Abstract:
A product dispenser comprising a cover, a slidable push element, a base and a landing is provided. The cover and the base are rotatable with respect to each other about a common axis. The cover comprises a roof opening in which the push element slides in opposing directions, advancing product from the interior of the cover onto the landing. In a preferred embodiment, the dispenser houses miniature zinc air batteries, secured to the base using an adhesive layer. When a cell is advanced from the interior of the cover onto the landing, the cell is separated from the adhesive layer, allowing air to pass into the cell and the cell to be activated. The landing preferably comprises a magnet for releasably securing product. The dispenser is then used as an inserter for orienting and placing the product in position in a device. The product is not directly handled during its removal from the dispenser or during its insertion into a device. In the case of a zinc air cell, the cell is untabbed without any direct handling of tab material by the user, and the material functioning as a tab stays with the dispenser upon separation from the cell.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation in part of and claims priority to application Ser. No. 09/764579 filed Jan. 18, 2001, which is a continuation in part of application Ser. No. 09/658201 filed Sep. 8, 2000. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates to a dispenser for housing and dispensing product, such as miniature batteries including zinc air cells used in hearing aids. As used herein, “battery” means one or more cells.  
           [0003]    Handling of miniature batteries is difficult because of their small size. Handling of miniature batteries is typically required in order to remove the batteries from their packaging, to insert the batteries in the proper orientation into a device, and, in the case of air cells, to remove any individual tabbing associated with the cell prior to use. Tabbing is normally associated with metal air cells such as zinc air cells, to limit the ingress of oxygen into the cell until such time as the cell is placed into service. The tab also functions to limit the transport of water vapor in or out of the cell and limits the ingress of carbon dioxide into the cell. Typically, the tab comprises an adhesive material covering one or more air ports. Upon removal of the tab, the ports are exposed to the oxygen of the ambient environment, thereby enabling the cell to be activated. The challenge of handling miniature batteries is exacerbated in the event the user suffers from reduced dexterity, poor vision or other physical infirmity.  
           [0004]    Efforts to address some of these issues are found in the art. For example, U.S. Pat. No. 6,039,185 discloses a device for inserting a hearing aid battery into a hearing aid. The device comprises so-called “petals” with an air cell residing on each petal. The cells are individually tabbed, and each tab is then adhered to the petal. The cell is inserted into the hearing aid by gripping the inserter and bringing the appropriate petal up close to the hearing aid battery door to enable the cell to be engaged within the door. The cell is then separated from the inserter using a wiping motion, purportedly leaving the tab adhered to the petal. The method of separating the cell from its associated tab and the inserter as disclosed in the &#39;185 patent places stresses on the hearing aid device, presenting the potential for damage to the device.  
           [0005]    Typical packaging for miniature zinc air cells presents further problems. Common packaging for miniature zinc air cells is disclosed for example in U.S. Pat. No. 4,593,700. The packaging disclosed therein consists of a thermoformed or molded blister rotatably attached to a paperboard card. The blister comprises multiple compartments each containing a battery. A battery is dispensed from the package by rotating the blister to align a loaded compartment with a trap door accessible in the back of the card. The trap door can come open during transport and batteries will fall out. The trap door becomes weak and ineffective after multiple uses. The base of the dial can also separate or pull away from the card allowing batteries to fall out. Finally, the consumer must still handle the battery to remove the tab, properly orient the cell in connection with the device terminals and insert the cell into the device once the battery has been removed from the package.  
           [0006]    Some consumers use a separate tool to assist them in loading miniature batteries into devices. This tool consists of a magnet on the end of a wand. The tool can be easily misplaced and provides little aid in removing the individual tabbing associated with common zinc air cells.  
           [0007]    Handling of other small products including but not limited to pharmaceuticals such as pills, foodstuff such as candy, hardware such as screws, and the like can be equally difficult because of their size, particularly for those users suffering from reduced dexterity, poor vision or other physical infirmity. While the within invention is illustrated in connection with miniature cells, and in particular in connection with miniature zinc air cells, it will be appreciated that the within invention can also be utilized in connection with the transport, storage and dispensing of such other small products. As used herein, the term “product” is not limited to miniature cells or batteries, and fully comprehends such other small products as those identified above.  
           [0008]    It is therefore a first object of the present invention to provide a product dispenser that acts as both a structural package for housing and transporting product and a dispenser for removing product from the package and an inserter for manipulating and orienting product into a device or other end use location.  
           [0009]    It is also an object of the present invention to provide a product dispenser that removes any direct handling of product prior to its insertion into a device or other end use location.  
           [0010]    It is a further object of the present invention to provide a product dispenser that obviates the need for direct handling of tab material in the case of a metal air cell such as a zinc air cell.  
           [0011]    It is a further object of the present invention to provide a product dispenser that both activates and dispenses air cells such that the user does not have to handle the cells either before or after insertion into a device.  
           [0012]    Another object of the present invention is to provide a product dispenser that eliminates the need for additional tools to handle and orient product for insertion or placement for end use.  
           [0013]    Another object of the present invention is to provide a product dispenser that avoids unintended dispensing from the dispenser.  
           [0014]    Another object of the present invention is to provide a refill base cartridge for a product dispenser.  
           [0015]    Another object of the present invention is to provide a product dispenser that optionally allows the user to attach a refill base after removal of a spent base cartridge.  
           [0016]    Another object of the present invention is to provide a product dispenser that allows the consumer to store used product for disposal or material recovery purposes.  
           [0017]    The foregoing and additional objects of this invention will become fully apparent from the following description and the accompanying drawings.  
         SUMMARY OF THE INVENTION  
         [0018]    The present invention provides for a product dispenser that is easy to use for storing and dispensing product, such as miniature batteries. The dispenser of the within invention obviates the need to handle the product at any point during the dispensing process or during the insertion or placement process of the product for its end use. To achieve this and other advantages, and in accordance with the purposes of the present invention as embodied and described herein, the present invention provides for a product dispenser comprising a cover and a base, each rotatable with respect to the other about a common axis, a retractable push element slidably engaged along an opening in the roof of the cover, and a landing. The cover further comprises a wall and a wall opening. The roof opening, wall opening and landing are aligned to enable product to be advanced from the interior of the cover, through the wall opening and onto the landing by the push element. The landing is designed to accept and removably retain individual product. The push element slides in opposing directions along the roof opening to engage product and advance product from the interior of the cover onto the landing. The base cooperates with the cover assembly to house the product and provides locations for securing product prior to dispensing.  
           [0019]    In another embodiment, the cover is removably attached to the base allowing the base to be disposed of and a replacement base with additional product to be joined with the cover.  
           [0020]    In another embodiment the bottom side of the base comprises a storage area for storing used product for disposal or material recovery purposes. The entire dispenser could be processed for material recovery or otherwise recycled. In the event the cover and the base are separable, the base alone could be processed for material recovery or otherwise recycled.  
           [0021]    In another embodiment the cover is made of see-through material and the push element or base or both can be color coded to indicate various product characteristics, such as size.  
           [0022]    These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.  
         BRIEF DESCRIPTION OF DRAWINGS  
         [0023]    [0023]FIG. 1 is an exploded view of a product dispenser according to the within invention.  
           [0024]    [0024]FIG. 2A is a view of a cover of a product dispenser according to the within invention.  
           [0025]    [0025]FIG. 2B is another view of the cover of FIG. 2A.  
           [0026]    [0026]FIG. 3 is a view of a base platform of a product dispenser according to the within invention..  
           [0027]    [0027]FIG. 4 is a view of one layer of the adhesive product platform of a product dispenser according to the within invention.  
           [0028]    [0028]FIG. 5A is a view of a push element of a product dispenser according to the within invention.  
           [0029]    [0029]FIG. 5B is another view of the push element of FIG. 5A.  
           [0030]    [0030]FIG. 6A is a view of the base ring of a product dispenser according to the within invention.  
           [0031]    [0031]FIG. 6B is another view of the base ring of a product dispenser according to the within invention.  
           [0032]    [0032]FIG. 7 is a view of a product dispenser according to the within invention.  
           [0033]    [0033]FIG. 8A is a view of an alternate embodiment of the push element of a product dispenser according to the within invention.  
           [0034]    [0034]FIG. 8B is another view of the push element of FIG. 8A.  
           [0035]    [0035]FIG. 9A is a view of an alternate embodiment of the cover of a product dispenser according to the within invention.  
           [0036]    [0036]FIG. 9B is another view of the cover of FIG. 9A. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0037]    The specific embodiments illustrated in the appended drawings and described in the following specification are simply exemplary embodiments of the inventive concept defined in the appended claims. Hence, specific dimensions and physical characteristics relating to specific embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.  
         [0038]    The dispenser  10  of the within invention comprises a cover  12 , a retractable push element  14  and a base  16 . The cover  12  and the base  16  are connected such that each can be rotated about a common axis with respect to the other. That is, the cover can be rotated while maintaining the base in a stationary position, or, conversely, the base can be rotated while maintaining the cover in a stationary position.  
         [0039]    The rotatable cover  12  comprises a roof  121 , a roof opening  122 , a wall  123 , a wall opening  124 , a landing  125  and cover snap hook connectors  126 . The cover  12  can be made from a readily-available, polycarbonate-based material such as Lexan®  143 R resin manufactured by GE Plastics and available from Polymerland Service Center, Pittsburgh, Pa. 15264. It should be appreciated that other durable materials may be used in producing the cover  12 .  
         [0040]    The roof opening  122  is coincidental with the wall opening  124  and the landing  125  is secured to the cover  12  at a location adjacent to the wall opening  124 . Product passes through the wall opening  124  from the interior of the cover  12  onto the landing  125 . Product aligned at the wall opening  124  for such transition is said to be located in the product dispensing position.  
         [0041]    The landing  125  is preferably inclined as shown to further aid in transitioning the product from the interior of the cover  12  to the landing  125 . The landing  125  optionally comprises a magnetic component  127  embedded within the landing. Alternatively, the magnet can be secured to the landing surface via a pressure sensitive adhesive or otherwise affixed to the landing, as is known in the art. The magnetic component  127  aids in controlling and removably maintaining metallic products such as miniature batteries on the landing  125 . Alternatively, as dictated by the product, other surfaces or materials, such as velcro or adhesives, may be utilized for controlling and removably maintaining products on the landing as will be appreciated by those skilled in the art. These alternate surfaces or materials may comprise the entire landing. Further, the magnetic component  127  can be planar or otherwise shaped. Where product use and placement permit, the landing  125  may further include a stop wall (not shown) at its distal end to further control the forward motion of the product as it transitions from the interior of the cover  12  to the landing  125 . It should be appreciated that the landing  125  may be integral to either the cover  12  or the base  16  or may be a separate component connected to either the cover  12  or the base  16 .  
         [0042]    The snap hook connectors  126  extend inwardly from the inner surface of the cover  12  and are positioned at regular intervals around the interior perimeter of the cover  12 . The connectors interact with the base ring  162  during connection of the base ring with the cover as will be more fully explained below and maintain tension contact with the base ring upon completion of the connection process. The number, shape and positioning of the snap hook connectors is a matter of design choice and can be varied without departing from the scope of the within invention.  
         [0043]    The outer surface of the cover wall  123  may be all or partially ribbed as illustrated or otherwise textured to provide a grip for the cover  12  during relative motion between the cover  12  and base  16 . Additional gripping can be provided by extending the upper surface of the cover  12  outwardly beyond the cover wall  123  at one or more locations.  
         [0044]    The push element  14  comprises a thumbpiece  141  having a gripping rib  142  or alternatively a textured surface secured to the upper surface of the thumbpiece  141  for gripping the push element  14 . The push element can be molded from a polystyrene material such as Styron 6075 manufactured by Dow Plastics and available from General Polymers, Columbus, Ohio 43216, or such other suitable material as is known in the art.  
         [0045]    The push element  14  further comprises a projection  143 . The projection  143  extends over at least a portion of the product located in the product dispensing position during transport and storage of the dispenser  10 , to aid in maintaining the product in this position. The projection  143  further aids in controlling the movement of product during transition from the interior of the cover  12  onto the landing  125 , and in maintaining the position of individual product on the landing  125 . Optionally, a lip  144  is located on the bottom surface of the projection  143  which aids in securing individual product in the product dispensing position and in position on the landing  125 .  
         [0046]    The push element  14  further comprises two slide rails  145  and a central rudder  146  and two side rudders  146   a  secured to the lower surface of the thumbpiece  141 . When the rudder  146  aligns with a base platform turret opening  167  in the fully retracted position of the push element, the push element  14  can be extended to advance product onto the landing  125 . Extension of the push element causes the center rudder  146  to occupy a base platform turret opening  167 , preventing rotation of the base  16  with respect to the cover  12 . When the push element  14  is fully retracted, the rudder  146  does not occupy a base platform turret opening  167  and the base  16  and the cover  12  are free to move with respect to each other, enabling product to be located in the product dispensing position. Movement of the push element  14  is further controlled by upper projections  172  on base ring  162 . When the push element is extended to advance product onto the landing  125 , side rudders  146   a  occupy an opening between upper projections  172 , thereby preventing rotation of the cover and base with respect to each other.  
         [0047]    The slide rails  145  maintain a snap connection between the push element  14  and the cover  12  and cooperate with the surfaces of the roof opening  122  to allow the push element to move along the roof opening.  
         [0048]    It should be appreciated that the projection  143  and the lip  144  may be contoured to shape according to the product contained within the dispenser without departing from the teachings herein.  
         [0049]    The slide rails  145  comprise snap hooks to provide a snap connection between the push element and the cover  12  while enabling the push element to slidably extend and retract along the roof opening  122 . The slide rails  145  contact the inside surface of the cover wall  123  preventing further extension and defining the fully extended push element position.  
         [0050]    The base  16  comprises a base platform  161 , a base ring  162  and a product platform  163 . The base platform  161  comprises openings  164  at regularly spaced intervals that cooperate with extensions  165  on the base ring  162  to provide a snap connection between the base platform  161  and the base ring  162 . The base platform  161  further comprises turret extensions  166  defining turret openings  167  arranged in a concentric circle, to control the movement of the push element  14  as explained above.  
         [0051]    All or a portion of the base platform  161  may be ribbed as shown or otherwise textured to provide a grip for the base  16  during relative motion between the cover  12  and base  16 . Extensions (not shown) from the base may be included to provide handles to aid in separating the base  16  from the cover  12 .  
         [0052]    Product is fixed onto the product platform  163  via adhesive or other suitable means. In a preferred embodiment of the within invention, zinc air miniature cells  200  are exemplified as the product, and the adhesive product platform comprises an adhesive tab layer  168 , a kill liner layer  169  and an adhesive foam layer  170 . The tab layer  168  has an adhesive upper surface and comprises precut tab areas  171 . Air cells  200  are positioned onto the adhesive surface at the tab areas  171 , thereby preventing the ingress of air sufficient to activate the cells prior to dispensing the cells from the dispenser  10 . A kill liner layer  169  is positioned between the tab layer  168  and the foam layer  170 . The function of the kill liner layer  169  is to selectively block the upper adhesive surface of the foam layer  170  from contacting selected portions of the lower surface of the tab layer  168  and is shaped accordingly. A mylar film suitable for this function can be selected as is known in the art. In this way only a portion of the precut tab areas  171  are adhesively secured to the foam layer  169  prior to dispensing the cell, enabling a measure of control over the amount of force required to separate the cell from the tab as the cell is advanced by the push element from the interior of the dispenser to the dispenser landing. The foam layer and the tab layer are available from Label Technologies, Suwanee, Ga.  
         [0053]    In an alternate embodiment, the kill liner layer can be eliminated by selectively applying an adhesive to only those portions of the upper surface of the foam layer  170  where adhesive contact with the lower surface of the tab layer  168  is desired. In another embodiment, selective application of adhesive is accomplished in only those portions of the upper surface of the tab layer  168  where adhesive contact with the product is desired.  
         [0054]    The product platform  163  is further joined to the base platform  161  via the snap connection between the base ring  162  and the base platform  161 . The base ring  162  comprises a lip about the perimeter to capture the outer perimeter of the tab layer  168 , and lower extensions  165  spaced about the perimeter that cooperate with openings  164  in the base platform to provide a snap connection. The base ring  162  further comprises grooves  173  preferentially corresponding in number to the number of product positions in the dispenser. The grooves  173  cooperate with a boss  127  located on a cover snap hook connector  126  to define a stop position during rotation of the base and cover with respect to each other. The stop position effectively aligns the push element  14  with product in the product dispensing position.  
         [0055]    The base ring  162  captures the outer perimeter of the tab layer  168  during assembly of the dispenser, aiding in the separation of the cell from the precut tab areas and in the retention of the precut tab areas with the dispenser as the cell is advanced off of the precut tab areas in transition from the interior of the dispenser to the landing  125 .  
         [0056]    In this embodiment, the air cells are not individually tabbed with discrete tabs, thereby obviating the expense associated with such an operation. Further, the tabbing material layer remains with the dispenser when the cell is dispensed, avoiding the need to handle or otherwise dispose of an individual tab. It will be appreciated, however, that the dispenser of the within invention can be utilized with individually tabbed air cells. In such an embodiment, the discrete tab is mechanically or adhesively joined to the base. The cell is then separated from the tab when the cell is advanced from the interior of the cover onto the landing while the tab remains attached to the dispenser base.  
         [0057]    Other techniques and methods for adhering product to the base may also be used without departing from the teachings of the within invention. Adhesive to secure product may be applied as a surface coating to the upper surface of the base platform  161 , or alternatively, may be applied in discrete locations to coincide with the number and spacing of product on the upper surface, thereby obviating the need for discrete adhesive layer  168 , kill liner layer  169  and foam adhesive layer  170 . Adhesives appropriate to the type of product can be selected as is known in the art.  
         [0058]    In another aspect of the within invention, the dispenser can be reused by discarding all or a portion of the base  16  once all of the product has been completely dispensed. A refill kit, comprising fresh product to be dispensed using the dispenser on a replacement base  16  is provided for re-introduction into the dispenser for use with the original cover  12  and push element  14 .  
         [0059]    In an alternate embodiment of the within invention, additional stability is provided to the push element  14  as it transitions between its fully extended and fully retracted positions by additional grooves  174  positioned on the underside of the push element  14 . These grooves  174  cooperate with projections  175  positioned on the cover  12 . It will be appreciated that the grooves  174  could alternatively be located on the cover  12  and the projections  175  be located on the push element  14  without departing from the scope of the within invention.  
         [0060]    The underside of the base  16  optionally comprises a series of storage compartments (not shown) for spent product. Spent product can be secured in position using an interference fit between the product and the storage compartment. Alternatively, spent product can be secured into position by sealing the compartments with a rotatable covering (not shown) having an opening aligned with an individual storage compartment to allow the spent air cells to pass through the opening into the compartment.  
         [0061]    To operate the dispenser from the starting position, the push element  14  is placed in the retracted position. The cover  12  and base  16  are then rotated with respect to each other until product is located in the product dispensing position. The push element is then advanced to the fully extended position, causing the product to transition from the product dispensing position to the landing. At this point, the dispenser  10  may be used as a handle to orient the product and insert it correctly into a device.