Patent Publication Number: US-8985346-B2

Title: Multi-deck product dispensing system with rear guide

Description:
FIELD 
     This application relates to the dispensing of products from packaging containers and, more particularly, to dispensers for dispensing products initially provided in packaging containers. 
     BACKGROUND 
     Products are typically shipped to retailers in bulk by enclosing multiple individual product units in a container, such as a carton or box. For example, canned beverages may be shipped to a retailer in a carton containing twelve individual cans. When the products are to be sold individually, the retailer must remove the individual product units from the carton and stack them on a display, such as a shelf. 
     Alternatives to the traditional package-ship-unpack-display model have been developed in an effort to improve operating efficiency. For example, U.S. Ser. No. 13/184,639 filed on Jul. 18, 2011, the entire contents of which are incorporated herein by reference, discloses a gravity-fed product dispensing system with multiple dispensing decks. The system includes a dispenser configured with an upper deck for supporting a container and multiple dispensing decks positioned below the upper deck, wherein each dispensing deck includes a product display area. The dispenser may be positioned on a retailer&#39;s shelf and loaded with product simply by placing a container comprising multiple units of product onto the upper deck of the dispenser. Once the container is positioned on the upper deck, the products exit the container through an opening in the container and travel to the product display areas under the force of gravity. Consumers may retrieve the products from the product display areas. 
     Despite advances already made in the field, those skilled in the art continue with research and development efforts directed to apparatus and systems for dispensing products initially provided in packaging containers. 
     SUMMARY 
     In one aspect, the disclosed multi-deck product dispensing system may include a frame structure having a front end and a rear end, the frame structure including an upper support deck extending between the front and rear ends, a lower support deck positioned below the upper support deck, the lower support deck extending between the front and rear ends and defining a first product display area, and an intermediate support deck positioned between the upper support deck and the lower support deck, the intermediate support deck extending between the front and rear ends and defining a second product display area, wherein the upper support deck and the intermediate support deck define a vertical drop zone proximate the rear end, the vertical drop zone extending from the upper support deck to the lower support deck, and a guide positioned between the upper support deck and the intermediate support deck, the guide extending into the vertical drop zone. 
     In another aspect, the disclosed multi-deck product dispensing system may include a frame structure having a front end and a rear end, the frame structure including a rear wall proximate the rear end, an upper support deck extending between the front end and the rear end, the upper support deck defining a first opening proximate the rear wall, a lower support deck positioned below the upper support deck, the lower support deck extending between the front end and the rear end and defining a first product display area proximate the front end, and an intermediate support deck positioned between the upper support deck and the lower support deck, the intermediate support deck extending between the front end and the rear end and defining a second product display area proximate the front end, the intermediate support deck defining a second opening proximate the rear wall, wherein the first opening and the second opening define a vertical drop zone extending from the upper support deck to the lower support deck, and a guide connected to the rear wall between the upper support deck and the intermediate support deck, the guide protruding from the rear wall into the vertical drop zone. 
     In yet another aspect, disclosed is a method for dispensing a plurality of products initially provided in a container. The method may include the steps of (1) providing a dispenser including a frame structure having a front end and a rear end, the frame structure including a rear wall proximate the rear end, an upper support deck extending between the front end and the rear end, the upper support deck defining a first opening proximate the rear wall, a lower support deck positioned below the upper support deck, the lower support deck extending between the front end and the rear end and defining a first product display area, and an intermediate support deck positioned between the upper support deck and the lower support deck, the intermediate support deck extending between the front end and the rear end and defining a second product display area, the intermediate support deck defining a second opening proximate the rear wall, wherein the first opening and the second opening define a vertical drop zone extending from the upper support deck to the lower support deck, (2) positioning a guide between the upper support deck and the intermediate support deck such that the guide extends into the vertical drop zone, (3) forming an exit opening in the container and (4) positioning the container on the upper support deck to align the exit opening with the vertical drop zone such that at least one product exits the container and moves through the vertical drop zone into engagement with the guide. 
     Other aspects of the disclosed multi-deck product dispensing system and method with rear guide will become apparent from the following detailed description, the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front and side perspective view of one aspect of the disclosed multi-deck product dispensing system with rear guide; 
         FIG. 2  is a side elevational view, in section, of the product dispensing system of  FIG. 1 ; 
         FIG. 3  is a front perspective view of the container of the product dispensing system of  FIG. 1 ; 
         FIG. 4  is a rear and bottom perspective view of the container of  FIG. 3  shown in an open configuration; 
         FIG. 5  is a side elevational view of the rear guide of the product dispensing system of  FIG. 2 ; 
         FIG. 6  is a front and side perspective view of the rear guide of  FIG. 5 ; and 
         FIG. 7  is a side elevational view of an alternative embodiment of the rear guide of  FIG. 5 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1 and 2 , one aspect of the disclosed multi-deck product dispensing system with rear guide, generally designated  10 , may include a dispenser  12  and a container  14 . The container  14  may initially house multiple units of product  16 , such as cans (e.g., canned soft drinks), jars (e.g., jarred soup) or bottles (e.g., bottled sauce). The products  16  may be released from the container  14  into the dispenser  12  when the container  14  is opened and loaded onto the dispenser  12 . 
     The container  14  may be any container capable of initially housing the products  16  and beneficially interacting with the dispenser  12 . For example, as shown in  FIG. 3 , the container  14  may be a paperboard carton or a corrugated box having six walls  18 ,  20 ,  22 ,  24 ,  26 ,  28  that define an internal volume  30  for receiving the products  16  ( FIGS. 1 and 2 ). Opposed walls  18 ,  20  may define the front and rear walls, respectively, of the container  14 . Opposed walls  22 ,  24  may define the left and right side walls, respectively, of the container  14 . Opposed walls  26 ,  28  may define the base and upper walls, respectively, of the container  14 . 
     In accordance with well-established techniques, the container  14  may be assembled on a container machine using a container blank that has been pre-cut from a sheet of stock material. As one example, the stock material may be a paperboard-based material, such as C1S paperboard, which may have a coating (e.g., clay) on a first major surface thereof, which may form the outer surface of the container  14 , and an uncoated second major surface. As another example, the stock material may be C2S paperboard, which may have a coating (e.g., clay) on both major surfaces thereof. Optionally, the outer surface  32  ( FIG. 1 ) of the container  14  may be marked with various indicia  34  ( FIG. 1 ), such as printed text and graphics. 
     Still referring to  FIG. 3 , the container  14  may include a removable opening feature  36  in at least one wall (e.g., the base wall  26 ). The removable opening feature  36  may be defined by weakened severance lines  38 ,  40 ,  42 ,  44 . The weakened severance lines  38 ,  40 ,  42 ,  44  may be formed by weakening the container  14 , such as with score lines, perforations or zipper-like cuts, to facilitate tearing the removable opening feature  36  from the container  14  along the weakened severance lines  38 ,  40 ,  42 ,  44 . 
     Thus, as shown in  FIG. 4 , the removable opening feature  36  may be removed from the container  14  to form an opening  46  into the internal volume  30  of the container  14 . The opening  46  may extend generally laterally between the side walls  22 ,  24  of the container  14 , and may be positioned proximate the rear wall  20  of the container  14  such that the products  16  ( FIG. 1 ) may exit the container  14  through the opening  46 . Those skilled in the art will appreciate that the step of removing the removable opening feature  36  from the container  14  may be performed prior to loading the container  14  onto the dispenser  12 . 
     In an alternative embodiment, the dispenser  12  may include an opening tool (not shown) arranged to automatically form the opening  46  in the container  14  as the container  14  is loaded onto the dispenser  12  (e.g., by sliding the container  14  longitudinally along the upper support deck  58  of the dispenser  12 ). The use of an opening tool associated with a dispenser to automatically form an opening in a container is described in greater detail in U.S. Ser. No. 13/184,639 (discussed above), as well as in U.S. Pat. No. 7,922,437 issued on Apr. 12, 2011, the entire contents of which are incorporated herein by reference. Those skilled in the art will appreciate that the use of an opening tool may eliminate the need for removing the removable opening feature  36  from the container  14  prior to loading the container  14  onto the dispenser  12 . 
     Referring back to  FIGS. 1 and 2 , the dispenser  12  may include a frame structure  50  that supports the container  14  and products  16  in a desired configuration. The frame structure  50  may include a first (e.g., right) side wall  52 , a second (e.g., left) side wall  54 , a rear wall  56 , an upper support deck  58 , a lower support deck  60  and one or more intermediate support decks  62  (only one is shown in  FIGS. 1 and 2 ) positioned between the upper support deck  58  and the lower support deck  60 . The frame structure  50  may define a front end portion  66  and a rear end portion  70 , wherein the rear end  70  is longitudinally opposed from the front end  66 . 
     The right side wall  52  may be laterally spaced from the left side wall  54 , and may be generally parallel with the left side wall  54 . The spacing between the right and left side walls  52 ,  54  may be sized to closely receive the products  16  in a rolling configuration, thereby providing lateral containment for the products  16  within the frame structure  50 . 
     The rear wall  56  may be positioned proximate the rear end  70  of the frame structure  50 , and may laterally extend between the right and left side walls  52 ,  54 . The rear wall  56  may be generally vertically arranged, though an angled rear wall  56  (i.e., angled relative to vertical in side view) may be used without departing from the scope of the present disclosure. 
     The lower support deck  60  may laterally extend between the right and left side walls  52 ,  54 , and may include a front end  64  that longitudinally extends toward the front end  66  of the frame structure  50  and a rear end  68  that longitudinally extends toward the rear end  70  of the frame structure  50 . Therefore, the lower support deck  60  and the side walls  52 ,  54  may define a lower level  72  of the frame structure  50 . 
     The lower support deck  60  may be inclined from the front end  64  to the rear end  68  (i.e., the rear end  68  may be elevated relative to the front end  64 ) such that products  16  deposited proximate the rear end  68  of the lower support deck  60  roll down to the front end  64  of the lower support deck  60  under the force of gravity. The extent of the incline of the lower support deck  60  may be dictated by, among other things, the coefficient of friction of the material used to form the frame structure  50  and the shape of the products  16  to be dispensed by the dispenser  12 . 
     A ramp  48  may be positioned between the rear wall  56  of the frame structure  50  and the rear end  68  of the lower support deck  60 . The ramp  48  may provide a gradual vertical-to-horizontal transition for products  16  dropping down to the lower level  72 . 
     A stop  74  may be positioned proximate the front end  64  of the lower support deck  60  to prevent products  16  from rolling beyond the front end  64  of the lower support deck  60 . Therefore, the stop  74  may collect products  16  at the front end  64  of the lower support deck  60 , thereby defining a first product display area  76  proximate the front end  64  of the lower support deck  60 . The first product display area  76  may be configured to allow consumers to retrieve products  16  from the lower level  72  of the dispenser  12 . 
     The intermediate support deck  62  may be positioned between the upper support deck  58  and the lower support deck  60 . The intermediate support deck  62  may laterally extend between the right and left side walls  52 ,  54 , and may include a front end  78  that longitudinally extends toward the front end  66  of the frame structure  50  and a rear end  80  that longitudinally extends toward, but not to, the rear wall  56  of the frame structure  50 . Therefore, the intermediate support deck  62  and the side walls  52 ,  54  may define an intermediate level  82  of the frame structure  50 . 
     The spacing S 1  between the rear end  80  of the intermediate support deck  62  and the rear wall  56  of the frame structure  50  may define an opening  84 , which may function as a chute to allow products  16  to move from the intermediate level  82  down to the lower level  72  of the frame structure  50  under the force of gravity. 
     The intermediate support deck  62  may be inclined from the front end  78  to the rear end  80  (i.e., the rear end  80  may be elevated relative to the front end  78 ) such that products  16  deposited proximate the rear end  80  of the intermediate support deck  62  roll down to the front end  78  of the intermediate support deck  62  under the force of gravity. The extent of the incline of the intermediate support deck  62  may be dictated by, among other things, the coefficient of friction of the material used to form the frame structure  50  and the shape of the products  16  to be dispensed by the dispenser  12 . 
     A stop  86  may be positioned proximate the front end  78  of the intermediate support deck  62  to prevent products  16  from rolling beyond the front end  78  of the intermediate support deck  62 . Therefore, the stop  86  may collect products  16  at the front end  78  of the intermediate support deck  62 , thereby defining a second product display area  88  proximate the front end  78  of the intermediate support deck  62 . The second product display area  88  may be configured to allow consumers to retrieve products  16  from the intermediate level  82  of the dispenser  12 . 
     Optionally, the second product display area  88  may be longitudinally (e.g., inwardly) displaced relative to the first product display area  76  such that the second product display area  88  does not obstruct access to the first product display area  76 . As an example, the longitudinal displacement may correspond to the width of one product  16 . 
     The upper support deck  58  may laterally extend between the right and left side walls  52 ,  54 , and may include a front end  90  that longitudinally extends toward the front end  66  of the frame structure  50  and a rear end  92  that longitudinally extends toward, but not to, the rear wall  56  of the frame structure  50 . Therefore, the upper support deck  58  and the side walls  52 ,  54  may define an upper level  94  of the frame structure  50 . 
     The spacing S 2  between the rear end  92  of the upper support deck  58  and the rear wall  56  of the frame structure  50  may define an opening  96 , which may function as a chute to allow products  16  to move from the upper level  94  down to the intermediate  82  and lower  72  levels of the frame structure  50  under the force of gravity. 
     The upper support deck  58  may be declined from the front end  90  to the rear end  92  (i.e., the front end  90  may be elevated relative to the rear end  92 ). Therefore, products  16  supported on the upper support deck  58  may roll under the force of gravity down to the rear end  92  of the upper support deck  58 , through the opening  96 , to the lower and intermediate levels  72 ,  82  of the frame structure  50  and, ultimately, to the first and second product display areas  76 ,  88 . 
     Optionally, a stop  98  may be connected proximate the rear end  70  of the frame structure  50 . The stop  98  may extend into the upper level  94  of the frame structure  50  to inhibit rearward horizontal movement of the container  14  along the upper support deck  58  beyond the stop  98 . Furthermore, the stop  98  may ensure alignment of the opening  46  ( FIG. 4 ) in the container  14  with the opening  96  of the upper level  94  of the frame structure  50 . 
     Thus, the openings  84 ,  96  in the intermediate and upper levels  82 ,  94 , respectively, may define a vertical drop zone  100  proximate the rear end  70  of the frame structure  50 . The vertical drop zone  100  may extend from the upper level  94  to the lower level  72  of the frame structure  50 . Products  16  exiting the opening  46  ( FIG. 4 ) in the container  14  may fall through at least a portion of the vertical drop zone  100  as the products  16  travel (under the force of gravity) to either the lower level  72  or the intermediate level  82  and, ultimately, to either the first product display area  76  or the second product display area  88 . 
     A guide  102  may be position proximate the rear wall  56  of the frame structure  50 , and may protrude into the vertical drop zone  100  to beneficially interact with products  16  moving through the vertical drop zone  100 . The guide  102  may introduce a slight forward, horizontal movement to the products  16  dropping through the vertical drop zone  100 . The introduction of a slight forward, horizontal movement to the products  16  dropping through the vertical drop zone  100  may minimize (if not eliminate) the potential for products  16  becoming stuck on top of the last product  16 ′ in the lower level  72  and forming a bridge that clogs the system  10  (e.g., prevents products  16  from moving onto the intermediate support deck  62 ). 
     Referring to  FIGS. 5 and 6 , the guide  102  may include an elongated body  104  having a mating surface  106  and an engagement surface  108 . As shown in  FIG. 2 , the guide  102  may be connected to the rear wall  56  of the frame structure  50  such that the elongated body  104  of the guide  102  laterally extends between the side walls  52 ,  54  of the frame structure  50 . 
     The guide  102  may be positioned below the upper support deck  58 , but above the intermediate support deck  62 . Therefore, the products  16  moving through the vertical drop zone  100  may interact with the guide  102  prior to reaching either the lower support deck  60  or the intermediate support deck  62 . 
     In one construction, the guide  102  may be connected to the rear wall  56  of the frame structure  50  by mating the mating surface  106  of the guide  102  with the interior surface of the rear wall  56 . For example, a tongue  110  ( FIG. 5 ) may protrude from the mating surface  106  of the guide  102  and the rear wall  56  of the frame structure  50  may include a corresponding groove (not shown). Therefore, the guide  102  may be connected to the rear wall  56  of the frame structure  50  by inserting the tongue  110  into the groove. Other techniques for connecting the guide  102  to the rear wall  56  of the frame structure  50  will be readily apparent to this skilled in the art. 
     In another construction, the guide  102  may be integral with the rear wall  56  of the frame structure  50  (i.e., the guide  102  and rear wall  56  may be formed as a single, monolithic body). 
     The engagement surface  108  of the guide  102  may be contoured in various ways such that the engagement surface  108  protrudes away from the rear wall  56  (i.e., toward the front end  66  of the frame structure  50 ) and into the vertical drop zone  100 . Therefore, products  16  moving from the upper level  94 , through the opening  96  and dropping through the vertical drop zone  100  may come into contact with the engagement surface  108  of the guide  102  and may be at least slightly redirected away from the rear wall  56  of the frame structure  50  (i.e., may be urged slightly forward toward the intermediate support deck  62 ) upon making contact with the engagement surface  108 . 
     The guide  102  may have a protruding length L ( FIG. 5 ), which may be the maximum distance the guide  102  protrudes from the rear wall  56  into the vertical drop zone  100 . The protruding length L may be sufficiently large to urge products  16  forward (i.e., toward the intermediate support deck  62 ) so as to avoid the problem of stacking of products  16  on top of the last product  16 ′ in the lower level  72 . However, the protruding length L may not be so large as to prevent products  16  from dropping through the opening  84  in the intermediate level  82  down to the lower level  72 . Those skilled in the art will appreciate that using a guide  102  having a large protruding length L may require increasing the spacing S 1  between the rear end  80  of the intermediate support deck  62  and the rear wall  56  of the frame structure  50  to ensure that products  16  being redirected by the guide  102  are still capable of dropping to the lower level  72  of the frame structure  50 . 
     In one embodiment, the guide  102  may be semi-circular in side view, thereby providing the engagement surface  108  with a rounded contour, as shown in  FIGS. 5 and 6 . Therefore, the upper portion of the guide  102  may urge products  16  forward, while the lower portion of the guide  102  may gradually direct products  16  toward the rear wall  56  of the frame structure  50 . 
     In another embodiment, the engagement surface  108 ′ of the guide  102 ′ may be contoured as a ramp, as shown in  FIG. 7 , or as a tear drop (not shown). The angle and curvature of the engagement surface  108 ′ may be selected to direct dropping products  16  forward, but not so forward that the products  16  fail to drop through the opening  84  down to the lower level  72  of the frame structure  50 . 
     At this point, those skilled in the art will appreciate that guides  102  of various shapes and configurations may be used to effect the beneficial redirection of products  16  dropping through the vertical drop zone  100 . 
     Thus, the guide  102  may be positioned to interact with products  16  exiting through the opening  46  ( FIG. 4 ) in the container  14 , passing though the opening  96  in the upper level  94 , and dropping through the vertical drop zone  100 . The initial products  16  dropping through the vertical drop zone  100  may be urged slightly forward as they engage the guide  102 , but may continue to drop down through the opening  84  in the intermediate level  82  to the lower level  72 , where they may be gravity-biased toward the first product display area  76 . Once the lower level  72  of the frame structure  50  has been filled with products  16  such that the opening  84  in the intermediate level  90  is bridged by a product  16 ′, the remaining products  16  (i.e., the products  16  above the last product  16 ′ in the lower level  72 ) may be urged slightly forward as they engage the guide  102  such that they are not stacked on top of the last product  16 ′ in the lower level  72 . Therefore, the remaining products  16  dropping through the vertical drop zone  100  may fill the intermediate level  82  of the frame structure  50 , where they may be gravity-biased toward the second product display area  88 . 
     The product dispensing system  10  may be assembled by opening the container  14  (e.g., tearing away the removable opening feature  36 ) and urging the opened container  14  along the upper support deck  58  of the dispenser  12  until the rear wall  20  of the container  14  comes into abutting engagement with the stop  98 , thereby aligning the opening  46  in the container  14  with the opening  96  in the upper level  94  of the frame structure  50 . With the opened container  14  loaded onto the dispenser  12 , the force of gravity may urge the products  16  down through the vertical drop zone  100  of the frame structure  50 , into engagement with the guide  102  and, ultimately, to the first and second product display areas  76 ,  88 . Once the products from the container  14  have been transferred to the dispenser  12 , a second container may be positioned on the upper support deck  58  of the dispenser  12 . The products  16  in the second container may fill the dispenser  12  as customers remove products  16  by way of the first and second product display areas  76 ,  88 . 
     Accordingly, the disclosed product dispensing system employs multiple support decks with product display areas, thereby increasing the amount of product being displayed to potential consumers and increasing the amount of product that may be supported by a given dispenser. Furthermore, the use of a guide may minimize (if not eliminate) the potential for product clogs in the system, thereby reducing (if not eliminating) the need for manual intervention to ensure proper dispensing. 
     Although various aspects of the disclosed multi-deck product dispensing system with rear guide have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.