Information
-
Patent Grant
-
6604556
-
Patent Number
6,604,556
-
Date Filed
Wednesday, August 28, 200222 years ago
-
Date Issued
Tuesday, August 12, 200321 years ago
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Inventors
-
Original Assignees
-
Examiners
Agents
-
CPC
-
US Classifications
Field of Search
US
- 141 65
- 141 331
- 141 114
- 141 98
- 141 66
- 141 70
- 220 49506
- 220 527
- 220 528
- 220 529
-
International Classifications
-
Abstract
Particles are packed in a container. The container is either cylindrical-shaped or box-shaped. The container has a container inner wall and an inner bottom. A ramp is disposed on the container inner bottom. The ramp has a ramp base that is narrower than the container inner bottom. A conical-shaped inclined ramp surface extends upward from the ramp base at a substantially constant ramp surface angle with respect to horizontal and towards the container inner wall. The inclined ramp surface defines a ramp upper rim that is substantially proximate to the container inner wall. The particles have an angle of repose that is less than the ramp surface angle. The particles flow down the inclined ramp surface towards the ramp base. The particles are removed from the container using a vacuum feed nozzle that is disposed proximate to the particles in the container.
Description
BACKGROUND OF THE INVENTION
It is known to pack particles in a container. For example, it is known to ship plastic resin particles in a large bulk box-shaped container or toner carrier particles in 55-gallon cylindrical-shaped drum container.
It is also known to use a vacuum feed nozzle to remove such particles from the container. For example, at the internet web address “www.piab.com” there is provided information of various “vacuum conveyor” products available from the Swedish supplier PIAB AB, whose mailing address is P.O. Box 4501, SE-183 04 Täby, Sweden.
However, there are problems with this vacuum-feed-nozzle process of removing particles from cylindrical-shaped containers or box-shaped containers. For example, assume that containers are initially only 50% filled with about 700 pounds of plastic resin or toner carrier. When the level in the drum gets down to the last 3 or 4 inches, with 150 pounds of plastic resin particles or toner carrier particles still remaining in the container, the nozzle will clear a hole around itself and no longer pick up material. To get the last 25% of plastic resin or toner carrier particles out of the container an operator must manually manipulate the nozzle every couple minutes until the level is low or light enough that the container liner bag can be picked up and dumped into another open container. The extra manpower required for attending the nozzle is a problem and frequent cause of downtime. Also as operators are attending the feed nozzle and dumping bags, there might be a safety hazard presented to the human operators, as the humans might be exposed to health hazards such as, for example, inhaling harmful material or fumes related to the plastic resin or toner carrier. For example, recently a human operator was diagnosed with a lung inflammation condition named “interstitial pneumonitus” caused by toner carrier particles entering his lungs.
There are several existing methods to solve the problem of having to attend to the feed nozzle but these methods are more costly, complex, require more floor space, and create other safety hazards. A method, as used in several plants, is conveying out of a fixed carrier supply hopper that holds 3-5 containers of carrier. The hoppers used are loaded by a dedicated container dumper. Special perimeter guarding and safety mats are required around the container dumper because when the drum is lifted into the air serious hazards exist under and near it. In another plant a fork truck using a special container handling attachment dumps the carrier into a supply hopper. There are dedicated hoppers and container dumpers for each pack line and sometimes for each carrier type, thus requiring a large amount of floor space. An other existing method is to place the drum onto a container tilter. The carrier flows toward the corner of the tilted container where the nozzle is located allowing almost all the carrier to be sucked out without manipulation of the nozzle. This method works well but the container tilter device takes up a minimum of 20 square feet of floor space. Also, when the container is tipped there is a hazardous area underneath that must be guarded in some way, thus taking more floor space. Another drawback to using the tilter is the container must be handled requiring a fork truck with a special attachment to lift the container off the skid and place it on the drum tilter.
Moreover, this problem is currently addressed by adding capital equipment such as container tilters, fork truck container handling tools, container dumpers, and supply hoppers. This equipment adds complexity and cost, increases material handling of the drums and plastic resin particles or toner carrier particles, creates new safety hazards and spill risks, and requires a much larger floor space.
SUMMARY OF THE INVENTION
In one aspect of the invention, there is described a container having a container inner wall, a container inner bottom with a ramp disposed thereon, the ramp having an included ramp base that is narrower than the container inner bottom, the ramp forming a conical-shaped inclined ramp surface that extends upwardly from the ramp base at a substantially constant ramp surface angle with respect to horizontal towards the container inner wall, the inclined ramp surface defining a ramp upper rim that is substantially proximate to the container inner wall. In one embodiment, the container is cylindrical-shaped. In another embodiment, the container is box-shaped.
In another aspect of the invention, there is described a method of removing particles that are disposed in a container having a container inner wall, a container inner bottom with a ramp disposed thereon, the ramp having an included ramp base that is narrower than the container inner bottom, the ramp forming a conical-shaped inclined ramp surface that extends upwardly from the ramp base at a substantially constant ramp surface angle with respect to horizontal towards the container inner wall, the inclined ramp surface defining a ramp upper rim that is substantially proximate to the container inner wall, the particles having an angle of repose that is less than the ramp surface angle and flow down the inclined ramp surface towards the ramp base, the method comprising removing particles using a vacuum feed nozzle that is disposed proximate to the particles in the container. In one embodiment, the container is cylindrical-shaped. In another embodiment, the container is box-shaped.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1
is a cutaway, cross-section view of a cylindrical-shaped container
10
with a conical-shaped ramp
20
, in accordance with the present invention. Also depicted is a horizontal reference line
1
.
FIG. 2
depicts one embodiment of the conical-shaped ramp
20
.
FIG. 3
depicts the cylindrical-shaped container
10
with the conical-shaped ramp
20
, including particles
40
being disposed therein.
FIG. 3
also depicts a vacuum conveyor device such as, for example, a vacuum feed nozzle
50
. In accordance with the present invention,
FIG. 3
also depicts the feed nozzle
50
being used to remove the particles
40
from the container
10
.
FIG. 4
depicts a cutaway, cross-section view of a box-shaped container
100
with a conical-shaped ramp
20
, in accordance with the present invention, including particles
40
being disposed therein.
FIG. 4
also depicts a vacuum feed nozzle
50
being used to remove the particles
40
from the box-shaped container
100
.
DETAILED DESCRIPTION OF THE INVENTION
Briefly, particles are packed in a container. In one embodiment, the container is cylindrical-shaped. In another embodiment, the container is box-shaped. The container has a container inner wall and an inner bottom. A ramp is disposed on the container inner bottom. The ramp has a ramp base that is narrower than the container inner bottom. A conical-shaped inclined ramp surface extends upward from the ramp base at a substantially constant ramp surface angle with respect to horizontal and towards the container inner wall. The inclined ramp surface defines a ramp upper rim that is substantially proximate to the container inner wall. The particles have an angle of repose that is less than the ramp surface angle. The particles flow down the inclined ramp surface towards the ramp base. The particles are removed from the container using a vacuum feed nozzle that is disposed proximate to the particles in the container.
Referring now to
FIG. 1
there is depicted a barrel-shaped or cylindrical-shaped container
10
having a concave, curved container inner wall
15
, a circular-shaped container inner bottom
14
with a conical-shaped ramp
20
disposed thereon, the ramp
20
having an included circular-shaped ramp base
22
that is narrower than the container inner bottom
14
. As shown, the ramp
20
forms a conical-shaped inclined ramp surface
25
that extends upwardly from the ramp base
22
at a substantially or generally constant ramp surface angle
28
with respect to horizontal
1
towards the container inner wall
15
. As depicted in
FIG. 1
, the inclined ramp surface
25
defines a circular-shaped ramp upper rim or ramp lip
21
that is substantially congruent with or proximate to the container inner wall
15
.
In one embodiment, the conical-shaped ramp
20
is detachable from the container inner bottom
14
.
In another embodiment, the conical-shaped ramp
20
is fixed to the container inner bottom
14
.
Still referring to
FIG. 1
, in one embodiment the container
10
includes a liner
30
(shown in broken lines) disposed on the inclined ramp surface
25
, and also on the container inner wall
15
. In one embodiment, the liner
30
comprises a plastic or polyurethane bag.
The ramp
20
is separately depicted in FIG.
2
. Referring now to
FIG. 2
, the conical-shaped inclined ramp surface
25
depicted therein forms a rounded or circular-shaped ramp lower rim or ramp lower lip
26
which, in turn, forms the circular-shaped ramp base
22
. The ramp base
22
, in turn, is disposed on the container inner bottom
14
of the container
10
.
In one embodiment, the ramp lower rim
26
is open, thereby defining a ramp lower opening
27
.
In another embodiment, the ramp lower rim
26
is enclosed, thereby forming a ramp inner bottom
24
.
It will be appreciated that the shape of the cone-shaped ramp
20
may be characterized as a frustum of a cone.
In one embodiment, the ramp
20
is fabricated from a metal such as, for example, a spun stainless steel of having a ramp material thickness
29
of {fraction (1/16)} inch or 40 mil.
In another embodiment, the ramp
20
is fabricated from a plastic.
In still another embodiment, the ramp
20
is fabricated from a fiberglass.
Returning again to
FIG. 1
, in one embodiment the container
10
comprises a 55-gallon size drum which may be fabricated, for example, from steel.
Also, in one embodiment, the circular-shaped or round lower rim
26
comprises a ramp base
22
of about 3 inches in diameter.
In one embodiment, the ramp surface angle
28
is about 45 degrees.
In one embodiment, the ramp upper rim
21
is about 22 inches in diameter.
Referring now to
FIG. 3
, there is depicted the container
10
with the conical-shaped ramp
20
, the container
10
including particles
40
disposed therein. In one embodiment, the particles are free flowing, granular or powder.
FIG. 3
also depicts a vacuum conveyor device such as, for example, a vacuum feed nozzle
50
. The vacuum feed nozzle
50
includes a vacuum nozzle mouth or opening
53
that is positioned proximate to the ramp base
22
. As shown, a vacuum force
58
that is supplied by the vacuum feed nozzle
50
causes particles
40
that are proximate to the vacuum nozzle mouth
53
to initially move towards the nozzle mouth
53
and thereafter to be conveyed within the vacuum feed nozzle
50
to a vacuum particle conveyor
60
.
In one embodiment, the particles
40
have diameters that vary from 5 microns to 2 millimeters.
In one embodiment, the particles
40
comprise a plastic resin.
In another embodiment, the particles
40
comprise a toner carrier.
In accordance with the present invention,
FIG. 3
also depicts the vacuum feed nozzle
50
being used to remove the particles
40
from the container
10
. Thus, there is depicted in
FIG. 3
a method of removing particles
40
that are disposed in a cylindrical-shaped container
10
having a container inner wall
25
, a container inner bottom
14
with a ramp
20
disposed thereon, the ramp
20
having an included ramp base
22
that is narrower than the container inner bottom
14
, the ramp
20
forming a conical-shaped inclined ramp surface
25
that extends upwardly from the ramp base
22
at a substantially constant ramp surface angle
28
with respect to horizontal
1
towards the container inner wall
15
, the inclined ramp surface
25
defining a ramp upper rim
21
that is substantially proximate to the container inner wall
15
, the particles
40
having an angle of repose that is less than the ramp surface angle
28
so that particles
40
flow (depicted by reference number
45
) down the inclined ramp surface
25
towards the ramp base
22
, the method comprising removing particles
40
located proximate to the ramp base
22
using a vacuum feed nozzle
50
.
Still referring to
FIG. 3
, it will be understood that the particles
40
having an angle of repose that is less than the ramp surface angle
28
is equivalent to the ramp surface angle
28
exceeding the angle of repose of the particles
40
.
Still referring to
FIG. 3
, in one embodiment the container
10
includes a liner
30
(depicted in broken lines) disposed on the inclined ramp surface
25
.
Referring now to
FIG. 4
, there is depicted a box-shaped container
100
with a conical-shaped ramp
20
, in accordance with the present invention, including particles
40
being disposed therein.
FIG. 4
also depicts a vacuum feed nozzle
50
being used to remove the particles
40
from the box-shaped container
100
.
Thus, there has been described a container, the container comprising either the cylindrical-shaped container
10
depicted in
FIG. 1
or the box-shaped container
100
depicted in
FIG. 4
, having a container inner wall, a container inner bottom with a ramp
20
disposed thereon, the ramp
20
having an included ramp base that is narrower than the container inner bottom, the ramp
20
forming a conical-shaped inclined ramp surface that extends upwardly from the ramp base at a substantially constant ramp surface angle with respect to horizontal towards the container inner wall, the inclined ramp surface defining a ramp upper rim that is substantially proximate to the container inner wall.
Further, there has also been described a method of removing particles that are disposed in a container, the container comprising either the cylindrical-shaped container
10
depicted in
FIG. 1
or the box-shaped container
100
depicted in
FIG. 4
, having a container inner wall, a container inner bottom with a ramp
20
disposed thereon, the ramp
20
having an included ramp base that is narrower than the container inner bottom, the ramp
20
forming a conical-shaped inclined ramp surface that extends upwardly from the ramp base at a substantially constant ramp surface angle with respect to horizontal towards the container inner wall, the inclined ramp surface defining a ramp upper rim that is substantially proximate to the container inner wall, the particles having an angle of repose that is less than the ramp surface angle and flowing down the inclined ramp surface towards the ramp base, the method comprising removing particles using a vacuum feed nozzle that is disposed proximate to the particles in the container.
In summary, in one embodiment, the invention comprises a conical-shaped ramp insert placed in the inner bottom of a cylindrical-shaped container or a box-shaped container. The plastic resin particles or toner carrier particles and vacuum feed nozzle flow or slide by gravity to the center of the drum for easy material pick up. In one embodiment, the conical ramp insert has a 45 degree side wall and is made from metal, plastic, or fiberglass. Since the containers are lined with a heavy plastic bag, the conical ramp insert does not require a tight seal to the inside of the drum. Or, in another embodiment, a rubber seal is used to fit the conical ramp insert to the inside of the container. At the plastic resin or toner carrier supplier the ramp insert is placed in a standard container, then the bag, then the plastic resin particles or toner carrier particles are filled. Later, at the plant, all the plastic resin or toner carrier is sucked out without operator intervention, the bag is removed, and the conical ramp insert is removed. The conical ramp inserts can nest and are stacked up on a skid for return to the plastic resin or toner carrier supplier. A variation of this invention is to weld the insert into place in the container's inner bottom. This latter variation may be beneficial for plants that fill the plastic resin or toner carrier container on site, have a container return program in place, or do not use a container liner bag.
As a result, this invention will eliminate the manpower, downtime and associated hazards currently required to manually manipulate the plastic resin particles or toner carrier particles vacuum feed nozzle. By using this invention, a plant may continue to use the simplistic method of sucking plastic resin particles or toner carrier particles straight from the plastic resin or toner carrier container, thus avoiding the addition of capital equipment, complexity, and safety or spill risks for container tilters, supply hoppers, container dumpers, and special fork truck attachments. This method thus minimizes floor space requirements and container and material handling. This method minimizes changeovers, as there are no hoppers to clean.
In one embodiment, the container is a cylindrical-shaped drum. In another embodiment, the container is a large bulk box-shaped container.
The table below lists the drawing element reference numbers together with their corresponding written description:
|
Reference number:
Description:
|
|
|
1
horizontal reference line
|
10
cylindrical-shaped container
|
11
container upper rim
|
13
container mouth, or container opening
|
14
container inner bottom
|
15
container inner wall
|
16
container inner diameter
|
17
container height
|
19
container material thickness
|
20
ramp
|
21
ramp upper rim, or ramp upper lip
|
22
ramp base
|
23
ramp upper mouth, or ramp upper opening
|
24
ramp inner bottom
|
25
ramp surface
|
26
ramp lower rim, or ramp lower lip
|
27
ramp lower mouth, or ramp lower opening
|
28
ramp surface angle
|
29
ramp material thickness
|
30
liner
|
39
liner material thickness
|
40
particles
|
45
flow of particles down the ramp surface
|
50
vacuum feed nozzle
|
53
vacuum nozzle mouth, or vacuum nozzle opening
|
58
vacuum force
|
60
vacuum particle conveyor
|
100
box-shaped container
|
|
While various embodiments of a container with a conical-shaped ramp and a method of removing particles from the same, in accordance with the present invention, are described above, the scope of the invention is defined by the following claims.
Claims
- 1. A container having a container inner wall, a container inner bottom with a ramp disposed thereon, the ramp having an included ramp base that is narrower than the container inner bottom, the ramp forming a conical-shaped inclined ramp surface that extends upwardly from the ramp base at a substantially constant ramp surface angle with respect to horizontal towards the container inner wall, the inclined ramp surface defining a ramp upper rim that is substantially proximate to the container inner wall.
- 2. The container of claim 1 being cylindrical-shaped.
- 3. The container of claim 1 being box-shaped.
- 4. The container of claim 1, the ramp being detachable from the container inner bottom.
- 5. The container of claim 1, including a liner disposed on the ramp surface.
- 6. The container of claim 5, the liner comprising a plastic bag.
- 7. The container of claim 1, the ramp being fabricated from a metal.
- 8. The container of claim 1, the ramp being fabricated from a plastic.
- 9. The container of claim 1, the ramp being fabricated from a fiberglass.
- 10. The container of claim 1, the container comprising a 55-gallon drum.
- 11. The container of claim 10, the ramp surface angle being about 45 degrees.
- 12. The container of claim 10, the ramp upper rim of about 22 inches in diameter.
- 13. The container of claim 1, including particles disposed therein.
- 14. The container of claim 13, the particles being free flowing, granular or powder.
- 15. The container of claim 14, the particles having diameters of 5 microns to 2 millimeters.
- 16. The container of claim 13, the particles comprising a plastic resin.
- 17. The container of claim 13, the particles comprising a toner carrier.
- 18. A method of removing particles that are disposed in a container having a container inner wall, a container inner bottom with a ramp disposed thereon, the ramp having an included ramp base that is narrower than the container inner bottom, the ramp forming a conical-shaped inclined ramp surface that extends upwardly from the ramp base at a substantially constant ramp surface angle with respect to horizontal towards the container inner wall, the inclined ramp surface defining a ramp upper rim that is substantially proximate to the container inner wall, the particles having an angle of repose that is less than the ramp surface angle and flowing down the inclined ramp surface towards the ramp base, the method comprising removing particles using a vacuum feed nozzle that is disposed proximate to the particles in the container.
- 19. The method of claim 18, the container being cylindrical-shaped.
- 20. The method of claim 18, the container being box-shaped.
- 21. The method of claim 18, the particles comprising a plastic resin.
- 22. The method of claim 18, the particles comprising a toner carrier.
US Referenced Citations (6)