Patent Grant
8485232
The present application claims priority to U.S. Nonprovisional application Ser. No. 13/632,398 entitled “CONTAINER TAMPING SYSTEM” filed concurrently with this application on Oct. 1, 2012. The disclosure of which is incorporated herein by reference in its entirety for any purpose.
This invention relates to a system and apparatus for filling containers, and more particularly, to a system and method directed to a container filler comprising an integral tamper.
Although, in general, the container filling process is known, a number of deficiencies are apparent in the prior art. Most notable of these deficiencies is that the conventional industrial container filling process often results in material spillage. Spillage may be material that is intended be transferred from a first location to a container that does not arrive at its intended destination and/or arrive in the intended positioning. For instance, lettuce leaves delivered through a filler which arrive completely or partially outside of a intended container. As such, use of conventional industrial container fillers often requires downstream personnel to cure cosmetic and functional imperfections resultant from material spillage. Of course, increases of manpower needs, in turn, increase production costs and often slow the rate of production. It would be advantageous to reduce number of additional personnel utilized.
Also, conventional industrial container filler systems often employ downstream tamping systems to depress at least a portion of the material so that a lid may be coupled to the container. In this way, the material does not create an impediment to lid placement. Each downstream additional tamping system increases the overall system footprint. Moreover, each additional piece of machinery caries a cost and a potential for failure. It would be advantageous to reduce the number of these additional downstream mechanical systems.
Often times, material traveling through an industrial container filler may become temporarily caught on a structure within the filler. For instance, lettuce leaves may become adhered to an internal surface of a filler due to a slope of a surface being too flat or surface characteristics of the filler that encourage suction. This results in a production delay as the container filling process is ordinarily paused and steps are taken to remove the caught material and/or accumulated aggregate caught material. This delay increases production costs. It would be advantageous to reduce the number of production delays.
Reduction in distance between the filler bottom and the container minimizes spilling of material outside of the container. Often times if the gap between the container and the filler bottom is too small, material may make contact with the bottom of the filler as the container is advanced on the production line. This often results in spillage of the material which workers must address by hand. It would be advantageous to have a filler system which reduces material spillage.
Optimally, the motion of tamping and/or compression is in a downward direction towards the bottom of a container; however, optimally, the path of material traveling through a filler is straight down into a container with little impeding the flow of the material from a top opening to a bottom opening. As one can appreciate, these two goals have been at odds as a tamper positioned directly over the container impedes the flow of material through a vertical conduit of the filler. Conventional tampers implemented with fillers have been offset and/or configured to tamp in a less than optimal direction, such as a direction other than a vertical direction towards the bottom of a provided container. It would be advantageous to have a filler system which allows for and is configured to tamp in a direction towards the bottom of the container.
Moreover, historically, empty containers have been moved into position under the filler, filled with a material, tamped if desired and indexed forward. The time each of these steps takes impact the efficiency the container filling system. Thus, decreasing the time for any of these steps results in increased system efficiency and increased product runs. Thus, a premium is often placed on decreasing the tamper stroke time and/or tamper stroke distance. Thus, it is desirable to place the compressed tamper relatively close to the material to be tamped by the extended tamper to minimize tamper travel time. It would be advantageous to have a system which reduces tamper travel time and distance.
The present inventors have recognized that filler with integral tamper design would allow a significant increase in productivity with a decrease in system footprint, and production costs, particularly for a process where a container is filled with a material, such as vegetable (e.g. lettuce).
The present invention relates to an improved container filler and apparatus designed to address, among other things, the aforementioned deficiencies in prior art container filling systems.
While the way in which the present invention addresses these deficiencies and provides these advantages will be discussed in greater detail below, in general, the use of an integral vertical tamping system enables efficient and cost-effective container filling. Furthermore, the use of such a system reduces the need for down-stream personnel and additional downstream tamping machinery, such as downstream vertical tampers, which is advantageous. Moreover, the integral vertical tamping system can self-clear obstructions within portions of its conduit.
A filler may direct material, such as a leafy vegetable, from one location to another. In accordance with one aspect of an exemplary embodiment of the invention the filler may utilize a conduit to direct material from an opening in the filler to a container positioned below the filler. In a preferable embodiment, the filler may direct material from a first location external to a container into a second location within the container.
In accordance with one aspect of an exemplary embodiment of the invention, a tamper is integrally coupled to the filler. Due to this integral coupling, material may be filled and tamped in a container without the container being moved between the filling and tamping processes. In this way, material spillage is reduced. Tampers are utilized in the container filling industry to, among other things, compress material filled in a container.
The present integral tamper system comprises a system where a container may be moved into a position substantially under the filler to be filled with material by the filler. After the container is filled with material, without moving the container, the tamper may be moved into tamping position directly above the container without further advancement and/or movement of the container under the filler. Then, aspects of the tamper may move in a substantially vertical motion to tamp the material in the container. In various embodiments, the vertical motion of the tamper begins from a position within the filler directly above the container.
The tamper may move into a position directly above the container from a position where its presence does not impact operation of the filler filling the container. For instance, this position may be beside, above, and/or external to a path of material traveling through the filler to the container.
In accordance with one aspect of an exemplary embodiment of the invention, a device for filling a container with a material includes a conduit comprising a top opening and a bottom opening, and a tamper integrally coupled to the conduit. The tamper may be configured to move laterally from a first position to a second position. In various embodiments, the first position is out of the path of material moving through the filler. The second position may be substantially directly above a filled container. Though it may take any path to move from the first position to the second position, preferably, the tamper generally travels in a straight, horizontal path. In this context, horizontal generally refers to along x and y axes in a Cartesian coordinate system.
Upon arrival at the second position, the tamper is ready to tamp the material previously filled in the container. The tamping face of the tamper is configured to tamp the material in the container using a vertical tamping motion. In this context, vertical generally refers to along the z axis in a Cartesian coordinate system.
In various embodiments, to reduce spillage, a shape of the bottom opening may be configured to mirror a shape of an opening of a container.
These and other features and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawing figures, wherein there is shown and described various illustrative embodiments of the invention.
The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present invention, however, may best be obtained by referring to the detailed description and to the claims when considered in connection with the drawing figures, wherein like numerals denote like elements and wherein:
The present invention provides for significant advancements over prior art processes, particularly with regard to process efficiency, process economics, and reduction of material arriving in an unintended positioning. For instance, the present system results in filled containers with the material compressed strait down towards the base of the container. After use of the present system, these filled containers are generally ready to receive a lid and other packaging for sale.
Moreover, existing tray filling systems, in many instances, may easily be retrofitted to exploit the many commercial benefits the present invention provides. As mentioned above, the present system reduces spilling of material outside of the container. Additionally, though down-stream tampers may be used with the present system, they are not likely to be implemented as the present system can perform their function. These and other exemplary aspects of the present invention are discussed in greater detail herein below.
With initial reference to
In various embodiments, top opening 110 may be any suitable shape, such as rectangular, square, rounded, ovoid and/or the like. Generally, this shape is determined based on the feeding system and/or hopper used to deliver material 102 to the filler 100. Top opening 120 should be large enough such that material being fed into top opening 120 does not spill over or around the edge of top opening 120. With reference to
Conduit 120 may be any suitable shape. For instance, conduit 120 may be an open chute which connects top opening 110 to bottom opening 130. Conduit 120 may be made from any suitable material. For example, conduit 120 may be made from a durable material which may be cleaned and sanitized with ease. Preferably, conduit 120 is primarily made of stainless steel. Also, conduit 120 may be made from a material configured to reduce material 102 dragging on or sticking to, such as via suction, its interior side walls. For example, portions of conduit 120 may be made from a rigidized metal, such as welded rigidized stainless steel configured in a pattern, such as a 7DL pattern.
In accordance with one aspect of the invention, with further reference to
With renewed reference to
Bottom opening 130, may comprise any suitable shape. For instance, in an exemplary embodiment, bottom opening 130 may be shaped to mirror the shape of an opening of a container. Bottom opening 130 may be suitably shaped such that its outer surface is slightly smaller than, matches or is slightly larger than the opening of a container.
In an exemplary embodiment, conduit bottom portion 126 and/or a portion of bottom portion 126 may be removed from system 100 and replaced with a second conduit bottom portion 126 with larger or smaller dimensions suitably shaped to correspond with the shape and dimensions of a provided container. In various embodiments in accordance with aspects of the invention, conduit bottom portion 126 may be configured to receive a semi-permanent adapter suitably shaped to correspond with the shape and dimensions of a provided container. This adapter may reduce the size of conduit bottom portion 126 to a smaller shape or modify the shape of conduit bottom portion 126 to substantially mirror the respective shape of a provided container, as desired.
In accordance with one aspect of the invention and with reference to
Though a piston is depicted and described, it is understood that any modality of moving tamping face 170 from a compressed position to an extended position in a substantially vertical motion may be utilized. For instance, tamping face 170 may be pulled, dropped and/or pushed into position (from a compressed position to an extended position and/or vice versa). This movement may be accomplished via mechanical, fluid, electrical, pneumatic, and/or magnetic operation. The compressed position refers to tamping face 170 which is not extended from tamper housing 160 by tamping piston 180.
Also, in various embodiments, though it may be moved by any suitable means, integral tamper 150 may be coupled to a housing piston 165 configured to move tamper housing 160. Though this motion may be in any suitable direction, preferably, this movement is in the horizontal direction along a substantially horizontal plane.
Though a piston is depicted and described, it is understood that any modality of moving tamper 150 and tamper housing 160 from the first position to the second position, such as in the substantially horizontal plane, may be utilized. For instance, tamper 150 and tamper housing 160 may be pulled, pushed, dropped, lifted, or rotated into position from the first position to the second position. This movement may be accomplished via mechanical, electrical, pneumatic, fluid and/or magnetic operation. This tamper 150 operation and movement will be described in greater detail below.
As noted above, in various embodiments, such as an embodiment where tamper 150 is positioned outside of conduit 120 while material 102 is traveling through the conduit 120, portions of integral tamper 150, such as side face 155, may comprise portions of conduit 120.
Tamper housing 160 may comprise circuitry and/or a controller for operating tamper 150. Tamper 150 may be configured such that tamping face 170 may be extended and compressed from tamper housing 160. For instance, tamper housing 160 may be coupled to tamping piston 180. Tamping piston 180 may be coupled to tamping face 170. In response to a received signal, tamping face 170 may be extended from a compressed first position to an extended position or a partially extended position via operation of tamping piston 180. Thus, tamping face 170 will move from a position near tamper housing 160 to a position away from tamper housing 160 depending on the length, stroke, and operation of tamping piston 180.
Tamping piston 180 may be a mechanical actuator, such as hydraulic cylinder with mechanical, electronic, fluid and/or pneumatic operation. The controller may control the force, speed, distance, and/or acceleration of tamping piston 180. These variables may be controlled in response to material 102 being delivered by integral vertical tamping system 100. Thus, tamping face 170 may be programed to travel deeper into a container or with greater force as desired. For instance, tamping face 170 may be programed to travel deeper into a container or with greater force based on the type volume and/or condition of material 102 being tamped.
Also, in an exemplary embodiment, tamping face 170 may optionally be programed to clear debris (e.g. material 102) from the interior walls of conduit 120 but not make contact with material 102 delivered to the container. In this embodiment, tamping face 170 may be fitted with an adapter configured to clear material 102 from conduit 120. This functionality may be programed to occur on a periodic basis such as after each container is filled or after a set number of containers are filled and/or be called upon on an ad hoc basis, such as initiated by a user. Optionally, in various embodiments, the operation of tamper 150 may be temporarily disabled.
As mentioned above, in accordance with one aspect of the invention, tamper housing 160 may be coupled to housing piston 165. Housing piston 165 may be coupled to integral vertical tamping system 100. Housing piston 165 may be a mechanical actuator, such as hydraulic cylinder with mechanical, electronic, fluid, or pneumatic operation. Housing piston 165 may comprise and or be coupled to circuitry and/or a controller for operation. Housing piston 165 may move tamper housing 160 from a first position to a second position and vice versa. In general, this movement is along a horizontal plane. Thus, in practice, tamping face 170 along with tamper housing 160 (generally in a compressed orientation) move from a first position to a second position along a horizontal plane. Then, tamping face 170 moves from its compressed orientation to an extended orientation in a substantially vertical plane.
The controller may control the timing of movement, speed, and/or range of movement of housing piston 165. These variables may be controlled in response to material 102 being delivered by integral vertical tamping system 100. Thus, tamping face 170 may be programed to travel deeper or shallower into a container or with greater or less force based on the type, volume and/or condition of material 102 being tamped. Optionally, the operation of the housing piston 165 may be temporarily disabled. In this way, material 102 may be filled by integral vertical tamping system 100 without tamping. Thus, there is no delay for moving tamping housing 160 from the first position to the second position and back between material 102 being filled into each newly indexed container.
In accordance with one aspect of the invention, coupled to tamping face 170 (or a portion of tamper housing 160) is tamper 150 side face 155. When tamper housing 160 and tamping face 170 is in a first position, the exterior of side face 155 may comprise a portion of an interior wall of conduit 120. With reference to
In accordance with various embodiments, side face 155 of tamper 150 may not comprise a portion of conduit 120. In this embodiment, tamper 150 moves into and/or is oriented in the second position over the container for tamping from a first position where it does not impede material 102 traveling through conduit 120 to the container. For instance, in an exemplary embodiment, and with reference to
In accordance with one aspect of the invention and with reference to
In an exemplary embodiment, tamping face 170 may comprise surface features designed to reduce material 102 sticking to elements of tamper 150. As discussed above, tamping face 170 may be configured to make contact with and/or compress material 102. Tamping face 170 and portions of tamper 150 may be made from any suitable material, such as a polymer. For instance, for ease of construction and/or to aid with sanitation, tamping face 170 may be made from molded plastic. Tamping face 170 and/or tamper 150 elements may be coupled to tamping piston 180 by any known coupling means. If desired, tamping face 170 may be conveniently removed for repair, replacement or swapped with a tamping face 170 comprising alternative properties, such as made from a different material, made with different surface properties, and/or made with a different shape, for instance to correspond to a different provided container.
In various embodiments, with renewed reference to
In accordance with one aspect of the invention and with reference to
Integral vertical tamping system 100 receives material 102 through top opening 110 (step 505). Material 102 may be dropped through conduit 120 via gravity. Material 102 is then directed towards bottom portion 126 of conduit 120 (step 510). For instance, using the angled surface features, such as angled side walls 124, of top portion 122 of conduit 120, material 102 is directed towards bottom portion 126 of conduit 120.
In an exemplary embodiment, material 102 is dropped in response to a timing scheme, programing and/or sensors indicating a container is positioned to receive material 102 substantially under integral vertical tamping system 100. In various embodiments, positioned to receive material 102 may refer to the opening of the container being substantially in line with bottom opening 130.
In an exemplary embodiment, in response to programing and/or sensors indicating material 102 is ready to be, is being and/or has been dropped, a container is positioned to receive material 102 substantially under integral vertical tamping system 100 (step 515). In accordance with one aspect of the invention and with reference to
Material 102 passes through conduit 120 and is delivered to bottom opening 130. Integral vertical tamping system 100 is configured to direct material 102 through bottom opening 130 into an awaiting container. Preferably, there is as little gap as possible or no gap between the container and the integral vertical tamping system 100. Thus, so that material 102 in the container does not make unintended contact with a surface or an edge of integral vertical tamping system 100 and/or to aid with placing a lid on the container, material 102 in the container is compressed via tamper 150.
In an exemplary embodiment, in response to material 102, such as a leafy vegetable, being dropped through conduit 120, housing piston 165 is provided a signal to move tamper housing 160 from the first position to a second position (step 520). The movement of housing piston 165 may be triggered by programming, sensor or electronic notification. For instance, the timing of the duration of material dropping from a filler box to bottom opening 130 may be known, calculated or observed. Based on this timing, conduit 120 is ready to receive tamper 150 and may be obstructed (by tamper 150) as material 102 has already passed through. Stated another way, the first position of tamper 150 is generally outside of the path of material 102 dropping within conduit 120. This position may be outside or inside of conduit 120. While the tamper 150 is traveling from the first position to the second position, tamping face 170, which makes contact with material 102 during the tamping, may be oriented in any desired orientation. In accordance with one aspect of an exemplary embodiment of the invention, tamping face 170 is oriented in the downward direction, generally normal to the horizontal path of travel of tamper 150 from the first position to the second position. When tamper 150 is in the second position, it is generally positioned for operation in a vertical line with the container, preferably directly over the container opening. Tamper 150 may travel in any path from the first position to the second position; however, as the time tamper takes to arrive at the second position will effect productivity, a short travel path is generally preferred.
Different material 102 and/or conditions of the material 102, (e.g. dry or wet) may affect material 102 drop times through conduit 120. The operation the system 100, such as a the operation of a conveyer belt indexing containers, housing piston 165, and the like, may be calibrated based on these drop times. As stated above, in various embodiments, the motion of tamper housing 160 is generally in a short path of travel, more preferably, generally along a horizontal plane. Preferably, when tamper housing 160 is in the first position, the tamper housing 160 is out of the path of material 102 traveling through conduit 120, such as exterior to conduit 120. Thus, the tamping face 170 and tamper housing 160 do not impede material 102 passing through conduit 120 when tamper housing 160 is in the first position. In various embodiments, not depicted, tamper 150 may be interior to the conduit 120 so long as its placement and/or features of the conduit allow for material 102 to travel to container without being impleaded by tamper 150.
With renewed reference to
In general, tamping unit comprising tamping face 170 is moved from a first position, such as a first position outside an opening in the conduit 150, to a second position generally covering the opening of the container and then at least the tamping face 170 moves to a third position. Preferably, movement of the tamping face 170 from the second position to the third position suitably compresses material 102 such that further efforts to compress material 102 or attend to spillage are unnecessary.
In a typical embodiment, where material 102 comprises leafy material, tamping face 170 and/or container are suitably moved during tamping such that tamping face 170 is within about ½ to about 3 inches from the bottom of the container, more preferably on the order of about 1 to about 2 inches and most preferably about 1.5 inches from the bottom. However, the desired distance may be suitably selected based on a number of factors, including, without limitation the type of material 102, the volume of the container, shape of the container, the condition of material 102, durability of material 102, and/or desired compression of material 102 within the container.
In accordance with an embodiment, in response to tamper housing 160 arriving at the second position, a signal is sent to tamping piston 180 to move tamping face 170 from a compressed position to an extended position (step 530). Though this may be in any suitable path, preferably, this motion is generally along a vertical plane. As tamping face 170 is extended, such as extended away from tamper housing 160, tamping face 170 makes contact with material 102. The stroke of tamping piston 180 may be its full range of motion or less than the full range of motion of tamping piston 180. For instance, tamping face 170 is extended between about 4 and 10 inches, more preferably on the order of about 5 to about 8 inches and most preferably about 6 inches. This results in tamping face 170 being about 1.5 inches from the base of the interior of the container. The preferable stroke distance is a balancing between a short stroke for efficiency against clearing/not making contact with a non-compressed (e.g. fluffed up) mound of material 102 in the container extending up into conduit 120 while tamper 150 moving horizontally. Additionally, as tamping face 170 is extended, tamping face 170 may clear material 102 stuck to and/or hung up in the interior of conduit 120. Thus, as tamping face 170 is extended, tamping face 170 is configured to move within at least two interior walls of conduit 120. In accordance with an exemplary embodiment and with reference to
With renewed reference to
Optionally, a signal may be sent to tamping piston 180 to extend tamping face 170 down conduit 120 a second time, such as to clear material 102 from conduit 120 or to further compress material 102 in the container. This movement may be less than the total range of motion of tamping piston 180, for instance to clear material in conduit 120. As above, a signal may be sent to tamping piston 180 to move tamping face 170 from the extended position to the compressed position. For instance, in response to tamping face 170 arriving at the desired extended position, a signal is sent to tamping piston 180 to move tamping face 170 from the desired extended position to the compressed position.
With renewed reference to
With renewed reference to
Integral vertical tamping system 100 is well suited for larger and/or heavy loads of material 102 in larger containers. The preferable downward/vertical stroke of the tamper 150 is preferable for these large containers as compared with historical angled tamping approaches. For instance, a large container may be a container suitably sized to hold between about 3 ounces and 2 pounds of material 102, more preferably on the order of about 5 ounces to 1 pound. According to various embodiments, a large container may be a container suitably sized to hold about 5 ounces or about 1 pound. Additionally, larger and/or heavy loads generally take longer to fill the container and are well suited to the horizontal and then vertical tamping motion of the tamper housing 160 and tamper face 170 described above.
One or more controllers may be coupled to integral vertical tamping system 100 configured to control the operation of the moving systems and/or parts. For instance, the timing and coordination of the filler box opening, the indexing of the container, the movement of tamping piston 180 and/or housing piston 165 may be controlled by the controller. These controllers may be preprogrammed and/or controlled by a user via a user interface. For instance, the programing of the system may be stored to a non-transitory computer readable medium and/or memory.
In an exemplary embodiment, not shown, additional tampers may be coupled to integral vertical tamping system 100. For instance, one or more additional tamper configured to roll and/or rotate into position located proximate bottom opening 130. This tamper and/or pair of tampers may be configured to direct their force down and away from the center of the container. This additional tamper may be configured to operate, before, after, and/or independent to tamper 150. For instance, this additional tamper may be configured to operate in lieu of tamper 150.
In an exemplary embodiment, more than one tamper may be integrally coupled to each conduit 120. For instance, two tampers from alternating opposite sides may be moved from a first position external to the interior of the conduit to a second position substantially interior to conduit 120 along a substantially horizontal plane.
In an exemplary embodiment, a single tamper may by integrally coupled to each conduit 120. For instance, this tamper may be configured to move/toggle between a first position within the interior a first conduit and a second position within the interior of the second conduit 120 along a substantially horizontal plane.
In various embodiments in accordance with aspects of the invention, tamper 150 may not require the tamper housing being moved from a first position to a second position. For instance, if the containers are moved into position beneath system 100 pre-filled with material ready for tamping. Additionally, in various embodiments in accordance with aspects of the invention, movement of tamper 150 from the first position to the second position may be temporarily disabled, for instance in the case where system 100 is used to fill containers with a material where tamping is not desired.
The present invention has been described above with reference to a number of exemplary embodiments and examples. It should be appreciated that the particular embodiments shown and described herein are illustrative of the invention and its best mode and are not intended to limit in any way the scope of the invention as set forth in the claims. Those skilled in the art having read this disclosure will recognize that changes and modifications may be made to the exemplary embodiments without departing from the scope of the present invention. These and other changes or modifications are intended to be included within the scope of the present invention, as expressed in the following claims.
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| Entry |
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| Office Action dated Dec. 4, 2012 in U.S. Appl. No. 13/632,398. |
