Abstract:
A vending machine for large flat objects such as collapsed boxes or garment containers. A cabinet is provided containing a plurality of flat objects in an upright orientation. A control box attached to the cabinet receives bills or coins as payment for an object contained within the cabinet—such as a box. Once payment is received, feed mechanisms propel the plurality of flat objects toward the front of the machine. A cross feed mechanism then propels a single flat object out a dispensing slot, where it can be grasped and removed by a user.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
   Not applicable. 
   STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
   Not Applicable. 
   MICROFICHE APPENDIX 
   Not Applicable 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to the field of vending machines. More specifically, the invention comprises a machine which stores and dispenses flat items such as cartons or boxes. 
   2. Description of the Related Art 
   Cartons or boxes are often needed for transportation and storage of small items. Such cartons or boxes (which terms are understood to be interchangeable throughout the remainder of this disclosure) are often designed to fold or collapse into a flat state for more convenient storage when they are not in use. Such boxes are often unavailable when they are needed most. 
   As one example, travelers often arrive at the airport with items they intend to carry on board an aircraft. Due to the increasing state of air travel security, these travelers may be informed that they must check these hand-carried items. The traveler may not have a piece of luggage available. A box would therefore be useful. The airlines, however, are increasingly reluctant to furnish passengers with storage boxes. The present invention seeks to provide boxes on demand by storing and dispensing them through a vending machine. 
   BRIEF SUMMARY OF THE PRESENT INVENTION 
   A vending machine for large flat objects such as collapsed boxes or garment containers. A cabinet is provided containing a plurality of flat objects in an upright orientation. A control box attached to the cabinet receives bills or coins as payment for an object contained within the cabinet—such as a box. Once payment is received, feed mechanisms propel the plurality of flat objects toward the front of the machine. A cross feed mechanism then propels a single flat object out a dispensing slot, where it can be grasped and removed by a user. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is an isometric view, showing the proposed carton dispensing machine. 
       FIG. 2  is a detail view, showing the control box. 
       FIG. 3  is an isometric view, showing a carton being dispensed. 
       FIG. 4  is an isometric view, showing a carton being dispensed. 
       FIG. 5  is a perspective view, showing the details of the vending machine&#39;s interior. 
       FIG. 6  is an isometric view, showing the left feed assembly. 
       FIG. 7  is an isometric view, showing the right feed assembly. 
       FIG. 8  is an isometric view, showing the crossfeed assembly. 
       FIG. 9  is a perspective view with a cutaway, showing the feeding process. 
       FIG. 10  is a perspective view with a cutaway, showing the feeding process. 
       FIG. 11  is a perspective view with a cutaway, showing the feeding process. 
       FIG. 12  is a perspective view with a cutaway, showing the feeding process. 
       FIG. 13  is an isometric view, showing the left drive helix. 
       FIG. 14  is a detail view, showing the feeding process. 
       FIG. 15  is a detail view, showing the feeding process. 
       FIG. 16  is a detail view, showing the feeding process. 
       FIG. 17  is a detail view, showing the feeding process. 
       FIG. 18  is a perspective view, showing the loading of the machine. 
   

   REFERENCE NUMERALS IN THE DRAWINGS 
     10  carton dispensing machine 
     12  main door
           14  display panel     16  base     18  right side panel     20  top panel     22  lock     24  control box     26  control box door     28  status panel     30  lock     32  change panel     34  LED display     36  ready light     38  exact change light     40  empty light     42  bill receiver     44  coin slot     46  coin return     48  dispenser slot     50  carton     54  carton cavity     56  upper beam     58  lower beam     60  fixed column     62  adjuster column     64  left side panel     66  crossfeed assembly     68  left feed assembly     70  right feed assembly     72  left pressure plate     74  right pressure plate     76  support panel     78  left backing plate     80  left support beam     82  gear motor     84  left drive helix     86  drive screw     88  right support beam     90  right drive helix     92  right backing plate     94  ejector     96  transverse screw drive     98  crossfeed bracket     100  lead carton     102  next carton     104  entrance stop     106  holding flange     108  feed grove     110  tray     112  carton separator     114  carton stack     120  proximity sensor     122  remove carton light     124  vertical wall       
   DETAILED DESCRIPTION OF THE INVENTION 
   The present invention is a vending machine for dispensing flat objects—typically cartons. Throughout this disclosure, the term “carton” will be understood to mean any type of box, garment bag, or other container which can be collapsed into a flat state. These objects are typically made of corrugated cardboard, but can also be made of sheet molding compound, thin gauge metal, and many other materials. The invention is capable of accommodating virtually any type of flat object. However, for purposes of illustration, a stack of collapsed cardboard packing boxes will be used throughout this disclosure. 
     FIG. 1  shows carton dispensing machine  10  in its assembled state—ready for use. A rectangular cabinet is formed by various panels using common prior art techniques. Base  16 , right side panel  18 , and top panel  20  are shown. A rear panel and left side panel are also present. The front of the cabinet is sealed by main door  12 , which is hinged on its left side. Main door  12  is customarily locked when closed, using the two locks  22 . Display panel  14  is provided on the front of main door  12 . It may simply be a glass frame for accommodating an advertising placard. On the other hand, it may be a sophisticated lighted display as commonly found on soft drink vending machines. The machine is typically located in public areas such as airports. Thus, display panel  14  is used to attract the attention of potential customers and inform them of the fact that the machine offers boxes for sale. 
   Control box  24  is attached to the side of the machine. Its front face contains status panel  28  and change panel  32 . Control box door  26  swings open to provide access to the interior in order to perform maintenance functions and to retrieve money deposited in the machine. It is customarily locked by lock  30 . Main door  12  provides access to the cabinet for loading new cartons into the machine. Control box door  26  provides access to the money received within control box  24 . As the functions of loading the cartons and retrieving the money may be performed by different persons, it is advisable to key locks  22  and lock  30  differently. 
     FIG. 2  is a detail view showing status panel  28  and change panel  32 . Status panel  28  collects money from persons desiring to purchase a carton. Bill receiver  42 —which is familiar to those skilled in the art—is provided to accept paper money. Coin slot  44  is provided to accept coins. A control unit is provided within the machine to count the money received and initiate the various functions the machine performs. LED display  34  informs the user how much money has been deposited. The price required to initiate the vending cycle is set in the control unit. Once this amount of money is received, the vending cycle is initiated. If change is owed, this is delivered though coin return  46 . 
   Three indicator lights are provided on status panel  28 . Ready light  36 —which is customarily green—indicates that the machine is ready to receive money and vend a box. Exact change light  38 —which is customarily yellow or orange—indicates that the machine is running low on change and that exact change should be provided. Empty light  40 —which is customarily red—indicates that the machine is out of cartons. In this state, of course, ready light  36  will not be illuminated. Remove carton light  122  is also provided. Its function will be explained in the following. 
   Once a customer has deposited the requisite amount of money, the machine dispenses a carton. Turning now to  FIG. 3 , the reader will observe the presence of dispenser slot  48  in the side of the machine. This opening passes through to the interior of the cabinet. When the vend cycle is complete, carton  50  will be ejected through dispenser slot  48 , coming to rest approximately in the position shown. Remove carton light  122  will then be illuminated. It may optionally be set to flash in order to gain the customer&#39;s attention. The customer then grasps carton  50  and pulls it free of dispenser slot  48  as shown in  FIG. 4. A  proximity sensor within the machine senses that the carton has been removed and the control unit then resets the machine. Ready light  36  is then re-illuminated (having been switched off during the vend cycle) to indicate that the machine is ready for another purchase. Once carton  50  is free of the machine, the customer can unfold it so that it is ready for use. 
     FIG. 5  shows the interior details of the cabinet. Main door  12  is shown in the open position. The interior is designated generally as carton cavity  54 . Left feed assembly  68  is provided to engage and move the left side of the cartons (with “left” being in reference to the view as shown). Right feed assembly  70  is provided to engage and move the right side of the cartons. Left pressure plate  72  and right pressure plate  74  push against the rear of the cartons to advance them toward the front of the cabinet. Cross feed assembly  66  is provided to eject an individual carton out the dispenser slot in the side of the machine. 
   The machine is capable of handling cartons of varying size. Adjustment means must therefore be provided. The feed mechanisms are generally attached to a set of upper beams  56  and lower beams  58 . Right feed assembly  70  is attached to a pair of fixed columns  60 . Left feed assembly  68  is attached to a pair of adjustable columns  62 . Adjustable columns  62  can be moved left and right to accommodate variations in the width of the cartons—as shown by the arrows. Left feed assembly  68 , right feed assembly  70 , and cross feed assembly  66  are vertically adjustable in order to accommodate variations in the height of the cartons. 
   Left side panel  64  completes the structure of the cabinet. Support panel  76  is positioned to carry the weight of the cartons placed within the cabinet. It contains three raised ribs which minimize surface contact between the bottom edge of the cartons and the machine. These features reduce friction as the cartons are fed forward. 
     FIG. 6  shows left feed assembly  68  removed from the machine for purposes of visualization. Left support beam  80  severs as an attachment point for the other features. Gear motor  82  is attached to its forward end. It controls and turns left drive helix  84 —which rotates in the direction shown. Screw drive  86  is provided to move left pressure plate  72  back and forth in the direction indicated. Left pressure plate  72  is mounted to left backing plate  78 . Left backing plate  78  is attached via a linear bearing to left support beam  80 . When screw drive  86  turns, left backing plate  78  is moved forward or backward, depending on the direction of rotation of screw drive  86 . 
   Left pressure plate  72  is attached to left backing plate  78  using elastic means, so that left pressure plate  72  can give somewhat with respect to left backing plate  78 . Sensing means are preferably provided for all these drive mechanisms. As a first example, optical sensors can be used to determine the position of the rear of the stack of cartons. The control unit will then activate screw drive  86  to advance left pressure plate  72  until it bears against the rear of the stack. The use of the elastic means in pressure plate  72  eliminates the need for precise motion control. As a second example, it is important that left drive helix  84  undergo one complete revolution per vending cycle. This can be accomplished using a limit switch, optical sensor, or other common means. As these sensing and control features represent common design choices known in the art, they have not been illustrated. 
     FIG. 7  shows the details of right feed assembly  70 . It is essentially the mirror image of left feed assembly  68 . It contains right support beam  88 , a second screw drive  86 , right backing plate  92 , right pressure plate  74 , a second gear motor  82 , and right drive helix  90 . The reader should observe that right drive helix  90  is not necessarily a mirror of left drive helix  84 . It may, in fact, be somewhat shorter, so that it releases its engagement with the right side of the carton before left drive helix  84  releases its engagement. 
   Proximity sensor  120  is provided on the spindle of right drive helix  90 . When a carton has been advanced forward via the two feed assemblies and fed transversely through the dispensing slot, proximity sensor  120  senses the presence of the carton. If the customer does not remove the carton at this point, it is undesirable for the machine to feed another carton—as the presence of two cartons in the dispensing slot could cause a jam. Thus, proximity sensor  120  alerts the control unit to the presence of a carton in the dispenser slot and prevents more feeding until it is removed. The position and type of proximity sensor  120  is a matter of design choice. It need not be placed on or near right drive helix  90 , so long as it is capable of sensing the presence of a carton. Suitable choices include mechanical limit switches and optocouplers. 
     FIG. 8  shows cross feed assembly  66 . It is supported by cross feed bracket  98 , which attaches to the forward adjustable column  62 . Transverse screw drive  96  provides controlled reciprocating motion of ejector  94 . Ejector  94  incorporates a protrusion which bears against the left side of a carton and pushes it out the dispenser slot. 
     FIG. 9  is a perspective view of the loaded machine. Main door  12  is removed in the view to expose the internal components. A cutaway is made in left side panel  64  as well. The machine is shown in its ready state. A stack of vertically oriented cartons is contained within the cabinet. Left drive helix  84  and right drive helix  90  engage the left and right edge of lead carton  100 . Next carton  102  is in position to be engaged by the drive helices once lead carton  100  is dispensed. The reader will observe that the two pressure plates are bearing against the rear of the stack of cartons to urge it forward. 
   When the controller initiates the vend cycle, the two drive helices turn and lead carton  100  is moved forward.  FIG. 10  shows this step. The two drive helices rotate in opposite directions, as shown by the arrows. Lead carton  100  is propelled forward while next carton  102  remains stationary (the features which hold next carton  102  in place will be describe subsequently). The two drive helices rotate until lead carton  100  is ejected from the helices and drops off the front of support panel  76 , falling into tray  110 . It is prevented from tipping forward by cross feed assembly  66  (as well as the inside surface of main door  12 —which is not shown). 
     FIG. 12  shows the final step in the vend cycle. The screw drive on cross feed assembly  66  is actuated, driving ejector  94  to the right. Lead carton  100  is thereby ejected from the machine. Next carton  102  then assumes the position formerly occupied by lead carton  100  and the cycle is ready to begin anew. 
     FIG. 13  shows left drive helix  84  in detail. It is viewed from the rear. Holding flange  106  would be facing the forward surface of lead carton  100  in its installed position. It customarily rotates in the direction shown by the arrow. Feed groove  108 —which assumes the form of a helical slot—provides the forward motion of the carton when left drive helix  84  is actuated. 
   The position shown corresponds to the initiation of a cycle. Vertical wall  124  is, at this point, oriented vertically. The vertical edge of the lead carton (the left edge, when viewed from the front), slips past vertical wall  124  and comes to rest against entrance step  104 . The lead carton&#39;s edge is therefore poised to enter feed groove  108 . When left drive helix  84  is rotated in the direction shown, carton separator  112  rotates between the edge of the lead carton and the next carton—thereby separating the two. Holding flange  106  rotates in front of the next carton, preventing its moving forward while the drive helix goes through one revolution. The lead carton is therefore propelled forward and ultimately out of the drive helix while the next carton is held in place. Once the drive helix rotates through 360 degrees and returns to the position shown, the next carton pops forward past vertical wall  124  and into entrance stop  104 . These operations are detailed in the following views. 
     FIG. 14  is a detail view showing the start of the cycle. The edge of lead carton  100  is resting in entrance stop  104 . When left drive helix  84  rotates as shown, carton separator  112  will pass behind the edge of lead carton  100  and in front of the edge of next carton  102 . Feed groove  108  then propels lead carton  100  forward.  FIG. 15  shows left drive helix  84  after it has rotated 180 degrees. Lead carton  100  has been propelled forward, while next carton  102  is held in place by holding flange  106 . 
     FIG. 16  shows left drive helix  84  after one complete revolution. Lead carton  100  has been propelled forward and out of the drive helices, dropping down into tray  110 . The reader will also observe that next carton  102  has moved forward into entrance stop  104 . 
     FIG. 17  shows the actuation of ejector  94 . The inward facing protrusion on ejector  94  bears against the edge of lead carton  100  and propels it toward the machine&#39;s right side, where it is ejected through the ejection slot. Tray  110  and ejector  94  guide its lateral motion. Features on the inside of the main door—such as roller or runners—can also be employed to ensure that lead carton  100  passes through the dispenser slot and out of the machine. After the completion of the lateral ejection, the machine is ready to begin a new cycle. Once the customer has grasped and removed lead carton  100  (and proximity sensor  120  has indicated such), a new cycle can begin. 
   The vending cycles continue until the machine exhausts its supply of cartons. It must then be reloaded. The controller, once it senses the exhaustion of the carton supply, retracts the two pressure plates to their rearmost position.  FIG. 18  shows the machine with the main door open. A service person then loads carton stack  114  into the machine as shown. Of course, cartons can also be loaded individually. 
   Common prior art features can be added to facilitate the reloading process, As an example, the left, right, and cross feeding assemblies can be mounted on hinges to swing out of the way when the machine is to be loaded. As such principles are well known in the art, they have not been illustrated in detail. 
   The preceding descriptions contain significant detail regarding the novel aspects of the present invention. They should not be construed, however, as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Thus, the scope of the invention should be fixed by the following claims, rather than by the examples given.