invention has been described herein with respect to a number of specific embodiments, the foregoing description is intended to illustrate, rather than to limit the invention. Those skilled in the art will realize that many modifications of the preferred embodiment could be made which would be operable. All such modifications, which are within the scope of the claims, are intended to be within the scope and spirit of the present invention.