The present invention relates to material compacting, and more particularly to industrial waste compactor systems and waste collection vehicles.
Methods and devices for picking up, storing and disposing of waste materials are in common use today. The devices include compactors with receiver containers, self-contained compactors and waste vehicles, among other devices and systems.
Stationary compactor systems typically include a compactor mechanism and one or more large metal box-like containers. The containers are put in a location adjacent the compactor device when empty, and then picked up when loaded. The loaded containers are then taken to a landfill or dump site and unloaded. At a site where containers are required continuously, empty containers are typically dropped off when the loaded containers are picked up. The containers typically have wheels or slide rails on the bottom so they can be more easily moved into position and loaded and unloaded on a vehicle.
Trash and other waste materials are loaded into the containers typically at a door at one end, or an opening in the top surface. A hydraulically operated pusher blade in the compactor device can be used to compact materials in some systems. Once compacted, the blade is returned to its rest position so additional materials can be loaded. Once the container is fully loaded, it is picked up (typically by a truck with a bed) and usually replaced with an empty container.
Waste collection vehicles (commonly called “garbage trucks”) have a large storage container on the back of the vehicle behind the cab and typically are made in two basic styles: a rear loading style, and a front loading style. The rear loading style has an opening in the lower portion at the rear of the truck where the trash can be loaded. Once a portion of the trash or waste is loaded, a hydraulically actuated blade member is used to transfer the trash toward the front of the container. A second hydraulically actuated blade member is then used to compact the trash inside the container. The front loading style has an opening in the top of the container behind the cab and uses hydraulic-actuated arms to pick up loaded dumpsters or waste containers and dump them into the opening. The waste materials are then compacted by a hydraulically operated blade member inside the container. Once loaded, both styles of waste trucks are driven to a landfill or other location where the loads are dumped out or ejected. Once empty, the trucks are available to pick up more trash and repeat the process.
Both of these types of compactors, i.e. the waste compactor systems and the waste collection vehicles, have concerns that need improvement. The forces necessary to adequately compact the trash and waste materials require heavy and strong metal structures. There are expensive and add to the total weight of the load. Collection containers and vehicles constructed of lighter and weaker materials would require additional expense and maintenance to prevent premature failure. Also, the present systems often require manual cleaning to remove loose materials, particularly those which become lodged behind the compaction blades.
In addition, the present collection containers, either freestanding or on waste collection vehicles, are inefficient in that they often leave significant voids and open areas in the compacted loads. Also, the compacted materials typically “fall-back” causing de-densification during blade retraction. The incomplete filling causes unnecessary trips for unloading over a given period of time. Further, the present collection members typically are not water tight and allow liquids in the waste materials to leak out. This also causes messy and time consuming clean ups.
There is a need in the waste collection field for compactor systems and compactor vehicles which are more efficient and can fill a larger percentage of the volume inside the containers. There further is a need for compactors which are more energy efficient and which do not cause premature wear on the container or components.
The present invention has particular use, but is not to be limited to, freestanding waste collection systems and front-loading waste collection vehicles. The inventive system utilizes a compactor blade member which is located at an elevated (raised) position above the floor of the waste containers and preferably adjacent the upper or top wall of the container. Preferably, the blade member has a vertical height about 20-80% of the vertical height of the cavity. The blade member is hydraulically operated and preferably guided by guide rails positioned on the sidewalls or upper walls of the containers.
As waste materials are introduced into the waste container through a door or opening in the ceiling or upper walls, the compactor blade is activated. This levels out the materials in the container and compacts a portion of the materials against the opposite end of the container. The heavier or more dense waste materials settle at the bottom portions of the collection container, while the lighter and less dense materials are pushed longitudinally along the existing filled volume of waste materials in the lower level of the container. As the volume of the container is filled, more and more of the materials will be compacted against the opposite end and vertically downwardly. Some of the waste material can also be pulled back in the retraction direction of the compactor blade in order to fill any open spaces. The compactor blade can be hydraulically operated in either a push or pull-type hydraulic system.
One embodiment of the present invention has two compartments in the container in order to collect different types of waste materials. This embodiment has particular use in collecting normal waste or trash materials in one compartment, and collecting recyclables in the other compartment, or in collecting two separate types of recyclable materials (e.g. paper and plastic). One method utilizes a platform or shelf located below the container entry opening and the materials can be pushed or pulled one way or the other, into the first or the second compartments, depending on the type of materials being introduced into the container. The platform also can have a hinged or moveable wall or partition so that the two compartments can be separately emptied. Removal openings or doors can be provided at one end or alternatively at each end of the container.
One of the benefits of a preferred embodiment of the invention is that materials in the container can be discharged from the same end of the container where the compactor blade is located. This allows the container to be located on a bed of a truck or on a trailer (pulled, for example, by a pick-up truck). Tilting of the container allows it to be emptied through a door behind or below the compactor blade. In another embodiment, the compaction blade is positioned at the front end of the container and compacts the materials rearward toward the rear wall which has a discharge door. Movement of the compaction blade can be utilized to assist in emptying the cavity or compartments in all of the embodiments.
Further features and benefits of the invention will become apparent from a review of the following detailed description, together with the accompanying drawings and appended claims.
The present invention will be described herein with respect to uses relative to waste collection containers and front-loading waste collection vehicles. It is to be understood, however, that the present invention can be used on other containers and other vehicles, and for purposes other than waste collection and disposal. In this regard, the invention can be used, and has utility and benefits for use, with any structures, equipment, and vehicles falling within the scope of the claims.
Some preferred uses of the invention relate to collection of recyclables and collection and disposal of organic materials, such as brush, leaves and moist garbage. The invention also can be used effectively, and with more advantages and benefits over the prior art, with respect to collection and disposal of these materials, or with other waste materials that contain a high percentage of liquids.
In the attached drawings,
The term “waste materials” and “trash materials” will be used synonymously herein, and includes recyclable materials. These terms also are to be interpreted in their broadest sense and encompass all types of materials that are intended to be discarded and/or disposed of. Waste and trash materials, for example, include, but are not limited to, paper materials, wood materials, cardboard materials, glass items or materials, plastic items or materials, metal items or materials, organic materials, lawn and forest materials, and the like. The waste/trash materials can be materials which can be recycled. The materials further can be dry or have a significant fluid content.
The container 10 is used to hold waste materials of all types. The container has two sidewalls 12 and 14, two end walls 16 and 18, a top wall 20 and a bottom wall 22. For purposes of description in this document, the “front” end of the waste container will be the end that faces the cab of a truck when the container is mounted on a truck or on the bed of a truck or faces a vehicle which is pulling the container. The other end will be called the “rear” or “back” end. In
The container 10 is preferably made of a strong and durable metal material, such as steel. As shown in
Some embodiments of the container 10 also can have an opening (not shown in
Further, a plurality of wheels 34 or skid members (not shown) are positioned on the bottom corners of the container 10, as well as a pair of lower side rails 36. These allow the container 10 to be more easily loaded and unloaded from a delivery vehicle. In use, empty containers are typically dropped off at a collection site and then picked up and emptied when they are full. The contents are typically emptied at a landfill or other dump site.
Waste collection containers, such as representative container 10, are typically utilized with a stationary compactor mechanism or device (not shown). The compactor mechanism receives waste and trash materials and typically compacts them and pushes them into the container through, for example, the opening in the lower portion 28 of the frame member 24 in door member 18. In some instances, as discussed in more detail below, the compactor mechanism is positioned interiorly or exteriorly to a building and receives the waste materials from a chute. Some compactor mechanisms also can pre-crush the materials in the compactor chamber as a first step and then push the crushed material into a container.
The present invention provides a waste container which incorporates a unique and different compaction system. The compaction system includes a compactor blade which is positioned and reciprocates in the upper areas of the containers above the floor, leaving a space between the blade and the floor. The compaction system is preferably hydraulically operated. For shorthand purposes of the present description of the invention, the waste collection container in accordance with the present invention will be simply called by the term “waste container” or “compacting waste container” herein.
One embodiment of the invention is depicted in
A compactor blade 75 which is preferably hydraulically operated, can reciprocate back and forth substantially along the longitudinal length of the container—as shown by arrow 77. The blade 75 preferably extends horizontally between the side walls 64, 66 (with a small clearance). A pair of hydraulic cylinder members 78 are provided (only one of which is shown in
The hydraulic cylinders are attached at one end 80 to the container and at the other end 82 to the compactor blade or vice versa. A pair of brackets 84 is provided on the blade for this purpose.
The blade is preferably made of a metal material and can be a solid structure or a thinner structure backed by supporting reinforcing members. The blade 75 is preferably guided along the length of the container by channels 86 or equivalent guide members. In this regard, two alternative exemplary ways to guide the movement of the blade in the container are shown in
The raised compactor blade can alternatively be attached to a carriage or frame which guides the blade along the length of its stroke in the container. The carriage can be designed to distribute any large twisting and movement loads into guide channels or guide rails.
The container 52 has at least one opening 100 on the top wall 60. Preferably with this embodiment, the top wall opening 100 is positioned adjacent to the front wall 56. This allows the blade 75 to push, redistribute and compact the materials as it proceeds in the direction towards the rear or back wall 58. The trash and waste materials are inserted into the hollow unitary volume inside the container through the opening 100. This is shown by arrow 102. A cover member (not shown) can be provided to cover the opening 100. A door member 120, which preferably is a hinged door member, is provided in the back wall for removal or dumping of the materials from the container.
The hydraulic mechanism used to actuate the compactor blade 75 can be positioned at any location inside or outside the container 52. The hydraulic mechanism also could be a separate unit connected to the container with hoses, cables, or the like. In the embodiment shown in
When the trash and other waste materials are introduced into the container 52, the compactor blade 75 is activated and is used to push the materials toward the rear wall 58 of the container. The heavier and more dense materials will fall by gravity toward the bottom wall or floor of the container and the blade will level out the materials along the container. The movement of the blade also compacts the materials below the blade by pressure through the other materials. Any materials which remain above the lower edge 76 of the blade can be compacted against the rear wall 58 of the container. The blade also can level out or help compact the lower level materials when the blade is being retracted to its start (rest) position. Movement of the compactor blade back and forth several times along its length of trash assists in redistributing and densifying the waste materials. The waste materials are identified by 99 in
When the container 52 is full, it is transported to a dumpsite or land fill and dumped, ejected or otherwise unloaded in a similar manner as set forth above with reference to
As indicated, preferably the compactor blade 75 is located at its rest position at the front end of the container (adjacent opening 100). The power unit which operates the blade includes an electric motor, hydraulic pump and hydraulic fluid reservoir, and is a self-contained system. A water tight seal is provided around the compartment 110 to prevent wet or semi-liquid waste materials from affecting the operation of the power unit.
The specific type of hydraulic mechanism utilized to reciprocate the compactor blade and level and compact the waste materials in the container is not critical. Most of the known hydraulic mechanisms in use today for the stationary waste compactors could be utilized. In addition, the hydraulic cylinders could be positioned behind the compactor blade and include a “scissor”-type mechanism.
As the material in the container increases in volume, the more the materials 99 will settle and migrate downwardly, and become compacted in the area below the lower edge 76 of the compactor blade. Any materials which stick up after the blade passes will be leveled or compacted as the blade travels in the opposite direction, or back-and-forth several times.
With the present invention, the amount of material that can be compacted and loaded inside the container is more than the amount that can be loaded and compacted into collection containers known today. Due to the top loading and raised compaction blade, the trash materials act in a manner more like fluid dynamics in filling the container volume to a greater extent. The amount of voids and open areas are decreased with the invention. Redistribution of materials of different densities can be achieved by continued movement of the raised blade. Also, the amount of “fall back” of the materials in the container that are compressed is less than with known compaction systems. This means that there is less “de-densifying” of the materials in a collection container with use of the present invention. It is believed that the use of a raised floor at one end of the container, such as wall 114 of compartment 110 in
As indicated, the compactor blade 75 is positioned only in the upper or raised elevations or areas of the space in the container 52. The blade 75 has a vertical dimension V which at its lower edge 76 is 20-80% of the height H of the inside of the container as measured from the top wall 60 toward the bottom wall 62. This means that the lower edge 76 of the blade is preferably spaced from the bottom wall an amount of 20-80% of the total height Z inside the container. Preferably, the lower edge is at a height H less than 50% of the overall height Z of the container and within the range of 30-60% of Z measured from the upper wall 60. The height V of the blade can also be changed depending on the waste materials that are to be loaded into the container. Typically, the heavier and more dense are the waste materials, the less is the distance V. Similarly, with lighter and less dense materials, the distance H can be increased.
The compactor blade 75 can be actuated by any conventional hydraulic compactor mechanism or system so long as it can move the blade along at least a portion of the container and compact waste materials against the rear wall. In some embodiments, it may be necessary to only have the raised blade travel about one-third to one-half the longitudinal length of the container. Other embodiments may require the blade to travel substantially the entire length of the container. One or more hydraulic mechanisms or cylinders can be used to either push or pull the compactor blade longitudinally inside the container.
It is understood that the travel of the blade inside the container can be for any portion of the length of the container from about 10-100%. The length of travel depends in part on the type of waste materials being collected. In most instances, the length of travel of the blade can be 25-75% of the length of the container, and preferably 30-70%. The longitudinal length of travel of the blade may also depend on the size and length of the hydraulic cylinders utilized.
In general, the guide rail members can have slots or tracks in them and the blade member can have corresponding fingers, appendages, protrusions, or the like which fit and slide in or on the slots or tracks. In other embodiments, sets of two guide rails are provided and can be spaced a certain distance apart, such as 6″-12.″ With these embodiments, the side edges of the compactor blade preferably have one or more protrusions or raised members which fit between pairs of guide rails (as shown in
In an additional embodiment, a plurality of rotatable or pivotable claw members 130 (or finger members) can be positioned extending downwardly on the lower edge 76′ of the compactor blade 75′. This is shown in
As indicated above, the heavier and more dense waste materials will fall or gravitate due to their weight or structure into the lower levels of the waste materials. The lighter and less dense materials will typically stay on top. Thus, with many of the strokes of the compactor blade, the principal materials that will be compressed either against the rear wall or against the lower wall and earlier compacted waste materials, are the lighter and less dense materials. This means that such strokes will result in less “wear and tear” on the floor of the container, as well as on the blade and hydraulic system. This would also result in the use of less energy. This also means that voids and open spaces in the trash materials are more likely to be filled in.
As the compactor blade returns to its rest position adjacent an end wall of the container, any materials which are still higher than the bottom edge of the blade, or which “pop up” after the blade passes them, will be leveled or pushed into the space against the rear wall on the subsequent strokes of the compactor blade.
With the present invention, that the fill volume in the container will be greater than with compaction systems or mechanisms which utilize short compaction blades positioned on the floor of the containers, or with full height compaction blades that extend from the floor to the upper wall. Also, the amount of voids or free space left unfilled in the container when it appears to be full and needs to be emptied, will be less with the present invention.
An alternate embodiment of the invention is disclosed in
With the embodiment of the invention depicted in
The size of the opening 160 can depend in part on the size of the waste materials being compacted. Typically the openings extend substantially across the width of the container, and extend in the longitudinal direction of the container. The present invention opening can be considerably larger in both width and length dimensions. The width may be 70 inches wide versus 60 inches with known containers today, and the length not limited to the catalog sizes of conventional compactors of 42 inches and 60 inches, but only limited to one-half the travel of the waste container longitudinal length. The nominal length of a conventional waste collection container is 22 feet.
As shown in
The distances “A” and “B” are dependent on the size of the container and the amount that the front end of the container has been lowered to be able to receive waste materials from a chute member or the like. In general, the distance “A” should be 30-50% of “X”, which is the height of the container at the opposite end. Also, the distance “B” should be about 20-30% of the height “X”.
It is also possible with other embodiments of the invention to provide two or more separate areas in a container for collection of separate types of materials, such as waste and recyclables, or two different types of recyclables (e.g., plastic and metals). One such embodiment is shown in
With this embodiment of the invention, the waste collection container can be used to collect two different types of waste materials, such as organic material on one side and metal or plastic materials on the other side, or as waste materials on one side and recyclable materials on the other side. This saves use of two separate vehicles traveling along the same route in order to pick up separate materials and also saves the expense and footprint of two separate waste containers.
In order to direct the waste materials into area A, the compactor blade 206 is used in the standard manner as discussed above. The materials are introduced into the opening 210 in
When it is desired to empty the container 190, a hinged door member 230 is provided at the rear end wall 192 for this purpose. After the materials in portion A are emptied, then the hinged shelf portion 208 is raised and the materials in portion B can be emptied out of the same door member. In this regard, the typical manner in which waste collection containers are emptied is to raise one end of the container and let the materials fall out the door at the other end. The activation of the compactor blade can assist in ejecting or removing the materials from the container.
In another embodiment, separate door members can be provided at each end of the container in order to allow the collected materials to be removed from separate ends of the container.
An alternate embodiment of a multi-compartment waste/recyclable container 700 is shown in
A moveable partition, door or wall 230 is positioned inside the container 700 and separates the area inside the container into two separate compartments A and B. The door or partition 230 is connected (hinged) to one side wall, such as side wall 710, and extends across the width of the container between the sidewalls. In
The dumping of materials from the container 700 is shown generally in
The compactor blade 720 can be the same as, and operated in the same manner as, any of the compactor blades previously shown in
The edge 222 of the partition or wall 230 can be rotatably connected or hinged to the side wall 710 in any conventional manner. In addition, the opposite edge 224 of the partition or wall can be releasably connected to the opposite sidewall 712 in any conventional manner. Preferably a releasable latch mechanism is provided on the edge 224 or sidewall 712, or both, in order to hold the partition in the separation position shown in
When the partition is positioned in its “open” position as shown in
It is also possible for the container 700 to have more than two compartments. For these embodiments, there will be two or more internal partitions or doors, and either one larger opening in the top wall or two or more openings in order to drop the waste or recyclable materials into the appropriate compartments in the container. This will also preferably require the compactor blade to be positioned appropriately for each of the materials being collected. For one or more of these embodiments, it also is possible to have doors at both ends of the container for ease of dumping or removal of the materials from the container.
In these collection container embodiments, one of which is shown in
The use of the present invention in waste collection vehicles (a/k/a “garbage trucks”) is shown in
The waste container 305 is a large collection vessel for compacting, storing, and transporting trash and other waste materials. A compactor blade 335 having a height 336 is positioned inside the container 305 and is hydraulically actuated to push the waste materials 340 in a direction toward the rear of the vehicle and compact the materials against the rear wall 342. This is in the manner similar to that described above with reference to
It is also possible for the compactor blade to have the shape shown as number 335′ in
The compactor blades 335 and 335′ are preferably operated hydraulically. The hydraulic systems can be positioned at any convenient location on the vehicle. The engines for waste collection vehicles are typically diesel engines or engines that run on compressed natural gas (CNG). In CNG driven vehicles, the CNG tanks and systems are typically positioned in a compartment 345 positioned at the top of the vehicle adjacent the rear end as shown in
It is to be understood that the present invention is not to be limited to the use of hydraulic systems to move the compactor blade and compact the waste materials. Other systems could be used for this purpose.
The embodiment of the invention shown in
Again, when it is desired to empty the two compartments C and D, the compartments are typically emptied separately. First, the materials in compartment C are emptied. Then, the hinged portion 382 is raised and the materials in compartment D are emptied. The trash collection containers are typically elevated like dump trucks in order to dump or unload the waste materials. The compaction blade can also be used to help eject the materials. Other systems could also be used to empty out the contents of a container, such as systems utilizing a manually operated “walking floor” apparatus.
An improvement in the location of CNG systems to operate a waste collection vehicle is possible with the present inventive raised compactor blade system. This is shown in
The floor 412 of the collection container 305 has a raised floor 422 positioned below the compactor blade and in the front of the container near the cab. The CNG cylinders and equipment 420 are positioned under the waste container formed by the raised floor 422. By positioning the CNG equipment under the waste container, rather than on top of the waste container, this prevents them from being damaged or interfering with the movement of the vehicle. The area 423 under raised floor 422 as a net gain of chassis additional space behind the cab. The area can be utilized for various engine and vehicle components and/or as room for the various electrical batteries requirements for the upcoming electric chassis for garbage trucks.
Additional embodiments of the present invention are first shown in
The blade member 515 has a height dimension H which is 20-80% of the full vertical height Z of the container 505 in the same manner as described above relative to other figures. The control and operation of the compactor blade are also preferably the same as, or similar to, the hydraulic systems set forth and described above.
In order to empty out the container 505, the container 505 is angled upwardly relative to the trailer 510 by one or more hydraulic cylinders, as represented by hydraulic cylinder 530 shown in
The container 505 can be tipped or elevated into the position shown in
With this embodiment of the invention, the trailer could be attached to a pick-up truck, such as truck 570 or the like. This would allow the waste collection system to travel and be positioned in numerous locations which could not be serviced due to difficult urban space limitations. The invention would also be more efficient than a traditional waste container truck of the type shown in
A second embodiment 600 shown in
The top wall opening 625 should be positioned at a rearward position on the top wall 619 which is adjacent to rear wall 620 when the compactor blade is positioned at rest adjacent to the rear wall.
The container and compactor blade function and operation are substantially the same manner as discussed above relative to other embodiments. In addition, preferably, the blade member 615 is positioned at a height dimension H of 20-50% of the full height Z of the container 605.
The vehicle 670 can have a hydraulically operated tilting mechanism 660 which, when activated, tips the container as shown in
In the
In order to show the benefits and advantages of the present invention, comparison tests were made with representative scale models. The tests compared the payloads and weight of containers which were loaded with similar materials and which used the following three types of compaction blades: (1) a full blade; (2) a partial blade on the floor; and (3) a raised partial blade.
A one inch-per-foot model was constructed to reflect the mobile and stationary compactor applications. The conventional mobile and box-like compactor containers are normally 22 feet in length, 8 feet in height, and 8 feet in width. The scale model chamber was correspondingly made to be 22″×8″×8″. The model had a wood box-type frame with an open space for loading materials at the upper end of the chamber adjacent the compactor blade.
The travel of the compaction blade was powered by an electric scissor-action device commonly used to power an automobile window. The electric motor was energized by a 12-volt automotive battery. A 12-volt battery charger was continuously utilized to maintain a constant charge in the battery.
The blades were all made of wood and attached to an elongated rod. Guide rails were used along the edge of the floor for blades (1) and (2). Mulch was used as the compaction material. The mulch was added to the containers during the tests in measured one liter units. The mulch was added and compacted in all of the tests in the same manner.
The model compaction chamber was placed on a digital scale in order to record the weight tests. The chamber was weighed before and after each test. Each test was run several times.
Full Blade Test:
The blade was 7½″×7½″ and was connected to the elongated rod. The model was operated several times without anything in the chamber to make sure that the blade traveled smoothly from one end to the other. The mulch was added in measured units through the opening in the top surface. The blade was activated and the mulch compacted after each unit of mulch was loaded into the chamber.
Floor Blade Test:
The blade was 4″ in height and 7½″ in width. The blade rested on and traveled along the floor. It was guided by guide rails positioned at the bottom corner of each of the side walls.
Raised Blade Test:
This test incorporated the invention. The blade was 3″ in height and 7½″ in width. The top edge of the blade was positioned immediately adjacent the top wall and the bottom edge of the blade was spaced about 5″ from the floor of the chamber. The movement of the blade along the chamber was guided by guide rails positioned on the upper edges of the side walls adjacent the top wall.
Test Results:
The mulch was added in the same liter units during each test, and the compaction blade operated and the material compacted in the same manner until it was not possible to add any additional mulch. The number of measured units of mulch was recorded for each of the four tests for each type of blade, and the four amounts averaged. The weight of the compactor chambers was also taken after each test and the amounts were averaged. The results are shown in the following chart:
As evidenced, the model representing the present invention was able to compact 20% more of the waste materials than the full blade embodiment and 69% more than the floor blade embodiment. In addition, the average weight of the compacted loads was 49% and 63% greater with the partial (raised) blade than the full blade and floor blade embodiments, respectfully.
The results of these tests showed that the present invention with use of a raised compactor blade resulted in filling the waste containers with 20% to 69% more of the waste materials and a load which was 49% to 63% heavier. Thus, the use of the present invention would result in substantial savings of time, money and labor in the collection of waste materials.
Although the invention has been described with respect to preferred embodiments, it is to be also understood that it is not to be so limited since changes and modifications can be made therein which are within the full scope of this invention as detailed by the following claims.
This application is a continuation-in-part of U.S. patent application Ser. No. 13/969,357, filed on Aug. 13, 2013, which is incorporated herein by reference in its entirety
Number | Date | Country | |
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Parent | 13969357 | Aug 2013 | US |
Child | 15859143 | US |