FIELD OF THE INVENTION
The present disclosure relates generally to a hopper system comprising a bottle for receiving and containing material, such as dry bulk materials, and a base for receiving and supporting the bottle, for example, for storage purposes.
BACKGROUND OF THE INVENTION
Rotationally molded dry bulk hopper systems are known. They generally comprise a base with a plurality of legs for supporting a bottle or tank. Typically, these systems are used to hold/store a variety of dry materials such as powders, or granular or pelletized material.
The present disclosure is directed to an improved dry bulk hopper system that has numerous features, including, but not limited to, improved stability, improved structural integrity, reduced manufacturing cost, and a simple and convenient means for securing/removing the bottle to/from the base, as compared to prior art systems.
BRIEF SUMMARY OF THE INVENTION
There is disclosed a thermoplastic, rotationally molded, dry bulk hopper system that comprises a bottle that interlocks with a base. The bottle comprises an upper wall that is generally rectangular in cross section and an integral lower frustoconical wall that tapers to form a circular discharge opening at the bottom of the bottle. There are arcuate transitions between the upper and lower walls that conform to arcuate edges on the base. Integral locking tabs are formed integral with the lower wall adjacent the discharge opening. Disposed on top of the bottle are a plurality of integral, spaced apart support beams, each of which extends from the fill opening to a corner of the upper wall. Apertures on the ends of the support beams are adapted to receive lifting hooks.
The base comprises an outer wall that is generally rectangular in cross section and an inner wall that is tapered to form a cradle adapted to receive and hold the bottle. A circular bottle receiving opening at the bottom of the base is adapted to receive the bottom end of the bottle. Disposed about the bottle receiving opening are a plurality of first and second notches, and engagement ledges formed adjacent the first notches but not the second notches. The bottle may be received into the cradle such that the locking tabs are received into either the first notches or the second notches. When the bottle is in a first orientation relative to the base, the locking tabs are received into the first notches and cooperate with the engagement ledges to secure the bottle to the base by a slight rotation of the bottle. The bottle is unsecured from base by rotation in the opposition direction. When the bottle is in a second orientation relative to the base, the locking tabs are received into the second notches and cannot engage the engagement ledges, such that the bottle is not secured to the base.
The base also comprises integral legs adapted to support the base on a support surface such that the bottle receiving opening is spaced from the support surface by the legs when on the support surface. Disposed on the underside of the base are a pair of forklift pockets defined by a pair of integral brackets, each of which extends from an area adjacent the bottle receiving opening to an edge of the outer wall. Disposed within cavities between the inner and outer walls are support columns extending from the underside of the base to at least the inner wall. Each support column is an elongate hollow extrusion of thermoplastic having portions in continuous contact with portions of the inner and outer walls. When a bottle containing material is disposed in the base, and the base is raised by a forklift, the support columns distribute a load from contents of the bottle to the times of the forklift.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of one side of a dry bulk hopper system, comprising a bottle and a base, according to one embodiment of the disclosure.
FIG. 2 is a perspective view of the system of FIG. 1, and illustrates, in an exploded view, details of the lib and valve assemblies for the bottle.
FIG. 3 is a side view of a pair of stacked dry bulk hopper systems.
FIG. 4 illustrates further details of the bottle and base, the cooperation therebetween.
FIG. 5 is a bottom view of the base taken above line 5-5 of FIG. 4.
FIG. 6 illustrates further details of the cooperation between the bottle and the base.
FIG. 7 is a cross section through the bottom portion of the assembled base and bottle.
FIG. 8 is a perspective view of the base illustrating further details thereof.
FIG. 9 is a cross section view taken through line 9-9 of FIG. 8.
FIG. 10 is cross section view taken through line 10-10 of FIG. 8.
FIG. 11 is a perspective view of the bottle illustrating further details thereof.
FIG. 12 is a view of the underside of the base and illustrates the bottle disposed therein in the first orientation and locked to the base.
FIG. 13 view of the underside of the base and illustrates the bottle disposed therein in the second orientation.
DETAILED DESCRIPTION
Referring to the drawings, where like numerals represent like elements, there is shown in FIG. 1 a dry bulk hopper system 10 according to one embodiment of this disclosure. The system 10 comprises a base 12 and a bottle 14. The base has an outer wall 70 that is generally rectangular in cross section. As described in more detail below, the shape of the exterior wall of the bottle and the interior wall of the base are complementary such that the bottle can rest in the base. Bottle 14 has a circular fill opening 16 for receiving material disposed at the top end thereof, and a circular discharge opening 18 at the bottom end thereof. Disposed in a bottom area of the base are a pair of forklift pockets 20 for receiving the times of a forklift for transporting the base (and the bottle, if the bottle is in the base). Four legs 22, one disposed at each corner of the base, support the base on a support surface such that the discharge opening of the bottle is spaced from the support surface so that material in the bottle can be emptied.
The bottle and base are each manufactured from a thermoplastic material, preferably through a rotational molding process. Accordingly, each of the elements of the bottle described herein are integrally molded to form the bottle (except as noted, i.e., a lib system for the fill opening and a valve system for the discharge opening are not integrally molded to the bottle), and each of the elements of the base described herein are integrally molded to form the base.
Further details of the base and bottle are illustrated in the remaining figures. As shown in FIG. 2, a flange 24 is integrally molded into the top of the bottle to form the periphery of the circular fill opening 16. A removable lib for the bottle comprises a ring 26 that seats onto the flange 24 and receives a removable dust cover 28. Also formed into the top of the bottle are four support beams 36, each extending from the periphery 82 of the fill opening to a corner 84 of the top of the bottle. See FIG. 11. An aperture 38 is disposed adjacent the distal end of each support beam. The apertures 38 are adapted to receive lift hooks from, e.g., a crane or other lifting machine, so as to allow the bottle to be lowered into, and lifted out of, the base. The support beams provide structural integrity to the top of the bottle, especially when systems are stacked, so as to prevent deformity of the bottle, and also to provide structural support while the bottle is being lifted and lowered.
Turing to the bottom end of the bottle, a flange 30 is integrally formed around the periphery of the discharge opening 18 and is adapted to receive a quick release adapter ring 32 which retains a rotatable discharge valve 34. In the disclosed embodiment, the ring 26, dust cover 28, adapter ring 32 and valve 34 are not integral with the bottle. The valve 34 may be a hand operated iris diaphragm valve commercially available from Mucon Schenck Process Group (www.mucon.com), The ring 32 may be a locking lever ring commercially available from Tri-Sure (www.tri-sure.com). As shown in FIG. 12, the valve 34 may have a handle 88 for manually opening and closing the valve by rotation thereof.
As also shown in FIG. 2, the base comprises a pair of viewing windows 46 for observing the bottle while it is being received into and removed from the base. Disposed at the bottom of each leg 22 is a notch 40 that cooperates with the edges of the support beams 36 to allow stacking of the hopper systems 10, 10′, as shown in FIG. 3. An aesthetic design 44 may be molded into selected walls of the base.
FIG. 4 illustrates additional features of the bottle and base. As shown, the bottle of the disclosed embodiment comprises integral upper and lower wall sections 90, 92. The upper wall section 90 has a generally rectangular cross section, and the lower wall section 92 is frustoconical, and has tapered walls 74 that meet the upper wall section 90 to form four arcuate transition regions 54. See FIGS. 6 and 11. Two such transition regions are shown in greater detail in FIG. 6, which illustrates how the transition regions are situated about the vertical axis 58 of the bottle. Integrally disposed adjacent the circular discharge opening are a pair of locking tabs 50, described in further detail below.
A tapered inner wall 72 defines an interior section of the base and has dimensions that generally conform to the dimensions of the lower wall section 92 of the bottle. See FIG. 8. The inner wall 72 serves as cradle for holding the bottle. The outer wall 70 and the inner wall 72 of the base meet to form arcuate edges 56 having dimensions that generally conform to the those of the arcuate transition regions 54. Accordingly, when the bottle has been received into the base, the walls 74 of the bottle rest against the inner wall 72 of the base (see FIG. 7), and the arcuate transition regions 54 of the bottle and the arcuate edges 56 of the base meet in a complementary fashion. As shown by arrow 42 (FIG. 6), the bottle may be lifted out of, and lowered into, the cradle of the base by means of lifting hooks that engage apertures 38.
FIG. 5 (which is a cross section taken through line 5-5 of FIG. 4) and FIG. 6 illustrate further details of the base and the cooperation between the base and the bottle. As shown in FIG. 6 (the left side of which is a top view of the base), there is a bottle receiving opening 60 at the bottom of the base. The bottle receiving opening is formed by the bottom terminal edge (i.e., periphery) of the inner wall 72 and is adapted to receive the bottommost portion of the bottle. Disposed about the periphery of the bottle receiving opening are a plurality of notches 63 adapted receive the locking tabs 50 when the bottle has been received into the base, Turning back to FIG. 5, and as described more fully hereinafter, there are integrally formed engagement ledges 52 disposed adjacent some, but not all, of the notches 63 that are adapted to engage with the locking tabs 50. Also molded integrally with the bottom of the base are a pair of brackets 68, extending from an area adjacent the bottle receiving opening 60 to the outer wall 70, that form the forklift pockets 20. FIG. 5 also illustrates a cross section of the aesthetic feature 48, the viewing ports 46, and the notches 40 in the legs. As described below, there are cavities 94 (see FIG. 7) formed between the outer wall 70 and the inner wall 72 in which there are disposed integral, hollow support columns 48 (see FIGS. 9 and 10). The support columns 48 serve to distribute a load from the contents of the bottle to the times of the forklift. Thus, as shown in FIG. 8, when the times of the forklift are inserted into the forklift pockets (arrows 72), the bottoms of support columns 48 are disposed directly over the times so as to receive the load transmitted from the bottle by the support columns.
FIGS. 7, 12 and 13 illustrate the cooperation between the locking tabs 50 and notches 63. As shown in FIG. 12, when the bottle has been received into the base, such that the locking tabs are received into first notches 64 (first orientation), the bottle can be slightly rotated such that the tops 86 of the locking tabs slide over, and engage, the engagement ledges 52. See FIG. 7. Detents in the engagement ledges, formed by slight, integral protrusions extending therefrom, may be provided to cause the bottle to snap and/or lock into place when the bottle is thus rotated. In this manner, the bottle is secured to the base. Rotation of the bottle in the opposite direction disengages the locking tabs from the engagement ledges and allows the bottle to be removed. There are no engagement ledges disposed adjacent second notches 66. Thus, as shown in FIG. 13, when the bottle has been received into the base, such that the locking tabs are received into second notches 66 (second orientation), the bottle is not able to be secured to the base and can be freely removed without the need to disengage it.
FIGS. 9 and 10 are cross sections taken through line 9-9 and line 10-10, respectively, of FIG. 8, and illustrate internal details of the base. Particularly, details of the support columns 48 are illustrated. As shown in FIGS. 5 and 7, a proximal end of each of the four columns 48 originates at the bottom of the base, and the columns are disposed on opposing sides of the forklift pockets 20. As shown in FIG. 7, the walls of each column 48 are extruded so as to extend from the bottom of the base through the cavities 94 defined by the tapered spaces between the exterior wall 70 and interior wall 72. As shown in FIGS. 9 and 10, a distal end 78 of each column 48 is slanted to conform to the taper of the interior wall 72 and terminates at the interior wall such that substantial continuous contact is formed between the slanted distal end 78 and the interior wall 72. In addition, the longitudinal portion 80 of each column is formed so as to be in substantial continuous contact with the exterior wall 70. Preferably, each column is hollow. Those skilled in the art will appreciate that, through the molding process, the distal ends 78 are formed integrally with the inner wall 72 and the longitudinal portions 80 are formed integrally with the exterior wall. These contact portions are sometimes known in the art as “kiss-offs”. Due to the positioning of the columns 48 relative to the lift pockets 20, the existence of the kiss-offs between the slanted ends 78 of the columns and the interior wall 72, and the kiss-offs between the longitudinal portions 80 of the columns and the exterior wall 70, any load created by material in the bottle will, when the bottle is in the cradle, be transmitted by the support columns to the proximal ends thereof, i.e., the ends of the columns at the underside of the base. Accordingly, when the system is raised by a forklift, the load is distributed to the forklift's times.
There has thus been described a dry bulk hopper system that embodies various novel and non-obvious features. The system described herein may be embodied in other specific forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the appended claims, rather than the foregoing specification, for indicating the scope of this application.
Patent Grant
11597589
