Intelligent Cabinet

Abstract

An intelligent cabinet for dispensing products contained therein that includes an outer wall, an inner liner defining an enclosed interior space adapted for housing an inventory of items, an intermediate layer provided between the outer wall and inner liner, and having a plurality of slots, and a system of modular cassettes including a plurality of cassettes where each cassette is adapted to be fittingly received in and removable from a corresponding slot from the plurality of slots, and a plurality of RFID antennas, where each RFID antennas is separately housed in one of the cassettes from among the plurality of cassettes

Claims

1. An intelligent cabinet for dispensing products contained therein, the intelligent cabinet comprising: an outer wall, an inner liner defining an enclosed interior space adapted for housing an inventory of items, the outer wall and inner liner being spaced apart by an intermediate layer provided therebetween and having a plurality of slots, and a system of modular cassettes comprising a plurality of cassettes, wherein each cassette is adapted to be fittingly received in and removable from a corresponding slot from the plurality of slots, and a plurality of RFID antennas, where each RFID antenna is separately housed in one of the cassettes from among the plurality of cassettes.

2. The intelligent cabinet according to claim 2, wherein the intelligent cabinet has a front side and a back side, where the inventory of items are accessible from the front side and the plurality of cassettes are accessible from the back side.

3. The intelligent cabinet according to claim 1 or claim 2, further comprising a main cassette containing an RFID reader.

4. The intelligent cabinet according to claim 3, wherein the main cassette is affixed to the back side of the intelligent cabinet, preferably in a central region of the intelligent cabinet.

5. The intelligent cabinet according to any of the preceding claims, wherein each cassette of the plurality of cassettes comprises at least one through hole dimensioned to accommodate an RFID antenna cable.

6. The intelligent cabinet according to any of the preceding claims, wherein each cassette is made of metal, preferably stainless steel.

7. The intelligent cabinet according to claim 6, wherein the stainless steel has a thickness of between 0.3 mm and 0.7 mm, preferably about 0.5 mm.

8. The intelligent cabinet according to any of the preceding claims, wherein the cassettes are positioned in the slots such that a space between the RFID antennas and the enclosed interior space is 2 cm or less, preferably about 1 cm.

9. The intelligent cabinet according to any of the preceding claims, wherein the intermediate layer comprises foam, preferably a high density foam that comprises cyclopentane.

10. The intelligent cabinet according to any of the preceding claims, wherein the intermediate layer is an insulation layer.

11. The intelligent cabinet according to any of the preceding claims, wherein additional foam insulation is provided in one or more of the plurality of cassettes, the additional foam being disposed adjacent to the RFID antenna in the cassette.

12. The intelligent cabinet according to any of the preceding claims, wherein the intelligent cabinet has opposing left and right sides, and the plurality of cassettes are preferably evenly divided such that the number of cassettes positioned on the left side is equal to the number of cassettes positioned on the right side.

13. The intelligent cabinet according to any of the preceding claims, wherein the plurality of cassettes comprises at least 8 cassettes.

14. The intelligent cabinet according to any of the preceding claims, wherein the plurality of cassettes comprises around 50% or less but more than 10%, preferably 25-50%, or more preferably around 35% of a total surface area of the intermediate layer.

15. The intelligent cabinet according to claim 14, wherein additional foam is provided in the plurality of cassettes to offset a reduction in a total volume of the intermediate layer, preferably when the intermediate layer is an insulation layer, so that the reduction in total volume of the intermediate layer is less than 20%, preferably less than 12%.

16. The intelligent cabinet according to any of the preceding claims, wherein the plurality of cassettes further comprises a first additional cassette positioned at a top end of the back side of the intelligent cabinet and/or a second additional cassette positioned at a bottom end of the back side of the intelligent cabinet, the first and second additional cassettes preferably being positioned in a central portion of the respective top and bottom ends of the back side of the intelligent cabinet.

17. The intelligent cabinet according to claim 16, wherein the first additional cassette, the second additional cassette, and the main cassette are positioned along a central longitudinal axis (Y) of the intelligent cabinet.

18. The intelligent cabinet according to any of the preceding claims, wherein the intelligent cabinet comprises a temperature controlled environment.

19. The intelligent cabinet according to claim 18, wherein the temperature controlled environment is one of a refrigerator, a freezer, or a heated cabinet.

20. The intelligent cabinet according to any of the preceding claims, wherein the intermediate layer further comprises a corrugated layer.

21. The intelligent cabinet according to claim 20, wherein the corrugated layers is a thin metal material, preferably stainless steel with a thickness of between 0.3 mm and 0.7 mm, preferably about 0.5 mm.

22. The intelligent cabinet according to any of the preceding claims, wherein the inner liner is formed of a material that provides a low shielding effect for the RFID field.

23. The intelligent cabinet according to any of the preceding claims, wherein the inner liner comprises a plastic material, preferably a high impact polystyrene.

24. The intelligent cabinet according to any of the preceding claims, wherein the outer wall comprises a metal material.

25. The intelligent cabinet according to any of the preceding claims, wherein one or more of the plurality of RFID antennas are circular polarized antennas.

26. The intelligent cabinet according to any of the preceding claims, wherein one or more of the plurality of RFID antennas are high gain antennas.

27. The intelligent cabinet according to any of the preceding claims, wherein the RFID reader is monostatic or bistatic.

28. The intelligent cabinet according to any of the preceding claims, wherein at least one of the plurality of cassettes comprises an RFID antenna and/or one or more additional sensors.

29. The intelligent cabinet according to claim 28, wherein the one or more additional sensor is a temperature sensor, pressure sensor, humidity sensor, an optical sensor, a camera, a light sensor, a laser, a motion sensor, a UV-c light, a radar sensor, an ultrasonic sensor, an audio sensor, one or more speakers, and/or a beamer.

30. A cassette for installation in an intelligent cabinet according to any of claims 1-29, comprising a front side, a back side, a top side, and a bottom side, the sides being connected by a wall forming a closed perimeter around a body of the cassette and forming an interior space, the interior space being adapted to receive an RFID antenna and/or an additional sensor, wherein the top side, bottom side, back side, and wall are formed of a metal, preferably stainless steel, the front side is at least partially open or formed from a material adapted to permit RF signals to be transmitted from and received into the interior space, and during use, the cassette is oriented such that the front side faces the inner liner and the back side faces the outer wall.

31. The cassette according to claim 30, further comprising at least one through hole dimensioned to accommodate an RFID antenna cable.

32. The cassette according to claim 30 or claim 31, further comprising a quantity of insulating foam in the interior space.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The present invention will be discussed in more detail below, with reference to the attached drawings, in which:

[0050] FIG. 1 shows a back view of an exemplary intelligent cabinet and cassette.

[0051] FIG. 2 shows a front side view of an interior of an exemplary intelligent cabinet.

[0052] FIG. 3 shows an exploded cross-sectional view of one wall of an exemplary intelligent cabinet.

[0053] FIGS. 4A and 4B show front and back views of an exemplary corrugated layer.

[0054] FIGS. 5A and 5B show cross-sectional views of a wall of an exemplary intelligent cabinet.

[0055] FIG. 6 is a front view of an exemplary cassette.

[0056] FIG. 7 is a front view of another exemplary cassette.

[0057] FIG. 8 is a cross-sectional view of the exemplary cassette of FIG. 7 taken along the line ‘x’.

DESCRIPTION OF EMBODIMENTS

[0058] The FIGS. 1 and 2 show an embodiment of an intelligent cabinet 100 according to the present disclosure. The intelligent cabinet 100 includes an outer wall 110, an intermediate layer 120, and an inner liner 130. Depending on the type of intelligent cabinet, e.g., one having a temperature controlled environment, such as a freezer, a refrigerator, or a heated cabinet, the materials used for forming the outer wall 110 may vary. In the present non-limiting example, the intelligent cabinet is a refrigerator-type cabinet in which the outer wall is formed from a metallic material, such as a sheet metal, and is preferably stainless steel. The sheet metal may be relatively thin, with a preferred thickness of about 0.5 mm.

[0059] The inner liner 130 defines an enclosed interior space (not shown in FIG. 1) that is adapted to house an inventory of items that may or may not be dispensed for vending. The front side of the intelligent cabinet has a door that is preferably hingedly or slidably connected to a side of the cabinet and is configured to provide access to the enclosed interior space. Like the outer wall 110, the material used for forming the inner liner 130 may vary depending on the type of intelligent cabinet. Materials that have a low shielding effect on the RFID field are desirable because they generally have minimal to no impact on the transmission and receipt of RF signals through the inner cabinet. In one non-limiting example, the intelligent cabinet is a refrigerator-type cabinet in which the inner liner is formed from a plastic material. Polystyrene plastic is one particular example of a plastic that may be used for forming the inner cabinet. Even more specifically, extruded impact modified polystyrene is an example of a preferred plastic. Plastic may be particularly beneficial for forming the inner liners of the intelligent cabinets of the present disclosure because plastic permits the RFID signals to pass, in contrast with metallic materials that may reflect the RFID signals. Though plastic may be preferred in forming the inner cabinet in some exemplary intelligent cabinets, it is further conceivable that other materials, such as sheet metal, may also be used.

[0060] An exploded cross-section of the layers of one wall of an exemplary intelligent cabinet can be seen in FIG. 3. It will be understood that a cabinet may be built of individual walls or panels or may be moulded as a whole. Merely for the sake of simplicity, the present description of FIG. 3 is directed to an individual wall. Shown at the left, inner liner 130 is adjacent to the enclosed interior space adapted to house an inventory of products. The inner liner 130 is fitted over the front side 122a of the corrugated wall 122 which comprises the plurality of slots 140 into which corresponding cassettes 150 may be fittingly received. An exemplary corrugated wall 122 is shown in FIGS. 4A and 4B. A foam layer 124 is disposed adjacent to the back side 122b of the corrugated layer 122 and preferably forms an airtight seal therewith. The intermediate layer 120 preferably comprises a foam material and may be formed by injecting hot liquid foam against the back side of the corrugated layer during manufacture of the intelligent cabinet. The hot liquid foam will expand and set to form an airtight seal with the corrugated layer. Lastly, outer wall 110 covers the foam layer 124 and forms the exterior surface of the intelligent cabinet. It is preferable that the RFID field is not extended beyond the outer wall 110. As such, the outer wall is preferably formed of a material that may limit and/or reflect the RFID signals towards an interior of the intelligent cabinet.

[0061] FIGS. 5A and 5B also show other cross-sectional views of one wall of an exemplary intelligent cabinet. Again, though a cabinet may be built of individual walls or panels or may be moulded as a whole, for the sake of simplicity, the description of FIGS. 5A and 5B is directed to an individual wall of an exemplary cabinet. FIG. 5A shows one wall of an intelligent cabinet without the outer wall 110. In the illustrated embodiment, the inner liner 130, preferably formed of a plastic material, is fit over the corrugated layer 122. Cassettes (not shown) may be inserted into slots 140 formed in the corrugated layer 122 and are preferably separated from the enclosed interior space of the intelligent cabinet only by the inner liner 130. Further, the foam layer 124 is provided adjacent to the back side of the corrugated layer. In this regard, the foam layer will not come into direct contact with the cassettes housed in slots 140 in the front side of the corrugated layer or with the inner liner 130. FIG. 5B shows a cross-section of a completed wall of an exemplary intelligent cabinet. Again, inner liner 130 is fit over corrugated layer 122, which carries the slots 140 for the cassettes (not shown). However, in FIG. 5B, outer wall 110 is disposed over the foam layer 124 (not shown) to form the exterior surface of the intelligent cabinet. In this regard, the exposed portion of the foam layer 124, as seen in FIG. 5A, is now entirely covered by the outer wall 110.

[0062] The number and size of the slots formed in the intermediate layer are subject to vary depending on the type, size, and shape of the intelligent cabinet to be provided. In other words, the number and size of the slots is freely customizable. In one non-limiting example, the plurality of cassettes comprises 50% or less of the total surface area of the intermediate layer. In other embodiments, the plurality of cassettes comprise 25-50%, preferably 35%, of the total surface area of the intermediate layer.

[0063] The quantity and type of inventory of the intelligent cabinet may also impact the number and size of slots. In one non-limiting example, four slots are provided on each of the left and right sides of the intelligent cabinet. This configuration is shown in FIG. 1. Although the number of slots is evenly divided between the left and right sides of the intelligent cabinet in one preferred embodiment, any combination of slots is conceivable.

[0064] Cassettes 150 are provided to precisely correspond with a respective slot 140 in the intermediate layer such that when the cassette is inserted into the slot it is fittingly received in an airtight engagement with the slot. In some embodiments, it is particularly desirable for the cassettes to form an airtight seal when inserted into a slot so that a reduction in the insulating properties of intermediate layer is minimized or avoided.

[0065] In terms of positioning within the intermediate layer, it is desirable for the transmission and reception of RF signals between the cassettes and the enclosed interior space that the distance between the slots and the enclosed interior space be minimized. Both the signal quality and the insulating capacity are considerations for determining an appropriate spacing. For example, placing the cassette at a greater distance may be beneficial for the RF signal, but it also means there will be less space for insulating material. In a non-limiting embodiment, the slots are formed in the intermediate layer so that a space between the RFID antennas and the enclosed interior space does not exceed 2 cm, and more preferably not greater than 1 cm.

[0066] FIG. 6 shows an exemplary cassette 650. The cassette has a front side 651, a back side 652, a top side 653, and a bottom side 654. The sides are connected by a wall 655 that forms a closed perimeter around a body of the cassette. An interior space 656 is formed by the closed perimeter. The interior space of the cassette is adapted to accommodate sensing equipment, such as an RFID antenna 660 and/or one or more sensors. The cassettes may be dimensioned to contain a single RFID antenna, one or more sensors, such as a temperature, pressure and/or humidity sensors, or both the RFID antenna and/or one or more sensors. In the illustrated embodiment, a through hole 657 is provided in the wall of the cassette. An RFID antenna cable (not shown) may be fed through the through hole for connection to the RFID reader. Depending on the size of the cassettes, an additional amount of insulation may be added to the cassette on adjacent sides of the RFID antenna and/or one or more sensors contained therein. When provided, the additional insulation should be situated such that it does not interfere with and/or obscure a portion of the RFID antenna and/or one or more sensors.

[0067] FIG. 7 shows another exemplary cassette 650. In the illustrated embodiment, the front side includes foam 6511. The foam is disposed in the interior of the cassette between the front side and the back side. The foam preferably surrounds the RFID antenna 660, but does not obscure any portion thereof on the front-facing side of the RFID antenna which is adjacent to the inner liner. A cable groove 6512 may be provided in the foam to streamline and/or guide the connection of the RFID antenna cable from the RFID antenna through the through hole 657. A cross-section of cassette 650 taken along the line ‘x’ of FIG. 7 can be seen in FIG. 8. The cassette 650 has the same features as the cassettes of FIGS. 6 and 7, including but not limited to, front side 651, back side 652, RFID antenna 660, and cable groove 6512, and additional insulation, which may comprise a foam material 6511, is shown in the interior space of the cassettes.

[0068] In one non-limiting example, the wall, the back side, the top and the bottom side of the cassettes are formed from a metallic material. Metallic materials, such as stainless steel, are particularly desirable for forming these portions of the cassettes because they will reflect RFID signal(s). In this regard, an RF signal may pass from the enclosed interior space through the front side of the cassette and to the RFID antenna. If the RF signal continues to pass through the interior space of the cassette until it reaches the back side of the cassette, it will be reflected back toward the interior space of the cassette once it contacts the back side.

[0069] The structure of and/or material used to form the cassette may also have an impact on the transmission and receipt of RF signals to and from the cassettes. Additionally for exemplary intelligent cabinets where the intermediate layer is an insulation layer, the thickness of the cassettes may have an impact on the level of insulation. Specifically, the thicker the cassette, the less insulating material there is in the insulating layer. Conversely, the thinner the cassette, the more insulating material there is in the insulating layer. In some embodiments, cassettes formed of stainless steel with a thickness of 0.5 mm is found to be particularly preferable for balancing the level of reflectiveness of the RF signals and reduction of material from the insulating layer.

[0070] In some embodiments, additional cassettes 170, 180 may also be provided along the top and bottom ends of the back side of the intelligent cabinet. The additional cassettes may be provided in a central portion of the respective top and bottom ends and positioned along a central longitudinal axis (Y) of the intelligent cabinet. The additional cassettes may be dimensioned similarly to the cassettes of the plurality of cassettes that are received in the plurality of slots formed in the intermediate layer and are similarly adapted to house RFID equipment and/or one or more sensors. When the additional cassettes are provided in the top and/or bottom ends of the intelligent cabinet, respective slots adapted to fittingly receive the additional cassettes may be provided in an intermediate layer, which may comprises a corrugated layer, of the top and/or bottom ends of the intelligent in the same manner as the plurality of slots previously described above.

[0071] A main cassette 160 is also provided at the back of the intelligent cabinet. The main cassette is arranged to contain an RFID reader that transits and receives signals from the RFID antennas. The main cassette may be mounted on or affixed to the back of the intelligent cabinet. The main cassette is preferably located in a centralized region of the back of the intelligent cabinet so that the plurality of RFID antennas contained in the plurality of cassettes can be easily connected to the RFID reader. Accordingly, each of the plurality of cassettes may be provided with at least one through hole dimensioned to accommodate an RFID antenna cable. When the main cassette is positioned in a centralized region of the back of the intelligent cabinet, all of the antenna cables extending from each RFID antenna can therefore be easily connected with the main cassette in the central region via cable guides formed the body of the cassettes and conveniently tethered together and/or neatly tucked away at the back of the intelligent cabinet.

[0072] As is shown in FIG. 1, the plurality of cassettes 150, the optional first and second additional cassettes 170, 180, and the main cassette 160 are all accessible from a back side of the intelligent cabinet. This configuration is particularly advantageous because each cassette can be easily and individually accessed for adjustment, repair, and/or replacement purposes with minimal or no impact to the operation of the equipment in the other cassettes.

[0073] Cassettes 150, 170, 180 are adapted to house RF equipment, including an RF antenna, and/or one or more sensors, such as temperature, pressure, and humidity sensors. In particular, the cassettes are designed preferably for use with UHF RFID systems. However, the cassettes are not specifically limited to use with UHF RFID systems and may also be equipped with HF RFID equipment, active RFID systems, microwaves, Bluetooth®, or other like systems that are compatible with radio waves.

[0074] The plurality of RFID antennas with which the cassettes may be equipped are not particularly limited to any specific RFID antenna. However, RFID antennas that have the following functional characteristics, in no particular order, have particular desirability: field size, (high) gain, (large angle) beamwidth, ease-of-assembly, low cost, frequency (ETSI and FCC), circular polarization, and directionality. Circular polarized antennas are particularly useful in that the RF tags/product and the RF reader do not need to be located on the same plane and/or at the same height. Further, circular polarized antennas do not require that the RF reader knows the orientation of the tag, which can be useful in the intelligent cabinet because the inventory may not necessarily always be oriented in the same direction, especially where a consumer may temporarily remove an item from the cabinet and then subsequently restock the same in a different orientation. High gain antennas are also considered to be desirable because they have a high level of functionality in high density RF tag environments and likewise in environments that contain liquid items, which can shield and/or obscure RF signals. RF antennas that support worldwide frequency coverage are also desirable so that the antennas do not need to be swapped in different geographic regions.

[0075] Another aspect of the present invention is an intelligent cabinet that is manufactured by: providing in a mold, a corrugated layer comprising a plurality of slots, each slot dimensioned to fittingly receive a corresponding cassette; injecting a foam material through the mold against the back side of the corrugated layer to form an intermediate layer, the foam material forming an airtight seal with the back side of the corrugated layer; removing the intermediate layer from the mold and attaching an inner liner over the front side of the corrugated layer; and providing an outer wall over the intermediate layer such that exposed foam of the intermediate layer is entirely covered by the outer wall. An intelligent cabinet according to the present invention can alternatively be manufactured by placing in a mold, the outer wall and the corrugated layer comprising a plurality of slots and the inner liner, the corrugated layer is arranged between the outer wall and the inner liner and a front side of the corrugated layer is in fitting engagement with the inner liner; injecting a foam material the space between the back side of the corrugated layer and the outer wall to form an airtight seal, and removing the composite structure from the mold.

[0076] It is desirable that the mold be formed of a material that is sufficiently rigid and strong to prevent deformation of the corrugated layer and also that can be easily and seamless removed from the composite structure following setting of the foam material. One exemplary material that has both of these characteristics is aluminium. Hydraulic rams may be provided to open and close the mold, as well as to hold the mold securely in position when the high pressure foam is added.

[0077] While the invention has been described herein by reference to certain embodiments, it is to be understood that modifications in addition to those described herein may be made to the structures and techniques described herein without departing from the spirit and scope of the invention. Accordingly, although specific embodiments have been described, they are examples only and are not limiting upon the scope of the invention.