Abstract:
A trash bin having parts optimized for partial or full automated assembly. Components are fabricated of materials that are easily manipulated by factory automation equipment as well as those that may be selectively deformed during the assembly or installation process. Elastic or deformable characteristics also facilitate the retention of assembled or installed parts. A barbed element deforms during installation into a received aperture, then returns to a relaxed state in which one or more barbs inhibit the dislocation of the element from the aperture. A post having an aperture for receiving an axle therein is formed of resilient materials such that the post flexes outward under the urging of the axle until the axle is aligned with the aperture, at which point the post resumes a neutral position with the axle engaged in the aperture. Interfaces between components are selected in order to simplify the mechanical mating of components.

Description:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0001]    n/a 
       BACKGROUND OF THE INVENTION 
       [0002]    Traditional assembly methods for mechanically operative home goods, such as waste bins with mechanically operating lids, have typically involved a significant degree of manual intervention. This includes parts picking and transportation within a factory workspace, mating actuation mechanisms to substrates, and packaging finished products. 
         [0003]    During the 1970&#39;s and 1980&#39;s, when U.S. automobile manufacturers were not producing vehicles of consistently high quality, it was said that a consumer should avoid buying a car that was made on a Monday or Friday. Cars made on Mondays were said to be assembled by hungover workers, and those made on Fridays were said to be assembled by workers already concentrating on the coming weekend. Whether there was any legitimacy to that warning, it does reflect the reality that assembly by humans is inherently variable, particularly assembly line work. While repeated motions, such as inserting tab A into slot B, may lead to efficiency of motion, it can also lead to boredom, inattention, and repetitive motion injuries, all of which can vary the quality of the work performed by the worker. 
         [0004]    On the other hand, a properly programmed factory automation robot suffers none of the same drawbacks and instead performs the programmed tasks the same way, every time. Sensors can be employed to verify the proper functioning of the robot, and work can be ceased should a malfunction be detected, thus minimizing the risk that substandard work will be present in a finished product. 
         [0005]    However, even with advanced automated assembly tools and techniques, not every product can be assembled without human intervention. For example, a waste bin with a pedal operated lid in the prior art has required a human operator to properly align and install the components of the lid actuation mechanism, including the Z-wire, lifting rod, mating elements, etc. 
         [0006]    What is needed in the context of the manufacturing of home goods including waste bins is optimization for automated assembly. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    The presently disclosed invention includes a waste bin having parts optimized for partial or full automated assembly. Aspects of the invention include components fabricated of materials that are easily manipulated by factory automation equipment as well as those that may be selectively deformed during the assembly or installation process. Elastic or deformable characteristics also facilitate the retention of assembled or installed parts. 
         [0008]    For example, a barbed element may deform during installation into a received aperture, then may return to a relaxed state in which one or more barbs inhibit the dislocation of the element from the aperture. In another example, a post having an aperture for receiving an axle therein may be formed of resilient materials whereby the post may flex outward under the urging of the axle until the axle is aligned with the aperture, at which point the post resumes it&#39;s neutral position with the axle engaged therein. 
         [0009]    Interfaces between components are preferably selected in order to simplify the mechanical mating of components. Often, this results in one component being stationary on a first planar surface and a second component being brought into contact therewith in a direction orthogonal to the first component. In this manner, a maximum amount of vertical force can be applied to the mating of the components, an aspect helpful in overcoming resistance to deformation and/or friction. 
         [0010]    Certain subcomponents are preferably provided pre-assembled to simplify the final assembly process. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0011]    Embodiments of the present invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which: 
           [0012]      FIG. 1  is a perspective view of a first embodiment of a trash bin assembled according to automated methods, as disclosed herein; 
           [0013]      FIG. 2  is an exploded, perspective view of the trash bin of  FIG. 1 ; 
           [0014]      FIGS. 3A-3D  are perspective views of an underside of trash bin lid in an inverted orientation and an S hook for mating therein, for use in the trash bin of  FIG. 1 ; 
           [0015]      FIGS. 4A-4C  are perspective views of the underside of the trash bin lid of  FIGS. 4A-4D  along with a hinge assembly for mating therein; 
           [0016]      FIG. 5A  is a perspective view of a base assembly, lid assembly, and actuating assembly of the trash bin of  FIG. 1 ; 
           [0017]      FIG. 5B  is an exploded perspective view of the base assembly and elements of the actuating assembly of  FIG. 5A ; 
           [0018]      FIG. 6A  is a perspective view of the base assembly of  FIG. 5A  with a Z wire of the actuating assembly installed therein; 
           [0019]      FIG. 6B  is a perspective detail view of a retaining feature associated with the base assembly of  FIG. 6A  and one end of the Z wire thereabove; 
           [0020]      FIG. 6C  is a perspective detail view of the retaining feature of  FIG. 6B  with the Z wire entrained therein; 
           [0021]      FIG. 7A  is a perspective view of the base assembly of  FIG. 5A  with a pedal assembly installed thereon; 
           [0022]      FIG. 7B  is a perspective view of the base assembly of  FIG. 7A  with an exploded view of the pedal assembly; and 
           [0023]      FIG. 7C  is a perspective detail view of the pedal assembly of  FIGS. 7A and 7B . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0024]    A trash bin comprised of components optimized for automatic or semi-automatic assembly is disclosed. While one particular configuration is shown, the illustrated and described novel aspects may be embodied in various configurations. Thus, while the trash bin as shown in  FIG. 1  is oval, when viewed from above, it may alternatively be square, round, rectangular, etc. 
         [0025]    Major portions of the trash bin  10  as shown in  FIG. 1  include a base assembly  12 , a side wall portion  14 , and a lid assembly  16 . A pedal assembly  18  is shown projecting from the side wall portion proximate the base assembly. 
         [0026]    The various parts that collectively make up the pedal operated trash bin  10  are shown in  FIG. 2 . The base assembly  12  includes a base platform  20  and, preferably, resilient feet  22 . Such feet enable the trash bin to be moved across a hard floor surface such as wood or tile without scuffing or scratching the floor and may resist inadvertent lateral movement of the trash bin. 
         [0027]    The pedal assembly  18  comprises a decorative plate  30 , a pedal member  32 , a retaining plate  34 , and fasteners  36 . The fasteners, which may be provided as threaded members such as screws, pass through the retaining plate from below and project up through the lower surface of the pedal member and into the underside of the decorative plate, thereby holding the pedal assembly together. The decorative plate in one embodiment is fabricated of metal in order to provide a higher degree of wear resistance. Fabrication of the decorative plate is preferably via injection molding. 
         [0028]    The side wall portion  14  comprises an outer side wall enclosure  40 , a liner  42 , and a pedal frame  38 . The side wall portion may be provided of metal such as stainless steel for ease of cleaning, for strength, and for a pleasant appearance. The liner is preferable provided in plastic such as polyethylene for ease of cleaning, for weight reduction, and for providing a somewhat resilient material. An outwardly projecting flange portion  44  at an upper extent of the liner defines an opening  46  into the interior of the liner. The lower surface of the flange is dimensioned to rest on the upper peripheral edge of the enclosure such that the liner is suspended within the enclosure. The pedal frame  38  is preferably made from metal to inhibit wear from pedal movement therein and for providing a pleasant appearance. The pedal frame may be provided with resilient members (not shown) for enabling the pedal frame to be inserted into and retained within a respective aperture  48  on the lower end of the outer side wall enclosure. 
         [0029]    The lid assembly  16  is comprised of a lid portion  50 , at least one S clip  52 , and a hinge assembly  54 . As will be discussed further, the S clip is configured for interference fit with a receiving member on the underside of the lid portion. 
         [0030]    A hinge assembly  54  is comprised of a hinge body  60  attached to an upper end of the outer side wall enclosure  40 , on a rearwardly facing surface thereof, via fasteners  56  such as threaded members such as screws. The hinge body is also attached to a lower surface of the lid portion  50 , at a rearwardly facing end, via a horizontal axle  58  passing through the hinge body, as will be discussed in further detail below. The hinge assembly further comprises a buffer or piston  62  that enables gradual lowering of the lid assembly onto the upper extent of the side wall portion, thereby avoiding a loud noise as the lid assembly closes. 
         [0031]    Also shown in  FIG. 2  is an actuating assembly  70  that enables the opening and closing of the lid portion  50  via actuation of the pedal assembly  18 . The actuating assembly comprises a Z wire  72 , a wire hook  74 , and a shaft  76 . Preferably, at least the Z wire and shaft are metal for strength and resistance to deformation. 
         [0032]      FIGS. 3A-3D  illustrate the physical relationship between lid portion  50  and the S clip  52 . In  FIGS. 3A and 3B , the lid portion is shown in an inverted orientation such that the underside of the lid portion is facing up. The lid portion comprises a central cover  80  that may be planar or domed surrounded by a peripheral lip  82 . The lip normally projects downward from the cover when the lid portion is in a closed configuration, such as seen in  FIG. 1 . The lip is preferably dimensioned to fit on and about the flange portion  44  of the liner  42  in order to inhibit the escape of odors associated with waste disposed within the trash bin  10 . 
         [0033]    The S clip, best seen in  FIG. 3D , has an aperture  84  with an arcuate control surface  86 . An upper end  78  of the shaft  76  is normally disposed within the aperture. As the shaft is moved upwards by operation of the pedal assembly, the upper end travels along the control surface as the lid assembly swings towards an open configuration about the axle  58 . The S clip is also provided with two opposing legs  88 , each having a respective barb  90  formed thereon. Each barb has a substantially horizontal upper surface and an inclined side surface extending from the upper surface to the respective leg outer surface. A region of reduced thickness  92  may be provided at a distal end of each leg to facilitate installation of the S clip within a receiving slot  94 , shown in section in  FIG. 3C . The receiving slot is integrally formed on a readwardly facing hinge cover  96  of the lid assembly  16  and comprises two mutually parallel vertical side walls  95  (only one of which is shown in  FIG. 3C ) for laterally supporting an S clip installed within the slot. The slot and legs are preferably sufficiently long such that the S clip, when disposed within the slot, resists lateral movement when under force of the actuating assembly  70 . Each barb projects outwardly from the respective leg and into a respective aperture  97  in one of two mutually parallel slot end walls  99 , thus enabling the S clip to resist being inadvertently removed from the slot. The S clip is preferably formed of plastic whereby the legs are capable of deformation towards each other as the S clip is inserted into the slot and as the barbs interact with the inside surface of the end walls. Once the barbs are inserted far enough into the slot, each projects into the respective aperture as the legs resume a neutral shape. Simultaneously, the region of reduced thickness of each leg may be entrained within a respective receptacle  101  at the base of the slot. The receptacles serve to maintain the S clip legs in a substantially vertical orientation once fully installed into the slot, thereby resisting deformation that would otherwise facilitate removal of the barbs from the respective apertures. 
         [0034]    Also disposed on the underside of the hinge cover  96  are axle mounts  98 , one of which is visible in  FIG. 3C . Each axle mount includes a laterally oriented aperture  100 , and an inclined surface  102  proximate the aperture. The mount is shown disposed on the hinge cover via two legs  104 , though a variety of configurations for the mount attachment are contemplated. The aperture has a diameter that is slightly greater than that of the axle  58 . The lid assembly  16  is installed on the hinge assembly  54  by forcing the axle end to travel against the inclined surface, thereby causing the inclined surface to deform outward until the axle end is received within the aperture, at which point the mount returns to its rest position, entraining the axle therein. Preferably, the lid assembly is installed on the hinge assembly via a robotic manipulator (not shown). 
         [0035]    In  FIG. 4A , the hinge assembly  54 , including the axle  58 , is illustrated in over the mounts  98  on the inverted lid portion  50 . In one embodiment, the axle is iron and is insert or injection molded in the hinge body at the time the hinge body is formed. In  FIG. 4B , the hinge body  60  of the hinge assembly is shown in an installed position on the lid portion in which the axle ends have been entrained within the respective mount. In  FIG. 4C , the hinge body and axle is vertically aligned for installation into the mounts. 
         [0036]    In  FIGS. 5A and 5B , the lid assembly  16 , actuating assembly  70 , base assembly  12 , and pedal assembly  18  are shown in an assembled configuration. Essentially, the view of  FIG. 5A  includes all components of the presently disclosed trash bin except the side wall portion  14 . In  FIG. 5B , the base platform  20  is shown proximate the Z wire  72 , wire hook  74  and a lower end  114  of the shaft  76 . The lower end of the shaft is substantially orthogonal to the vertical main portion of the shaft and is configured to be received within a socket  122  at one end of the wire hook. As the wire hook is raised and lowered in response to actuation of the pedal assembly, an outer surface of the lower end of the shaft is simultaneously raised and lowered and is free to rotate relative to the socket. A notch  116  is formed in the socket wall to prevent the shaft from interfering with the socket wall as it rotates about the shaft lower end. At the other end of the wire hook, a wire hook sleeve  120  is provided for receiving a first end  118  of the Z wire. Preferably, both the wire hook sleeve and the first end of the Z wire have complimentary cross-sections and are fixed together in order to inhibit relative motion therebetween. Such fixation may be friction fit. 
         [0037]    In  FIG. 6A , the Z wire  72  and wire hook  74  are shown in an installed configuration with respect to the base platform  20  and the pedal assembly  18 . In  FIG. 6B , the first end  118  of the Z wire is shown proximate retaining tabs  130 A,  130 B formed on the base platform. The retaining tabs are flexible and are capable of being laterally deflected in order to receive the Z wire therebetween. While in one embodiment the retaining tabs are identical, the illustrated pairs of dissimilar tabs is preferred. Specifically, one retaining tab  130 A of each pair is essentially a vertical post, while the other retaining tab  130 B of each pair is a vertical post having a horizontally projecting member  132  that projects towards the opposite retaining member. The latter retaining tab is essentially L-shaped when viewed from the side. Thus, the installed Z wire is retained between the two retaining tabs  130 A,  130 B of each pair and underneath the projecting member  132  of one retaining tab  130 B of each pair. 
         [0038]    There are two pairs of retaining tabs  130 A,  130 B on the base platform  20 , aligned such that the Z wire  72  passes through both, as shown in  FIGS. 6B and 6C . Importantly, the retaining tab  130 B having the projecting member  132  of one pair is on the opposite side of the installed Z wire from the retaining tab having the projecting member of the other pair. With this configuration, there is a reduced likelihood that the Z wire may be inadvertently freed from the grip of the retaining tabs as compared to a configuration in which the retaining tabs having the projecting member are on the same side of the Z wire. 
         [0039]    Also shown in  FIG. 6B  are bearing surfaces  134  on either side of the pairs of retaining tabs  130 A,  130 B. The Z wire  72 , when disposed within the retaining tabs, rests on the upper surface of the bearing surfaces and is free to rotate thereon. An additional bearing surface  134  is visible in  FIG. 6C , proximate the first end  118  of the Z wire. Also proximate the first end of the Z wire and projecting up from the base platform  20  is a vertical post  136  that serves to inhibit lateral movement of the respective end of the Z wire. 
         [0040]    With regard to  FIGS. 7B and 7C , the pedal assembly  18  is configured to selectively rotate about a lateral axle  150  when mounted on the base platform  20  via pedal axle receiving posts  136 . These posts are similar to the axle mounts  98  employed to join the lid assembly  16  with the hinge assembly  54 . Specifically, each post preferably includes an inclined surface  142  proximate a laterally oriented aperture  144  configured to receive the axle associated with the pedal assembly. The inclined surface of each post deflects outwardly as a horizontal axle end is moved vertically with respect to the post until the end is aligned with the respective aperture, at which point the post resumes its neutral shape and the axle end is entrained within the respective aperture. 
         [0041]    The second end  110  of the Z wire  72  is orthogonal to the central portion of the Z wire and angled slightly out of the plane defined by the Z wire first end  118  and the Z wire central portion, as shown in  FIG. 5B . A distal portion of the Z wire second end is angled back towards the plane defined by the Z wire first end and the Z wire central portion, thereby forming an upwardly projecting knuckle  140 . The knuckle rests against a lower surface of the pedal retaining plate  34 . When the lid assembly  16  is in a closed configuration, the upper end  78  of the shaft  76  is in a lowered position within the S hook  52 . This also means the second end  114  of the shaft rests within the wire hook  74 . The second end  110  of the Z wire is then in an elevated position with the knuckle  140  adjacent and preferably in contact with the retaining plate. The pedal assembly  18  is substantially horizontal. 
         [0042]      FIG. 7A  illustrates a pedal assembly  18  installed on the base platform  20 . In  FIG. 7B , the major components of the pedal assembly include the decorative plate  30 , pedal member  32 , and retaining plate  34 , all of which are joined together through the use of fasteners such as screws  36  ( FIG. 2 ). The receiving posts  136  are also shown, including inclined surfaces  142  and receiving apertures  144 .  FIG. 7C  provides a close-up view of the installed pedal assembly. Also visible is another bearing surface that supports the Z wire  72  from beneath. 
         [0043]    In operation, when a user presses down on the pedal assembly  18  with their foot, the pedal assembly rotates downward about the respective horizontal axle. This pushes down on the knuckle  140  on the second end  110  of the Z wire. As a result, the central portion of the Z wire rotates about its axis, within the retaining tabs  130 A,  130 B and on the bearing surfaces  134 . Rotation of the Z wire causes the first end  118  to rise, which causes the wire hook  74  to rise. This elevates the shaft  76 , which pushes up on the lid assembly via the S hook  52  as the shaft first end  78  travels along the arcuate control surface of the S hook. As the lid assembly opens via rotation about the horizontal hinge assembly axle  58 , the piston  62  extends in the absence of downward pressure applied by the weight of the lid assembly. When the user removes downward pressure from the pedal assembly, the weight of the lid assembly bears on the piston, which gradually compresses, and the lid assembly gradually closes. The upper end  78  of the shaft  76  travels down the control surface of the S hook. The wire hook is urged downward by the lowering shaft, thereby rotating the Z wire such that the knuckle  140  is elevated and the pedal assembly is again urged into a horizontal orientation. 
         [0044]    Preferably, the majority, if not all, of the components of the presently disclosed invention are assembled through automatic assembly processes, such as through the use of robots along a conveyorized assembly line. The S hook  52  is configured for vertical installation into the inverted lid portion  50  and for retention therein without the use of discrete fasteners; direct vertical movement is easily accomplished by robotic assembly mechanisms. Similarly, the hinge assembly  60  is easily inserted into the lid portion  50  through downward vertical pressure, and retention is accomplished as the result of momentary deformation and relaxation of axle mounts  98 . Installation of the hinge assembly onto the side wall portion  14  is via a plurality of fasteners, such as screws  56 . 
         [0045]    In a similar manner, the actuating assembly  70  is provided in materials and in physical shapes that facilitate simple, automated assembly. The upper end  78  of the shaft  76  is disposed within the S hook  52  through a simple lateral movement. The opposite, lower end  114  of the shaft is simply vertically inserted into the wire hook  74  socket  122 . The Z wire first end  118  fits into the wire hook sleeve  120  through friction fit, without the use of discrete fasteners, thus simplifying assembly. 
         [0046]    As described above, the Z wire  72  is installed on the base platform  20  by downward pressure against retaining tabs  130 A and  130 B. At least one tab of each pair deforms under the pressure applied by the Z wire, then relaxes, thereby retaining the Z wire between the pairs of retaining tabs and on bearing surfaces  134 . 
         [0047]    The components of the pedal assembly  18  are mutually joined together through the use of fasteners such as screws  36  prior to installation of the assembly into the pedal axle receiving posts  136  on the base platform  20  in a manner similar to installation of the hinge assembly  54  into the lid portion  20 , as described above. That is, the receiving posts are deformed outward as the pedal assembly axle  150  is pressed downward by robotic means. 
         [0048]    In one embodiment, assembly of the presently disclosed trash bin includes robotic pre-assembly of the pedal assembly through joining the decorative plate  30 , pedal member  32 , and retaining plate  34  using threaded fasteners  36 . Resilient feet are installed onto an underside of the base platform  20 . 
         [0049]    Other automated devices insert the first end of the Z wire  118  into the wire hook sleeve  120 , then drive that assembly down between the pairs of retaining tabs  130 A,  130 B and onto the bearing surfaces  134  on the base platform  20 . The pedal assembly  18  is then driven down onto the vertical posts  136  projecting upwards from the base platform through the use of a robotic manipulator, the ends of the pedal assembly axle  150  coming into contact with the inclined surfaces  142  and causing them to deflect outward under the downward force. Eventually, the ends are received within the apertures  144  and the posts resume a neutral stance. 
         [0050]    In an exemplary embodiment, the lid portion  50 , including the hinge cover  96 , is inverted so that the axle mounts  98  and the receiving slot  94  are directed upwards. This enables an automated manipulator to grasp an S clip  52  and direct the distal ends  92  of the two legs vertically, down into the receiving slot. The barbs  90  interact with the interior surface of the two end walls  99  and cause the legs to deform inwardly. Further forcing the reduced thickness distal ends into respective receptacles  101  brings the barbs into alignment with respective side wall apertures  97 . The substantially horizontal upper surface and the inclined side surfaces of the barbs then project outwardly into the apertures and the S clip legs relax into a substantially vertical neutral position, with the S clip firmly entrained within the receiving slot. 
         [0051]    The hinge body  60  with piston  62  and substantially horizontal axle  58  is then forced down onto the axle mounts  98 , in a fashion similar to that of the pedal assembly axle  150 , whereby the axle ends come into contact with inclined surfaces and deflect the axle mounts outward until the axle ends are received within the respective apertures. The lid assembly with hinge body may then be inverted and attached to the side wall portion  40  via fasteners  56 . 
         [0052]    The shaft  76  first end  114  is disposed within the wire hook socket  122  via a robotic actuator. The pedal frame  38  is pressed onto the outer side wall enclosure  40 , and the side wall portion  14  is lowered over the pedal assembly  18  so that the latter projects through the frame, with the shaft projecting upwards within the enclosure. The enclosure is then mated with the base platform  20 , such as through mechanically interfering clips or other mechanical means. The shaft second end  78  is disposed within the S clip opening, proximate the arcuate control surface  86 . The liner  42  is installed into the enclosure. Assembly is complete. 
         [0053]    Many changes in the details, materials, and arrangement of parts and steps, herein described and illustrated, can be made by those skilled in the art in light of teachings contained hereinabove. Accordingly, it will be understood that the following claims are not to be limited to the embodiments disclosed herein and can include practices other than those specifically described, and are to be interpreted as broadly as allowed under the law.