Patent Publication Number: US-2013248468-A1

Title: Product Dispensing System with Dispenser-Product Interaction

Description:
FIELD 
     This application relates to the dispensing of products from packaging containers and, more particularly, to product dispensers configured to cooperate with packaging containers to dispense products. 
     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 foods may be shipped to a retailer in a box containing twenty-four individual cans. Then, it is typically the retailer&#39;s obligation to remove the individual product units from the container and present them (e.g., on a shelf) to consumers. 
     Alternatives to the traditional package-ship-unpack-display model have been developed in an effort to improve operating efficiency. For example, U.S. Pat. No. 7,922,437 (issued on Apr. 12, 2011) discloses a product dispensing system that includes a dispenser having a support structure, a product display area and an opening tool. 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 support structure of the dispenser. As the container is being placed onto the support structure, the opening tool of the dispenser opens the container in such a manner that product rolls from the container and down to the product display area of the dispenser under the force of gravity. 
     Unfortunately, product dispensing systems may experience product bridging that prevents products from properly exiting the container and moving through the dispenser. For example, as shown in  FIG. 1 , when a container  2  is positioned on a dispenser  4 , a product  6 A may bridge the gap between the container  2  and product  6 B, thereby preventing all of the products  6  from passing through the opening  8  in the container  2  and moving into the dispenser  4 . 
     Accordingly, those skilled in the art continue with research and development efforts directed to product dispensing systems. 
     SUMMARY 
     In one embodiment, the disclosed product dispensing system may include a dispenser having a front end longitudinally opposed from a rear end, the dispenser including a first side wall laterally opposed from a second side wall, a protuberance extending from the first side wall toward the second side wall, a container support deck positioned below the protuberance between the first and second side walls, the container support deck extending at least partially between the front and rear ends, and a lower support deck positioned below the container support deck, the lower support deck extending at least partially between the front and rear ends, and defining a product display area. 
     In another embodiment, the disclosed product dispensing system may include a dispenser having a front end longitudinally opposed from a rear end, the dispenser including a first side wall laterally opposed from a second side wall, a protuberance extending from the first side wall toward the second side wall, a container support deck positioned below the protuberance between the first and second side walls, the container support deck extending at least partially between the front and rear ends, and a lower support deck positioned below the container support deck, the lower support deck extending at least partially between the front and rear ends, and defining a product display area, a container positioned on the container support deck, the container defining an engagement opening, and a plurality of products initially housed in the container, wherein the protuberance is engaged with at least one of the products when the engagement opening is aligned with the protuberance. 
     In yet another embodiment, disclosed is a method for dispensing products. The method may include the steps of (1) providing a dispenser including a container support deck and a lower support deck positioned below the container support deck, the lower support deck defining a product display area, (2) providing a container initially housing a plurality of products, (3) forming an access opening in the container, the access opening being size to allow the products to pass therethrough, (4) positioning the container with the access opening on the container support deck such that at least one product exits the container through the access opening and moves to the product display area and, while the container is positioned on the container support deck, restricting movement toward the access opening of another product within the container. 
     Other embodiments of the disclosed product dispensing system and method will become apparent from the following detailed description, the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevational view of a prior art product dispensing system, shown with product bridging within the container; 
         FIG. 2  is a side elevational view of a container configured in accordance with the present disclosure to avoid product bridging; 
         FIG. 3  is a side elevational view of the container of  FIG. 2 , shown with a product exiting the container; 
         FIG. 4  is a front and side perspective view of one embodiment of the disclosed product dispensing system with dispenser-product interaction; 
         FIG. 5  is a side elevational view of the container of the product dispensing system of  FIG. 4 ; 
         FIG. 6  is a front and side perspective view of the container of  FIG. 5 ; 
         FIG. 7  is a rear and bottom perspective view of the container of  FIG. 6 ; 
         FIG. 8  is a side elevational view, in section, of the dispenser of the product dispensing system of  FIG. 4 ; 
         FIG. 9  is a top plan view, in section, of a portion of the side wall of the dispenser of  FIG. 8 ; 
         FIG. 10  is a top plan view, in section, of a portion of the side wall of a dispenser in accordance with a first alternative embodiment of the disclosed product dispensing system; 
         FIG. 11  is a top plan view, in section, of a portion of the side wall of a dispenser in accordance with a second alternative embodiment of the disclosed product dispensing system; 
         FIG. 12  is a front elevational view, in section, of a portion of the product dispensing system of  FIG. 4 ; 
         FIG. 13  is a side elevational view, in section, of the product dispensing system of  FIG. 4 , shown during one phase of dispensing; and 
         FIG. 14  is a side elevational view, in section, of the product dispensing system of  FIG. 13 , shown during another phase of dispensing. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 2 and 3 , a container  10  suitable for use in connection with the disclosed product dispensing system may include an access opening  12 , and may initially house a plurality of products  14 . The container  10  may be arranged at a non-zero angle Θ relative to a horizontal plane P such that the force of gravity urges the products  14  toward the access opening  12 . 
     In  FIG. 2 , the container  10  is shown after two products have exited the container  10  through the opening  12 . Therefore, the next two products  14 A,  14 B in the container  10  have moved to a bridging configuration, wherein product  14 A is wedged over the access opening  12  between product  14 B and the rear wall  16  of the container  10 . 
     It has now been discovered that the problem of product bridging within the container  10  may be overcome by restricting movement toward the access opening  12  of some of the products  14  within the container  10  until the initial products (e.g., products  14 A,  14 B) have exited the container  10 . For example, as shown in  FIG. 3 , when rearward movement (i.e., movement toward the access opening  12 ) of product  14 C has been restricted, the weight of product  14 A acting on product  14 B may urge product  14 B in the direction shown by arrow A, thereby allowing product  14 A to pass through the opening  12 . Once product  14 A has passed through the opening  12 , the remaining products  14  in the container  10  may exit the container  10  without bridging. 
     Accordingly, disclosed is a product dispensing system that may include a dispenser and a container that initially houses products intended to be dispensed by the dispenser. The dispenser and the container may be configured to facilitate beneficial interaction of the dispenser with the products housed in the container such that the occurrence of product bridging within the container may be reduced or eliminated. 
     Referring to  FIG. 4 , one embodiment of the disclosed product dispensing system with dispenser-product interaction, generally designated  100 , may include a dispenser  102  and a container  104 . The container  104  may initially house multiple units of product  106 . When the container  104  is loaded onto the dispenser  102 , the container  104  may release the products  106  from the container  104  to the dispenser  102 . 
     The container  104  may be any container capable of initially housing products  106  and beneficially interacting with the disclosed dispenser  102  to release the products  106  to the dispenser  102 . For example, the container  104  may be a paperboard carton or a corrugated box. Optionally, at least one major surface  108  of the container  104  may be marked with indicia  110 , such as printed text and/or graphics. 
     Referring to  FIGS. 5-7 , the container  104  may be a generally rectilinear container having six walls  118 ,  120 ,  122 ,  124 ,  126 ,  128  that define an internal volume  130  for receiving the products  106 . Opposed walls  118  and  120  may define the front and rear walls, respectively, of the container  104 . Opposed walls  122  and  124  may define the first (e.g., right) and second (e.g., left) side walls, respectively, of the container  104 . Opposed walls  126  and  128  may define the base and upper walls, respectively, of the container  104 . Containers of other shapes and configurations are also contemplated. 
     The base wall  126  of the container  104  may define an access opening  132 , as shown in  FIG. 7 . The access opening  132  may be sized and shaped to allow the products  106  ( FIGS. 5 and 6 ) initially housed in the container  104  to pass therethrough when the container  104  is mounted on the dispenser  102 , as shown in  FIG. 4 . 
     The access opening  132  may be positioned proximate (i.e., at or near) the rear wall  120  of the container  104 , and may extend generally laterally between the side walls  122 ,  124  of the container  104 . However, those skilled in the art will appreciate that the location of the access opening  132  in the container  104  may depend on, among other things, the configuration of the dispenser  102 . 
     Various techniques, including manual and automatic techniques, may be used to form the access opening  132  in the container  104 . 
     In a first aspect, the access opening  132  may be pre-formed in the base wall  126  of the container  104 , as shown in  FIG. 7 . Optionally, a peelable label or the like (not shown) may be applied to the container  104  over the pre-formed access opening  132 . Therefore, the access opening  132  may be revealed by peeling away the optional peelable label from the container  104  prior to loading the container  104  onto the dispenser  102 . 
     In a second aspect, the access opening  132  may be defined by pre-formed weakening features, such as perforations or zipper strips, in the base wall  126  of the container  104 . Therefore, the access opening  132  may be formed by tearing a portion (e.g., a generally rectangular panel) of the base wall  126  away from the container  104  along the pre-formed weakening features prior to loading the container  104  onto the dispenser  102 . 
     In a third aspect, the access opening  132  may be automatically formed in the container  104  as the container  104  is urged along the dispenser  102 . In a first expression of the third aspect, an opening tool associated with the dispenser  102  may form the access opening  132  as the container  104  is urged along the dispenser  102 , as described in U.S. Pat. No. 7,922,437 to Loftin et al., the entire contents of which are incorporated herein by reference. In a second expression of the third aspect, a catch element associated with the dispenser  102  may form the access opening  132  as the container  104  is urged along the dispenser  102 , as described in U.S. patent application Ser. No. 13/032,734 filed by Gelardi et al., the entire contents of which are incorporated herein by reference. 
     The right side wall  122  of the container  104  may define a first container-product engagement opening  134  and the left side wall  124  may define a second container-product engagement opening  136 . While the first engagement opening  134  is shown in  FIG. 7  being laterally opposed from the second engagement opening  136 , also contemplated are configurations in which the first engagement opening  134  is longitudinally displaced relative to the second engagement opening  136 . 
     The engagement openings  134 ,  136  may be sized, shaped and positioned to allow protuberances (discussed below) associated with the dispenser  102  to pass therethrough and engage at least one product  106 ′ ( FIG. 5 ) within the container  104 . As is described in greater detail herein, the engagement between the dispenser  102  and the product(s)  106 ′ by way of the engagement openings  134 ,  136  may restrict movement of at least some of the products  106  within the container  104  when the products  106  are released from the container  104  to the dispenser  102 , thereby reducing or eliminating the occurrence of product bridging within the container  104 . 
     As best shown in  FIG. 5 , the engagement openings  134 ,  136  may have a longitudinal length B and a vertical height C. The length B and the height C may be sufficient to allow the protuberances (discussed below) to pass through the engagement openings  134 ,  136  and engage at least one product  106 ′ housed within the container  104 . While the engagement openings  134 ,  136  are shown having an elongated rectangular shape, those skilled in the art will appreciate that engagement openings  134 ,  136  of various sizes and shapes may be used, and that the size and shape of the engagement openings  134 ,  136  may be dictated by, among other things, the size and shape of the protuberances (discussed below). 
     The engagement openings  134 ,  136  may be spaced a longitudinal distance D from the rear wall  126  of the container  104  and a vertical distance E from the base wall  126  of the container  104 . The longitudinal distance D and the vertical distance E may be selected such that the engagement openings  134 ,  136  are positioned to align with the product(s)  106 ′ intended to be engaged by the protuberances (discussed below). For example, in the configuration shown in  FIG. 5 , the engagement openings  134 ,  136  are aligned with the product  106 ′ in the first row (i.e., the row adjacent to the base wall  126 ) and the third column from the rear wall  120 . Therefore, the longitudinal distance D may be less than or equal to three times the greatest diameter of the products  106  and the vertical distance E may be less than the greatest diameter of the products  106 . 
     The products  106  may be any products capable of moving from the container  104  to the dispenser  102  and, ultimately, being dispensed by the dispenser  102 . In one particular implementation, the products  106  may have a generally cylindrical shape and may be capable of rolling about a rolling axis F ( FIG. 6 ). For example, the products  106  may be cans (e.g., canned food), jars (e.g., jarred sauce) or bottles (e.g., bottled soft drinks). 
     Optionally, the products  106  may include a rim  138 , as shown in  FIG. 12 , or other feature that may catch the protuberances (discussed below) associated with the dispenser  102 . For example, the products  106  may be cans having a circumferential sealing rim at one end (or both ends). 
     As shown in  FIG. 5 , the products  106  may be initially arranged in longitudinal rows within the container  104  such that the rolling axis F ( FIG. 6 ) of each product  106  is generally normal to the planes defined by the side walls  122 ,  124  of the container  104 . One or more additional rows may be positioned over the first longitudinal row (i.e., the row adjacent to the base wall  126  of the container  104 ) of products  106 . For example, two stacked longitudinal rows of products  106  are shown in the container  104  of  FIG. 5 . 
     Referring to  FIG. 8 , the dispenser  102  may include a first (e.g., left) side wall  140 , a second (e.g., right) side wall  142  ( FIG. 4 ), a container support deck  144  and a lower support deck  146 . The left side wall  140  may be laterally spaced from the right side wall  142 , and may be generally parallel with the right side wall  142 . 
     The lower support deck  146  may laterally extend between the left and right side walls  140 ,  142 , and may include a front end  148  that longitudinally extends toward the front end  150  of the dispenser  102  and a rear end  152  that longitudinally extends toward the rear end  154  of the dispenser  102 . Therefore, the lower support deck  146  and the side walls  140 ,  142  may define a lower level  156  of the dispenser  102 . 
     The lower support deck  146  may be inclined from the front end  148  to the rear end  152  (i.e., the rear end  152  may be elevated relative to the front end  148 ) such that products  106  deposited proximate the rear end  152  of the lower support deck  146  roll down to the front end  148  of the lower support deck  146  under the force of gravity. 
     A stop  158  may be positioned proximate the front end  148  of the lower support deck  146  to prevent products  106  from rolling beyond the front end  148  of the lower support deck  146 . Therefore, the stop  158  may collect products  106  at the front end  148  of the lower support deck  146 , thereby defining a product display area  160  proximate the front end  148  of the lower support deck  146 . 
     The container support deck  144  may laterally extend between the left and right side walls  140 ,  142 , and may include a front end  162  that longitudinally extends toward the front end  150  of the dispenser  102  and a rear end  164  that longitudinally extends toward, but not to, the rear end  154  of the dispenser  102 . Therefore, the container support deck  144  and the side walls  140 ,  142  may define an upper level  166  of the dispenser  102 . 
     The spacing between the rear end  164  of the container support deck  144  and the rear end  154  of the dispenser  102  may define a dispenser opening  168 , which may function as a chute to allow products  106  to move from the upper level  166  to the lower level  156  of the dispenser  102  under the force of gravity. The access opening  132  ( FIG. 7 ) in the container  104  may be aligned with the dispenser opening  168  of the dispenser  102  when the container  104  is fully loaded onto the dispenser  102 . 
     The container support deck  144  may be declined from the front end  162  to the rear end  164  (i.e., the front end  162  may be elevated relative to the rear end  164 ). Therefore, the force of gravity may urge products  106  supported on the container support deck  144  toward the rear end  164  of the container support deck  108  and, ultimately, toward the dispenser opening  168 . 
     Referring to  FIGS. 8 ,  9  and  12 , the left side wall  140  of the dispenser  102  may include a first product engaging protuberance  170 . The first protuberance  170  may be positioned in the upper level  166  of the dispenser  102 , and may protrude inward from the left side wall  140  (i.e., toward the right side wall  142 ). 
     As shown in  FIG. 12 , the right side wall  142  of the dispenser  102  may include a second product engaging protuberance  172 . The second protuberance  172  may be positioned in the upper level  166  of the dispenser  102 , and may protrude inward from the right side wall  142  (i.e., toward the left side wall  140 ). 
     While the first protuberance  170  is shown in  FIG. 12  being directly laterally opposed from the second protuberance  172 , also contemplated are configurations in which the first protuberance  170  is longitudinally displaced relative to the second protuberance  172 . At this point, those skilled in the art will appreciate that the longitudinal position of the first protuberance  170  relative to the second protuberance  172  may depend on, among other things, the configuration of the engagement openings  134 ,  136  in the container  104 . 
     The protuberances  170 ,  172  may be spaced a longitudinal distance F from the rear end  154  of the dispenser  102  and a vertical distance G from the container support deck  144  of the dispenser  102 . The longitudinal distance F and the vertical distance G may be selected such that the protuberances  170 ,  172  align with the engagement openings  134 ,  136  in the container  104  when the container  104  is longitudinally urged along the container support deck  144  of the dispenser  102 . 
     In a first construction, the protuberances  170 ,  172  may be positioned to align with the engagement openings  134 ,  136  in the container  104  when the container  104  is fully loaded on the dispenser  102  (i.e., when the container  104  is at its rearward most longitudinal position on the dispenser  102 ). Therefore, the longitudinal distance F shown in  FIG. 8  may be substantially equal to the longitudinal distance D shown in  FIG. 5 . 
     In a second construction, the protuberances  170 ,  172  may be positioned to align with the engagement openings  134 ,  136  in the container  104  prior to the container  104  being fully loaded on the dispenser  102  (i.e., prior to the container  104  reaching its rearward most longitudinal position on the dispenser  102 ). Therefore, the longitudinal distance F shown in  FIG. 8  may be greater than the longitudinal distance D shown in  FIG. 5 . In a first implementation of the second construction, the longitudinal distance D may be at most 97 percent of the longitudinal distance F. In a second implementation of the second construction, the longitudinal distance D may be at most 95 percent of the longitudinal distance F. In a third implementation of the second construction, the longitudinal distance D may be at most 90 percent of the longitudinal distance F. 
     The protuberances  170 ,  172  may be sized and shaped to pass through the engagement openings  134 ,  136  in the container  104  when the engagement openings  134 ,  136  are aligned with the protuberances  170 ,  172 . Therefore, the size and shape of the protuberances  170 ,  172  may be dictated by, among other things, the size and shape of the engagement openings  134 ,  136 . 
     Referring to  FIG. 9 , the protuberances  170 ,  172  may include a distal-most end  174 , and the distal-most end  174  may protrude inward a distance H from the associated side wall  140 ,  142  of the dispenser  102 . Those skilled in the art will appreciate that the distance H may be of a magnitude sufficient to allow the protuberances  170 ,  172  to pass through the respective engagement openings  134 ,  136  and restrict movement of one or more products  106 ′ within the container  104 , as shown in  FIG. 12 . Therefore, the distance H may be greater than the cross-sectional thickness of the material forming the side walls  122 ,  124  of the container  104 . As one example, the distance H may be at least 0.125 inches. As another example, the distance H may be at least 0.25 inches. As another example, the distance H may be at least 0.375 inches. As yet another example, the distance H may be at least 0.5 inches. 
     The protuberance  170  shown in  FIG. 9  may be formed as a curved bump on the side wall  140  of the dispenser  102 . The protuberance  170  may include a body  176 , which may be connected to the side wall  140  (e.g., with an adhesive) or which may be integral with the side wall  140  (i.e., the side wall  140  and the protuberance  170  may be formed as a single monolithic body). The body  176  of the protuberance  170  may include sloped regions  178 ,  180 . The first sloped region  178  may provide a gradual transition from the side wall  140  to the distal-most end  174  of the protuberance  170  in the rearward longitudinal direction (i.e., from the front end  150  toward the rear end  154  of the dispenser  102 ). The second sloped region  180  may provide a gradual transition from the distal-most end  174  of the protuberance  170  back to the side wall  140  in the rearward longitudinal direction. 
     Alternatively, the protuberances  170 ,  172  may be constructed as spring-loaded detents. 
     Referring to  FIG. 10 , in a first alternative aspect, a protuberance  170 ′ may include a detent  182 , such as a ball, and a biasing element  184 , such as a coil spring. The side wall  140  of the dispenser  102  may define a recess  186 , and the detent  182  and the biasing element  184  may be at least partially received in the recess  186 . The biasing force of the biasing element  184  may urge the detent  182  out of the recess  186  in the direction shown by arrow I. 
     Thus, as the container  104  is urged relative to the protuberance  170 ′, the side wall  124  ( FIG. 12 ) of the container  104  may urge the detent  182  into the recess  186  such that the protuberance  170 ′ does not obstruct movement of the container  104  relative to the dispenser  102 . However, once the engagement opening  136  ( FIG. 12 ) is aligned with the protuberance  170 ′, the biasing force of the biasing element  184  may urge the detent  182  through the engagement opening  136  and into engagement with the product  106 ′, thereby restricting movement of the product  106 ′ within the container  104 . 
     Referring to  FIG. 11 , in a second alternative aspect, a protuberance  170 ″, may include a detent  190 , such as a tab, and a biasing element  192 , such as a leaf spring. The first end  194  of the biasing element  192  may be connected to the side wall  140  and the second  196  of the biasing element  192  may be connected to the detent  190 . Therefore, the biasing element  192  may urge the detent  190  away from the side wall  140  in the direction shown by arrow J. 
     Thus, as the container  104  is urged relative to the protuberance  170 ″, the side wall  124  ( FIG. 12 ) of the container  104  may urge the detent  190  against the side wall  140  of the dispenser  102  such that the protuberance  170 ″ does not obstruct movement of the container  104  relative to the dispenser  102 . However, once the engagement opening  136  ( FIG. 12 ) is aligned with the protuberance  170 ″, the biasing force of the biasing element  192  may urge the detent  190  through the engagement opening  136  and into engagement with the product  106 ′, thereby restricting movement of the product  106 ′ within the container  104 . 
     At this point, those skilled in the art will appreciate that protuberances of various shapes and configurations may be used to pass through the engagement openings  134 ,  136  in the container  104  to restrict movement of one or more products  106 ′ within the container  104 . The protuberances  170 ,  170 ′,  170 ″ shown in  FIGS. 9-11  are only three specific, non-limiting examples. 
     Referring to  FIGS. 13 and 14 , the product dispensing system  100  may be assembled by positioning the container  104  onto the container support deck  144  of the dispenser  102  such that the access opening  132  of the container  104  is aligned with the dispenser opening  168  of the dispenser  102 . For example, the container  104  may be longitudinally urged toward the rear end  154  of the dispenser  102  along the container support deck  144  until the access opening  132  is aligned with the dispenser opening  168 . Optionally, as noted above, the access opening  132  may be formed during the step of longitudinally urging the container  104  along the container support deck  144  of the dispenser  102 . 
     As the container  104  is urged along the container support deck  144  of the dispenser  102 , the engagement openings  134 ,  136  in the container  104  may approximate the protuberances  170 ,  172  on the dispenser  102 . Once the engagement openings  134 ,  136  are aligned with the protuberances  170 ,  172 , the protuberances  170 ,  172  may protrude through the engagement openings  134 ,  136  and may engage the product(s)  106 ′ within the container  104  that are aligned with the engagement openings  134 ,  136 , as shown in  FIG. 12 . The through-container engagement between the protuberances  170 ,  172  and the product(s)  106 ′ may restrict rearward movement (i.e., movement toward the access opening  132 ) of the product(s)  106 ′, as well as the products  106  behind product(s)  106 ′, as shown in  FIG. 13 . 
     Thus, when the access opening  132  of the container  104  is aligned with the dispenser opening  168  of the dispenser  102 , the first two products  106 A,  106 B may exit the container  104  through the access opening  132  and may pass through the dispenser opening  168  down to the lower level  156  of the dispenser  102 , as shown in  FIG. 13 . Furthermore, with rearward movement of product(s)  106 ′ restricted, the weight of product(s)  106 ′ may not act on product  106 D. Therefore, as shown in  FIG. 14 , the weight of product  106 C acting on product  106 D may urge product  106 D in the direction shown by arrow A, thereby allowing product  106 C to pass between product  106 D and the rear wall  120  of the container  104  and, ultimately, pass through the access opening  132  down to the lower level  156  of the dispenser  102 . Once product  106 C has passed through the access opening  132 , the remaining products  106  (including products  106 D and  106 ′) in the container  10  may exit the container  104  without bridging. 
     Accordingly, the disclosed product dispensing system  100  may reduce or eliminate the occurrence of product bridging within the container  104  by facilitating through-container engagement between the  102  dispenser and the products  106  within the container  104  that at least temporarily restricts movement toward the access opening  132  of at least some of the products  106  within the container  104 . 
     Although various embodiments of the disclosed product dispensing system 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.