Patent Description:
The present disclosure generally relates to the automatic dispensing of a flowable food product, such as condiments, from a storage container or pouch. More specifically, the present disclosure relates to a sanitary, touch-free automatic flowable food product dispensing apparatus and method to use such apparatus.

Flowable food products can include a wide variety of products, such as condiments (i.e. ketchup, mustard, mayonnaise, tartar sauce, etc.), syrups, dressings, cheeses, fudge, caramel or other similar food products that can flow and thus be pumped. At many restaurants or other food service locations, flowable food products are dispensed utilizing a manual pump from a reservoir containing the food product. Such pumps typically include a flexible diaphragm pump mounted to a main body that includes an open interior sized to receive a supply of the food product to be dispensed. These dispensers typically rely upon the manual action of a handle or lever that must be depressed by the user to depress and release a flexible diaphragm of the diaphragm pump. The depression of the handle creates pressure onto the diaphragm which, upon release, creates a negative source of pressure to draw the food product from the open. An example of a dispenser known in the art is disclosed in <CIT>, which discloses a condiment dispensing apparatus for dispensing condiments from a bag-in-box type container. A further example of a dispensing apparatus with a pump is disclosed by <CIT>.

One problem with manual pumps is that the pump handle collects bacteria or viruses since multiple users touch the same pump handle during daily usage. Typically, the pump handle is not sanitized during use in a single day and is sanitized only at the end of a day or the beginning of the next day. For this reason, the pump handle provides a point for possible contamination from the multiple users.

The present disclosure utilizes a flexible diaphragm pump in combination with an automated pump actuator to eliminate the need for a manual pump handle.

The present disclosure relates to a touch-free flowable food product dispenser according to claim <NUM>. The touch-free food product dispenser includes a sensor that detects the presence of the hand of a user above a sensing area. Upon detection of the presence of the user, an automated pump actuation unit operates a pump assembly to dispense a volume of food product from the food product dispenser. The automated pump actuation unit is designed to be removable from the main body of the dispenser as a single unit, which allows for the conversion of mechanical food product dispensers that include a manual actuation handle to touch-free dispensers.

The flowable food product dispenser of the present disclosure is designed to be operable to selectively dispense a food product as desired by a user. The dispenser includes a main body that has an open interior sized to receive a supply of food product to be dispensed. The main body receives and supports a pump assembly. The pump assembly is a flexible diaphragm pump that is securely mounted to the main body. The pump assembly includes a first end in fluid communication with the supply of flowable food product and a second, dispensing end that extends from the main body.

The food product dispenser includes an automated pump actuation unit that is operable to actuate the pump assembly. When the automated pump actuation unit actuates the pump assembly, the food product is dispensed from the pump assembly. A sensor is positioned to detect the presence of an actuation member in proximity to the sensor but out of contact with the sensor. In one embodiment, the actuation member can be a hand of the user. When the sensor detects the presence of a hand of the user, the pump actuator automatically actuates the pump assembly. In this manner, the product dispenser can operate touch-free to dispense food product.

The automated pump actuation unit includes a removable cover member and the sensor can be mounted within the cover member. The automated pump actuation unit can include an electric drive motor within the cover member that is operable by a control unit to selectively depress and release a flexible diaphragm of the pump assembly. Both the drive motor and the control unit are contained within the cover member of the automated pump actuation unit to be removable from the main body as a single unit.

In one contemplated embodiment of the present disclosure, an automated actuation unit is designed for use with a food product dispenser that includes a main body having an open interior and a diaphragm pump supported by the main body. The automated pump actuation unit includes a cover member that is removably mounted to the main body. The automated pump actuation unit is mounted to the cover member and is removable from the main body with the cover member. The automated pump actuation unit is operable to selectively actuate the diaphragm pump when the diaphragm pump is supported by the main body and the cover member is mounted to the main body. The actuation unit can include a sensor positioned on the cover member and operable to detect the presence of a hand of a user in close proximity to the sensor but out of contact with the sensor. A control unit can be included in the cover member and is in communication with the sensor and the automated pump actuation unit. Upon detection of the presence of the hand of the user, the control unit operates the pump actuator to actuate the diaphragm pump to automatically dispense the flowable food product. The automated actuation unit is designed to replace manual pump components such that a manual pump dispenser can be converted into a touch-free dispenser.

Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.

The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:.

<FIG> illustrates a flowable food product dispenser <NUM> constructed in accordance with an exemplary embodiment of the present disclosure. Throughout the present disclosure, the term "flowable food product" or "food product" is meant to refer to a wide variety of products, such as condiments (i.e. ketchup, mustard, mayonnaise, tartar sauce, etc.), syrups, dressings, cheeses, fudge, caramel or other similar food products that can flow and thus be pumped. These condiments/food products are typically supplied with another food item or are applied to the food item by either the customer or a restaurant worker.

As can be seen in <FIG>, the food product dispenser <NUM> includes a dispensing spout <NUM> that extends away from a main body <NUM>. The dispensing spout <NUM> includes an outlet nozzle <NUM> that directs the food product onto the food item or into a condiment container. In the embodiment shown in <FIG>, the main body <NUM> receives an automated pump actuation unit <NUM> that sits on top of the main body <NUM> during use of the food product dispenser <NUM>. As shown in <FIG>, the automated pump actuation unit <NUM> is removable from the body <NUM> as a single unit, the significance of which will be described in detail below. The automated pump actuation unit <NUM> includes a touch-free, automated dispensing mechanism mounted within a cover member <NUM>, the details of which will also be described in greater detail below. Although the automated pump actuation unit <NUM> is shown mounted within the cover member <NUM>, other configurations are contemplated in which the automated dispensing mechanism could be mounted in other locations, such as within the main body <NUM>, and would not be removable with the cover member <NUM>.

The cover member <NUM> includes a front face panel <NUM>. The front face panel <NUM> includes a sensor window <NUM>. The sensor window <NUM> is typically a clear area that provides the ability for an internal sensor to detect the presence of an actuation member, such as the hand of a user is in close proximity to the sensor. The details of the sensor and control system that form part of the automated pump actuation unit <NUM> will be described in greater detail below. In the embodiment shown in <FIG>, the sensor window <NUM> is contained within a larger sensing area <NUM> that provides a visual indication to a user where the sensor is located.

In the embodiment shown in <FIG>, the main body <NUM> and the outer portions of the cover member <NUM> are formed from a durable material, such as stainless steel or durable plastic. Such material allows the main body <NUM> and cover member <NUM> to be cleaned and sanitized after periods of use. As shown in <FIG> and <FIG>, the back face <NUM> of the cover member <NUM> includes a power switch <NUM> and a connector <NUM> that secures the cover member <NUM> to the main body <NUM>.

<FIG> is a section view of the food product dispenser <NUM>. In the section view of <FIG>, the details of a pump assembly <NUM> are shown. In the illustrated exemplary embodiment, the pump assembly <NUM> is a standard flexible diaphragm pump that has been utilized to dispense food products utilizing a variety of manual pump based food product dispensers, such as those available from Server Products. Although a flexible diaphragm pump is shown in the figures of the present application, it is contemplated that other pump assemblies could be used while operating within the scope of the present disclosure.

The pump assembly <NUM> shown includes a hollow dispensing spout <NUM> that terminates at the nozzle <NUM>. The dispensing spout <NUM> extends into a pump body <NUM> that has an internal pumping chamber <NUM>. The pump assembly <NUM> further includes a pumping tube <NUM> that extends downward into the open interior <NUM> defined by the main body <NUM>. The open interior <NUM> defines a reservoir designed to receive the supply of food product to be dispensed. The food product to be dispensed can be contained in a sealed pouch (not shown) or can be directly poured into the open interior <NUM> as shown in <FIG>.

In the alternate embodiment shown in <FIG>, the pump tube <NUM> could include a pouch fitting <NUM> having a piercing end <NUM> that is designed to be received within a fitting of a condiment pouch (not shown). However, it is contemplated that the pouch fitting <NUM> could be removed and the pumping tube <NUM> could extend down into the supply of food product that is directly contained within the open interior <NUM> as shown in <FIG>.

In the embodiment shown in <FIG> and <FIG>, the main body <NUM> of the food product dispenser <NUM> includes an outer shell <NUM> that receives a removable liner <NUM>. The removable liner <NUM> creates the open interior <NUM> and can be removed from the outer shell <NUM> for cleaning. As shown in <FIG>, the liner <NUM> includes a sloped bottom wall <NUM> that is used to direct the supply of condiment toward the pumping tube <NUM>, whether the condiment is included in a bag or pouch or is directly received in the open interior <NUM>.

As illustrated in <FIG>, the pump assembly <NUM> is securely mounted to the main body <NUM> such that the pump assembly <NUM> is supported by the main body <NUM> independent from the cover member <NUM>. The pump assembly <NUM> includes a flexible diaphragm <NUM> that extends from the pump body <NUM>. In normal use, pressure on the flexible diaphragm <NUM> pushes the food product out of the spout <NUM> through a one-way discharge valve <NUM>. When pressure is removed from the flexible diaphragm <NUM>, the flexible diaphragm <NUM> expands and creates a negative source of pressure that draws food product through a second one-way inflow valve <NUM>. The operation of such a flexible diaphragm pump is well-known in the industry.

In accordance with the present disclosure, the manual pump handle typically used with a flexible diaphragm pump is replaced with a touch free, automated pump actuation unit <NUM>. The automated pump actuation unit <NUM> includes a mechanical actuator <NUM> and the cover member <NUM>, which are shown in an exploded view in <FIG>. In <FIG>, the mechanical actuator <NUM> is shown mounted to the interior of the cover member <NUM> such that the automated pump actuation unit <NUM> can be removed as a single unit from the main body <NUM> of the food product dispenser <NUM> as was shown in <FIG>. The mechanical actuator <NUM> operates to depress and release the diaphragm <NUM> such that the diaphragm acts in a known and conventional manner to pump food product from the food product dispenser. However, in accordance with the present disclosure, the mechanical actuator <NUM> operates in an automated fashion and eliminates any need for the customer or food service worker to touch a manual handle as in the prior systems.

Referring now to <FIG>, the cover member <NUM> includes an outer hood <NUM> and an inner hood <NUM> that are both formed from a metallic material, such as stainless steel. However, it is contemplated that the inner and outer hoods could be formed from another material that is easy to clean, such as plastic. The outer hood <NUM> includes the sloping front wall <NUM> that includes the sensing area <NUM> shown in <FIG>. As can be understood in <FIG> and <FIG>, a control board <NUM> is mounted to the inner surface <NUM> of the front wall <NUM>. The control board <NUM> includes a control unit <NUM>, such as a processor or CPU, along with a variety of other electronic operating components, including a sensor <NUM> that is designed to be aligned with the sensor window. In one embodiment of the present disclosure, the sensor <NUM> is a capacitive proximity sensor that can sense the presence of an actuation member, such as user's hand, within a sensing area <NUM>. In an exemplary embodiment, the sensor <NUM> creates the sensing area <NUM> in the shape of a sensing cone that extends above the front wall <NUM>. Whenever an actuation member, such as a hand or other body part of a user enters the sensing cone and remains in the sensing cone for a predetermined period of time, such as <NUM> second, the sensor <NUM> generates an output signal. In one embodiment, the sensing area <NUM> created by the sensor <NUM> extends between one inch and six inches above the front wall <NUM>. Further, although the sensor <NUM> is contemplated as being a capacitive sensor, other sensor types, such as an inductive sensor, photo sensor or magnetic sensor could be utilized to detect the presence of a user.

As shown in <FIG>, in addition to the sensor <NUM>, the control board <NUM> includes other operating components, such as a control unit <NUM> that may be comprised of an operating processor. The control board <NUM> can also include memory device <NUM> for storing operating instructions. The control board <NUM> could also include a wireless communication device <NUM> that would allow for wireless communication and monitoring of the food product dispenser from a near or remote location. For example, the remote monitoring would allow a foodservice company to monitor the amount of the food product that has been dispensed to predict when the dispenser would need to be refilled.

Referring back to <FIG>, the mechanical actuator <NUM> of the automated pump actuation unit <NUM> includes a support plate <NUM> that provides operative support for the components of the mechanical actuator <NUM> within the outer hood <NUM> of cover member <NUM> of the automated pump actuation unit <NUM>. The support plate <NUM> is securely attached to the hood <NUM> by a series of connectors <NUM>, as can be seen in <FIG>.

The support plate <NUM> includes a mounting block <NUM> that provides a point of connection for an electric drive motor <NUM>. The electric drive motor <NUM> includes an output drive shaft <NUM> that extends through the mounting block <NUM>. The electric drive motor <NUM> is connected to a power supply and controlled by operation of the control unit <NUM>. The power supply for driving the electric drive motor <NUM> can be either a connection to the utility power in the area near the food product dispenser or could be an internal battery power supply (not shown). The power supply could also include a specifically designed power supply designed to convert utility power to a desired voltage and current source for driving the electric drive motor <NUM> and the other components on the circuit board <NUM>.

The drive shaft <NUM> of the drive motor <NUM> can be connected to a cam <NUM> through the central attachment opening <NUM> formed in the cam <NUM>. The cam <NUM> includes an attachment point <NUM> that is spaced radially outward from the center of the cam <NUM>. The attachment point <NUM> provides a point of attachment for a first end <NUM> of a actuator arm <NUM>. The first end <NUM> of the actuator arm <NUM> is connected to first end <NUM> of the cam <NUM> through use of a pivot pin <NUM>.

As can be understood in <FIG> and <FIG>, when the cam <NUM> rotates as a result of rotation of the drive shaft <NUM> of the drive motor <NUM>, the offset connection of the actuator arm <NUM> to the cam <NUM> through the pivot pin <NUM> causes the outer, second end <NUM> of the actuator arm <NUM> to move both vertically and horizontally.

As can be seen in <FIG>, the outer end <NUM> of the actuator arm <NUM> receives and supports a roller <NUM>. The roller <NUM> is rotatably supported on the second outer end <NUM> of the actuator arm <NUM> by a pin <NUM>. The roller <NUM> is designed to move along the outer surface of the diaphragm <NUM> to compress the diaphragm <NUM>, as can be seen in <FIG>. Further rotation of the cam <NUM> moves the roller <NUM> away from the diaphragm <NUM> to release the diaphragm <NUM> as shown in <FIG>.

In addition to the actuator arm <NUM>, a wheel drive bracket arm <NUM> is also pivotally connected to help guide the movement of the roller <NUM> along the outer surface of the diaphragm <NUM>. A switch <NUM> and spacer <NUM> are used to sense the movement of the cam <NUM>, as is illustrated in the mounting arrangement of <FIG>. The switch <NUM> is in communication with the control unit <NUM> on the control board <NUM> to provide monitoring information to the control unit <NUM>.

During operation, as the cam <NUM> rotates, the roller <NUM> moves along the outer surface of the diaphragm <NUM> to compress the diaphragm <NUM> and cause food product to be dispensed into a container <NUM> or onto another food product through the nozzle <NUM>, as shown in <FIG>. Once the diaphragm <NUM> has been fully compressed by the roller <NUM>, further rotation of the cam <NUM> causes the roller to both retract away from the diaphragm and upward to the condition shown in <FIG>, thereby allowing the diaphragm <NUM> to create a negative source of pressure to draw additional food product into the pumping tube <NUM> in a conventional manner.

In an exemplary embodiment shown in <FIG>, a second sensor <NUM> can be included in the nozzle <NUM>. The second sensor <NUM> creates a second sensing cone <NUM> that is able to determine whether a condiment container <NUM> is within the sensing cone <NUM>. A control wire <NUM> leads back to the switch <NUM> such that the switch <NUM> will only activate the drive motor when the sensor <NUM> detects the presence of the condiment container <NUM>. The sensor <NUM> can be one of multiple different sensor types, such as an optical sensor or inductive sensor. Although the sensor <NUM> is shown in several of the drawing figures, the sensor <NUM> can be eliminated and only the single sensor <NUM> utilized to trigger operation of the automated pump actuation unit <NUM>. The second sensor <NUM> could be used to make sure that a container <NUM> or food product is located in a position to receive the food product before the food product is dispensed.

As can be understood by the above description, the use of the automated pump actuation unit <NUM> can replace a conventional manual pump lever. During operation, when the sensor <NUM> detects the presence of a hand <NUM> (<FIG>) within a sensing cone <NUM>, the control unit <NUM> operates the drive motor <NUM> to rotate the drive shaft <NUM> a predetermined number of times to dispense the desired amount of food product. The control unit <NUM> will terminate operation of the drive motor <NUM> once the desired amount of food product has been dispensed. If the user removes his/her hand, the control unit <NUM> will reset and will begin the pumping operation again upon detection of the presence of the operator's hand. It is understood that the control unit can be programmed in various different manners to control the amount of material dispensed and the timing of the dispensing upon detecting the presence of a hand. Further, it is contemplated that the pumping can stop or start depending upon the presence of the operator's hand or can be programmed to dispense a predetermined amount of material each time the user's hand is detected.

As can be understood in <FIG>, the entire automated pump actuation unit <NUM> can be removed from the main body <NUM> as a single unit. The automated pump actuation unit <NUM> is designed to engage the pump assembly <NUM> as the automated pump actuation unit <NUM> is placed on the top edge of the main body <NUM>. Since the entire pump actuator <NUM>, including the cover member <NUM>, mechanical actuator <NUM>, control unit <NUM> and sensor <NUM> are assembled as a single unit, the automated pump actuation unit <NUM> could be used to retrofit existing food product dispensers that include a mechanical actuation handle. In such retrofit application, the flexible diaphragm pump would remain installed on the main body and the existing cover member and mechanical actuation handle would be removed from the main body. Once removed, the automated pump actuation unit <NUM> would be attached to the top end of the main body such that the mechanical actuator <NUM> would come into contact with the flexible diaphragm of the flexible diaphragm pump.

Once installed on the main body <NUM>, the automated pump actuation unit <NUM> would operate as described above to depress and release the flexible diaphragm to pump food product out of the main body. The automated pump actuation unit <NUM> of the present disclosure allows for existing manual food products dispensers to be upgraded to a touch-free dispenser without having to replace the existing main body and flexible diaphragm pump. The automated pump actuation unit <NUM> is designed such that all of the operating components are removable as a single unit to facilitate the conversion of food product dispensers in this manner.

As indicated above, <FIG> is a schematic illustration of the components used to control the operation of the pump dispenser of the present disclosure. Many of the components shown in <FIG> are mounted to the control board contained within the cover member. As discussed above, the control unit <NUM> is operatively connected to many of the components to control the operation of the automated pump actuation unit. The control unit <NUM> is connected to the drive motor <NUM> such that the control unit <NUM> can control when and for how long the drive motor <NUM> operates. Since the operation of the drive motor <NUM> compresses and releases the diaphragm of the pump, the control unit <NUM> can control the amount of food product dispensed each time the hand of the user is detected. In one embodiment, the control unit <NUM> operates to dispense a defined volume of food product, such as <NUM> ounce, each time the hand of the user is detected. However, the owner/operator of the dispenser can change this amount depending upon the specific application.

In the embodiment shown in <FIG>, a wireless communication device <NUM> allows the user to communicate with the control unit <NUM> to set various operating parameter, such as the amount of food product dispensed upon detection of the hand of the user. The operating parameters can be stored in the memory device <NUM>. In addition to the amount of product dispensed, the control unit <NUM> can also control how long the hand of the user must be detected by the sensor <NUM> until the drive motor <NUM> is activated. For example, the control unit <NUM> can be programmed to active the drive motor <NUM> only when the hand has been continuously detected for one second. This parameter can also be modified by the user through communication to the control unit <NUM>.

In the contemplated alternate embodiment, the second sensor <NUM> detect whether a hand, condiment holder or food item is below the dispensing spout <NUM>. The second senor <NUM> is shown connected to the sensing switch <NUM>. The sensing switch <NUM>, in turn, is connected to both the control unit <NUM> and the drive motor. The sensing switch <NUM> allows the control unit <NUM> to monitor the operation of the drive motor <NUM> and prevents operation of the drive motor <NUM> when the second sensor <NUM> does not detect a hand, container or food item. As described previously, the second sensor <NUM> is optional and is not required for operation of the dispenser.

A cover detector switch <NUM> is positioned to detect when the cover member <NUM> is properly positioned on the main body of the dispenser. If the cover member is not properly installed, the control unit <NUM> will not allow the drive motor <NUM> to operate. The cover detector switch <NUM> is also shown in <FIG> and is mounted to a mounting plate <NUM> that extends perpendicular to the mounting plate <NUM>. The cover detector switch <NUM> includes a wheel <NUM> that retracts when the cover member <NUM> is mounted to the main body. Specifically, the wheel <NUM> contacts the upper flange <NUM> on the main body <NUM>, which is shown in <FIG>. When the cover member <NUM> is installed on the main body <NUM>, the front end of the cover member <NUM> is initially connected to the main body <NUM> and the cover member <NUM> pivots downward until the wheel <NUM> contacts the upper flange, causing the cover detector switch <NUM> to indicate attachment of the cover member <NUM> to the main body <NUM>.

Claim 1:
A flowable food product dispenser (<NUM>) operable to selectively dispense a food product as desired by a user, comprising:
a main body (<NUM>) having an open interior (<NUM>) sized to receive a supply of flowable food product to be dispensed;
a pump assembly (<NUM>) supported on the main body (<NUM>), the pump assembly including a first end in fluid communication with the supply of flowable food product and a dispensing end extending from the main body (<NUM>), wherein the pump assembly (<NUM>) includes a diaphragm pump comprising: a pumping tube (<NUM>) including the first end in fluid communication with the supply of flowable food product; a dispensing spout (<NUM>) extending from the main body (<NUM>) and including the dispensing end; and a pump body (<NUM>) positioned between the pumping tube (<NUM>) and the dispensing spout (<NUM>), the pump body (<NUM>) including a flexible diaphragm (<NUM>) that can be depressed and released to draw the flowable food product through the pump assembly (<NUM>);
an automated pump actuation unit (<NUM>) operable to actuate the pump assembly (<NUM>) to draw the supply of flowable food product from the supply and discharge the flowable food product from the dispensing end of the pump assembly (<NUM>);
a cover member (<NUM>) supported on the main body (<NUM>), wherein the automated pump actuation unit (<NUM>) is mounted to the cover member (<NUM>) such that the cover member (<NUM>) and the automated pump actuation unit (<NUM>) are removable from the main body (<NUM>) as a single unit; and
a sensor (<NUM>) positioned to detect the presence of an actuation member in proximity to the sensor (<NUM>),
wherein the automated pump actuation (<NUM>) unit is operable to automatically actuate the pump assembly (<NUM>) upon detection of the presence of the actuation member.