Patent Application
20160213031
This invention relates generally to the field of food product processing, and more particularly to egg processing.
Eggs represent a food product distributed and consumed in large quantities. For many of the same reasons making them desirable food stuffs, eggs also present a unique safety risk. Eggs (most commonly chicken eggs) contain nutrients which can support the growth of dangerous bacteria, when contaminated.
Eggs are a perishable item susceptible to spoilage, as well. To address the concern about spoilage—i.e., whether the egg is fresh—egg packages typically (and often by law or regulation) have expiration dates marked on them. However, eggs may be stored for days or even weeks before being sold at retail. Furthermore and of additional consideration in certain jurisdictions such date marking on packaging may not actually represent a period of time from laying of eggs, but may only represent a period of time from packing, even though the eggs themselves may have aged prior to being packed. Expiration dates (a term encompassing such variations as “sell by” and “best if used by” dates) thus may not convey to a consumer or user how “old” an egg truly is. Many consumers, moreover, move eggs from their packages into special receptacles in their refrigerators or consolidate eggs from multiple cartons together. In this fashion, additionally, eggs from multiple cartons may come to be intermingled, usually indistinguishably. When one or more of these things are done, the consumer is no longer able to evaluate the expiration date of individual eggs prior to using them.
To reduce the chance of a consumer being sold a spoiled egg, certain governmental bodies in the United States and elsewhere, e.g., the United States Food and Drug Administration (FDA), the United States Department of Agriculture (USDA), and various state governments, currently do not allow retailers to “repack” eggs, i.e., to move eggs from one package to another. This restriction, unfortunately, can result in tremendous waste. For example, whenever the integrity of even a single egg in a package in the hands of a retailer is compromised (e.g., is broken), the entire package of eggs must be discarded.
Not only is this wasteful of otherwise good eggs, but also of the resources used to produce those eggs. Eggs typically undergo a great deal of processing before they are ready to be sold to the consuming public. In many circumstances, for example, eggs pass through several processing stations at which they are washed, candled, weighed, graded, and packed into packages (e.g., cartons, crates, or other commercially distributed containers). Examples of such processing stations and mechanisms for conveying eggs from station to station are described, for instance, in the following U.S. patents assigned to Diamond Automations, Inc.: U.S. Pat. Nos. 4,189,898; 4,195,736; 4,505,373; 4,519,494; 4,519,505; 4,569,444; 4,750,316; 5,321,491; and 6,056,341, the entire contents of each of which are incorporated herein by reference. It is not uncommon for a facility in which these stations operate to output about one million eggs in a single day. Accordingly, to be commercially acceptable, the throughput of the stations needs to be quite high, with some stations typically processing on the order of 20,000 eggs per hour.
When contamination (and possibly spoilage) of eggs is discovered, therefore, not only is it likely that the number of persons made ill—or worse—will be quite large, but also that enormous numbers of eggs must be recalled and destroyed. Many of those eggs will not have been contaminated and will have to be destroyed—at considerable financial loss—because there is no way to isolate the bad eggs from the total population of eggs from a suspect source.
Therefore for all the reasons discussed above, it is advantageous for both food safety and economic reasons, to be able to mark individual eggs with data including, but not limited to, expiration information and traceability information. Such eggs may then be consumed or discarded by the consumer or retailer, such decision being based on data marked directly on the egg.
Several techniques for marking individual eggs with expiration dates and the like have been proposed. One such approach is to use vegetable dyes or other water-soluble ink products to mark eggs. Such products, however, have a tendency to leak into the interior of eggs and can result in undesirable ink spots within them. Further many of these techniques also require the use of inks classified as Food Additives by the FDA. The tendency of such products is to be of poor aesthetic quality, and to wash off or fade. Therefore this also means that such markings are susceptible to tampering and even unintentional loss of integrity (e.g., dripping and smearing from condensation and handling), and has generally limited their acceptance.
Several techniques for marking individual eggs with expiration dates and the like use solvent based inks. These inks seek to overcome the issues presented by water soluble inks but still result in the use of food additives and solvents. Such products while approved for food use are undesirable compared to completely chemical free alternatives and are therefore limited in their acceptance.
It is also known to use lasers to mark indicia onto perishable products for the purpose of tracking their pedigree and/or integrity (e.g., using date codes and/or traceability codes), as well as for allowing textual or graphical advertising messages to be disseminated via such products. An example of a system for laser marking such information on hen eggs is described, for example, in U.S. patent application Ser. No. 11/725,099, Publication No. 2008/0223834 (“the '834 Publication”), published on Sep. 18, 2008 (now U.S. Pat. No. 8,084,712 issued Dec. 27, 2011 and U.S. Pat. No. 8,884,185 issued on Nov. 11, 2014 (continuation of U.S. Pat. No. 8,084,712). The disclosure of the '834 Publication is incorporated herein by reference in its entirety. Additional laser marking apparatus and methods are disclosed in, for example, U.S. patent application Ser. Nos. 12/690,859, 12/690,872, 12/690,876, 12/690,886, 12/690,890, 12/690,896, and 12/690,898, all filed Jan. 20, 2010 (now U.S. Pat. No. 8,455,030 issued Jun. 4, 2013, U.S. Pat. No. 8,657,098 issued Feb. 25, 2014, U.S. Pat. No. 8,499,718 issued Aug. 6, 2013, U.S. Pat. No. 8,715,757 issued May 6, 2014, U.S. Pat. No 8,455,026 issued Jun. 4, 2013, pending application Ser. No. 12/690,896, and U.S. Pat. No. 8,823,758 issued Sep. 2, 2014), each titled “Systems And Methods For Processing Eggs” and hereby incorporated by reference herein; and in PCT Application No. PCT/US2011/021680, Publication No. WO2011/091011 (the '011 Publication), which claims priority to these seven applications and is also incorporated by reference.
To use such a laser marking system to advantage, eggs preferably should be oriented in a predetermined fashion in order to facilitate focusing the laser beam, placing the markings uniformly on the eggs in a package and assuring that sufficient egg surface is exposed to the laser beam so that the entire intended marking can be applied. To facilitate achievement of such goals, the '011 Publication discloses use of a mechanical orienter apparatus which helps position eggs in a container prior to being exposed to the laser beam.
While the mechanical orienter succeeds in desirably arranging the eggs for laser marking, it does nothing to maintain the positions of the eggs in their containers thereafter. As a result, in shipment and handling, eggs may tilt, twist (spin) and otherwise move within their containers and when a purchaser opens the container, the uniform arrangement of the eggs at the time of marking will not have been maintained. Due to such movements, some of the markings (e.g., freshness date and traceability information) thus may not be readily visible to the purchaser simply by opening the container. Further, such movement may contribute to breakage of some eggs.
Such movements, moreover, may induce the consumer to touch, spin and/or remove and replace the eggs in the carton, for the purpose of moving the egg back into its original forward facing position, so the dates and traceability codes can be more easily read by the consumer. This touching and handling activity increases the risk of spreading disease organisms from hand to egg and from egg to hand, and then from hand to grocery wagon handle and other products in the supermarket. It also increases the risk of breakage—the more each egg is handled, the more eggs will break as a result of such handling.
In addition to the issues presented concerning orientation of eggs within their packaging, additional problems exist in the prior art concerning marking of eggs with lasers. Specifically, maintaining a consistent degree of laser beam focus on the surface of the egg is critical to consistency of marking contrast and controlled depth of mark.
Eggs, however, have a continuous distribution of sizes based on chicken age and other factors well known in the egg industry.
Eggs are sold by weight, not size. Therefore, the variety of sizes that are required to be marked within a carton, or between cartons, is highly variable despite the weight being fairly consistent and within required specifications.
Systems and methods are therefore needed to both control the arrangement of eggs of different sizes within a carton to optimize laser marking and to promote the readability of every egg when a purchaser opens a container of eggs, and to reduce movement and handling that might induce breakage and/or spread germs (especially in the supermarket) and to somehow maintain eggs in their uniform arrangement from the time of marking until purchase.
The following presents a simplified overview of the example embodiments in order to provide a basic understanding of some aspects of the example embodiments. This overview is not an extensive overview of the example embodiments. It is intended to neither identify key or critical elements of the example embodiments nor delineate the scope of the appended claims. Its sole purpose is to present some concepts of the example embodiments in a simplified form as a prelude to the more detailed description that is presented later.
In accordance with the embodiments herein, the present disclosure includes a system for an improved container for eggs as well as systems and methods for arranging eggs within a container. In a preferred embodiment, the present disclosure includes a container including a plurality of receptacles disposed in one or more rows, wherein each receptacle is constructed and arranged to hold an egg within a compartment of the receptacle so that the egg is substantially maintained in a resting orientation where a long axis of the egg is titled toward a rear portion of the container at an angle slightly offset from a vertical axis.
In some embodiments, the present disclosure includes receptacles that may include alternating tilting of the eggs when a pair of eggs are tilted in the opposite direction at the next pair of eggs. Additionally, the container may be made of transparent material that allows consumer to see the marking on the tilted eggs without having to open the container.
In some embodiments, eggs are gently manipulated using a static or dynamic orienting device, which centers the eggs in the carton pockets in a plane perpendicular to the direction of flow of the egg cartons in order to make the position of the eggs more consistent prior to the lasing process, resulting in more consistent marking performance. In other embodiments, the eggs are gently manipulated by the orienting device to a specific tilt angle that optimizes the marking performance by the laser depending on the laser configuration.
In some embodiments of the present disclosure, methods and systems are included to accommodate the differing marking tapestries of different sized eggs and to optimize the marking thereon. In some embodiments, this is accomplished by setting the laser marking source at a specific height and angle and adjusting the stopping point of the eggs on the conveyor prior to lasing such that the throw distance of the laser marking system is thereby adjusted without requiring the provision of additional motion systems specific to that purpose.
In some embodiments of the present disclosure, laser marking systems may be configured such that they face in alternate directions. Laser marking optimization can be achieved through various orientations of these laser marking systems and/or adjustments made to associated motion systems and devices.
For those experienced in the art of marketing and retail the advantages of an embodiment allowing marked eggs to face in both directions will be apparent in terms of improving retail performance of a product due to shelf appeal.
Still other advantages, aspects and features of the subject disclosure will become readily apparent to those skilled in the art from the following description wherein there is shown and described a preferred embodiment of the present disclosure, simply by way of illustration of one of the best modes best suited to carry out the subject disclosure As it will be realized, the present disclosure is capable of other different embodiments and its several details are capable of modifications in various obvious aspects all without departing from the scope herein. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
The accompanying drawings incorporated herein and forming a part of the specification illustrate the example embodiments. In the figures, like reference numerals designate corresponding parts throughout different views.
This description provides examples not intended to limit the scope of the appended claims. The figures generally indicate the features of the examples, where it is understood and appreciated that like reference numerals are used to refer to like elements. Reference in the specification to “one embodiment” or “an embodiment” or “an example embodiment” means that a particular feature, structure, or characteristic described is included in at least one embodiment described herein and does not imply that the feature, structure, or characteristic is present in all embodiments described herein.
In general, the embodiments herein provide for methods and systems for positioning a food product within its associated packaging for marking information thereon. In the embodiments contained therein, the disclosure includes a container with a plurality of receptacles disposed in one or more rows, wherein each receptacle is constructed and arranged to hold an egg within a compartment of the receptacle so that the egg is substantially maintained in a resting orientation where a long axis of the egg is tilted toward a rear portion of the container at an angle slightly offset from the vertical axis.
The receptacles may include alternating tilting of the eggs when a pair of eggs are tilted in the opposite direction at the next pair of eggs. Additionally, the container may be made of transparent material that allows consumer to see the marking on the tilted eggs without having to open the container.
The present disclosure relates to a container with receptacles that are configured to consistently guide eggs dropped into the receptacles into a particular resting orientation. The receptacles are also configured to hold the eggs so as to maintain their orientation within the receptacles in the resting orientation despite being subject to the forces of shipping and handling. A container that keeps the eggs in the same position during transit may greatly improve the overall display of indicia markings on the eggs, as well as reducing breakage.
The resting orientation of eggs held within the receptacles may be such that the eggs are tilted back toward the rear of the container. When the container is opened, the markings shown on the surface of the egg facing the front of the container are more prominently displayed and easily visible than if the eggs were not tilted back. For instance, the eggs may be arranged within the container such that when a person, such as a consumer, inspector or employee, opens the container, the eggs are oriented in a manner such that markings displayed on the front of the eggs are presented with a slight upward-facing tilt toward the person, in a consistent alignment with one another and, hence, easily viewed.
Receptacles of a container for holding eggs may have a number of features that serve to guide the eggs into a suitable resting orientation upon entry into the receptacle. In some embodiments, an egg that is dropped into a receptacle, without any particular orientation, may be directed into a suitable position by guidance features present within the receptacle. For example, as the egg falls into a compartment defined by the receptacle, the egg may come into contact with various guidance features of the receptacle that serve to cause the egg to move into a particular resting orientation where the long axis of the egg is tilted toward a rear portion of the container at an angle slightly offset from a vertical axis of the container. In some embodiments, eggs may be guided by features of the receptacles into their respective resting orientations automatically, i.e., by only the force provided by gravity. Alternatively, when eggs are dropped into corresponding receptacles, the container (and receptacles) may be slightly agitated so that the eggs are able to settle appropriately, or more rapidly, into designed resting orientations. This may be done intentionally by the addition of an agitation mechanism or it may occur naturally by virtue of the vibration and jarring caused by the packer mechanism by itself.
It will be appreciated that the aforementioned guidance features are optional and that in some embodiments tilting of the eggs may be accomplished without additional guidance features by receptacles that are contoured to support each egg in a tilted position. Such contouring may involve a surface that basically has the shape of a tilted egg, though the surface may be either curved like an egg or it may have tapered, flat sides that support the egg in limited places.
It will be appreciated that certain materials such as PET have different friction and abilities to be molded than pulp, fibres, and expanded polystyrene and that therefore a combination of embodiments of various disclosed features will be used selectively with various carton materials in order to effectuate the desired product placement characteristics and resting orientation using one or more of the embodiments disclosed herein.
Once the egg has suitably attained an appropriate resting orientation, the receptacle preferably is also constructed to provide a sufficient amount of resistance to movement of the egg, particularly rotation and tilting, so as to substantially maintain the egg in the resting orientation, such as during marking, shipping or handling. Avoidance of movement during the marking process, be it laser marking or ink marking, is advantageous to achieve the clearest image production; egg movement during marking results in some amount of blurring. While the container itself having eggs suitably positioned within receptacles of the container may be subject to rough handling, the eggs are substantially held in place and prevented (e.g., by friction and/or an appropriate structural feature) from moving out of their respective resting orientations. Accordingly, a container full of eggs may be transported from one location to another without concern for whether the eggs will move from their designed resting orientation. And as a result, markings on eggs held within containers in accordance with aspects of some embodiments of the present disclosure will be consistently presented toward the front of the container, faced front and tilted upward, so as to be readily visible upon opening of the container.
In some alternate embodiments, the eggs are presented in an alternating fashion toward the front and the back of the container. They orientation may alternate by row or by individual egg pocket or by pairs of pockets. Typically, when a consumer opens a carton of eggs at a retailer, he or she will open the carton either facing toward or away from themselves for a cursory inspection of the eggs. If the carton is opened away from the consumer, then all eggs leaning to the front of the carton remain facing away from the consumer, making any markings on them less visible. Thus, the alternating pocket directions have the advantage of making half the eggs markings visible to the consumer regardless of whether the consumer opens the carton facing away or toward himself.
A person opening an egg container will generally view the eggs from in front and above, indicated by the direction of gaze 100. However, some persons opening an egg container will view the eggs from the back and above at a gaze angle that is the reverse of gaze 100. In
In an embodiment according to the present disclosure including alternately tilted eggs, a clear and transparent carton design, and a suitably-positioned small covered label area, a consumer can view the freshness and other on-egg markings from the front, the rear, and above, indicated by the direction of gaze 100 and from the opposite angle.
Such an orientation shown in
The receptacle may have various structural features that serve one or more functions. For example, the receptacle may have a protrusion 56 that may be useful for maintaining the egg 6 in the same orientation by resisting movement of the egg once it is placed within the compartment of the receptacle. In addition, the inner surface of the bottom region 54 of the receptacle may also provide a friction surface within the compartment that assists in holding the egg in its resting orientation. In some embodiments, the exterior surface 55 of the bottom region 54 may be slightly indented from the exterior, as shown, so as to provide flexibility and cushioning for the receptacles of the container during transportation.
It may be preferable for the eggs to be consistently oriented in a uniform manner within the receptacles. That is, for some embodiments, the variation of the degree of tilt of the eggs disposed within the receptacles is small. In alternate embodiments, it may be preferable for the eggs to be oriented in an alternating manner, either by pocket, by pair of pockets, or by row. In such embodiments, the eggs facing one way are still consistently oriented with each other.
In some embodiments, the long axes of two eggs disposed within respective receptacles in a resting orientation and tilted back with respect to the vertical axis of the container are substantially uniform, being offset by no more than about 20 degrees (or, in some embodiments, no more than about 25 degrees, or no more than about 24 degrees, or no more than about 23 degrees, or no more than about 22 degrees, or no more than about 21 degrees, or no more than about 19 degrees, or no more than about 18 degrees, or no more than about 17 degrees, or no more than about 16 degrees, or no more than about 15 degrees, or no more than about 14 degrees, or no more than about 13 degrees, or no more than about 12 degrees, or no more than about 11 degrees, or no more than about 10 degrees, or no more than about 9 degrees, or no more than about 8 degrees, or no more than about 7 degrees, or no more than about 6 degrees, or no more than about 5 degrees, or no more than about 4 degrees, or no more than about 3 degrees, or no more than about 2 degrees, or no more than about 1 degree) from one another.
As shown in
Receptacles in accordance with aspects of the present disclosure may include a number of guidance features for directing an egg that is deposited over a receptacle compartment to settle into a suitable resting orientation. In some embodiments, a receptacle may include one or more railing elements that serve to steer the egg toward the center of the compartment, as opposed to leaning to one side or another, as well as to lean back toward the rear of the container, as the egg falls or slides into position.
As shown in
At the same time, it may be beneficial for the railing elements 52a, 52b to be short enough or spaced sufficiently apart from one another such that when the egg enters into the receptacle compartment, the egg is able to settle into the resting orientation without sitting too high within the compartment. If the egg sits too high where an upper region of the egg is raised past a certain threshold height in some cases, the egg could be damaged when the receptacle is closed.
Railing elements may also be shaped to provide a generally small area of contact with the egg until the egg has settled down into a final position where it exhibits a resting orientation. Such a small area of contact with the egg before it finally settles into the resting orientation keeps to a minimum the amount of friction with the egg so that friction does not stop the egg from reaching a fully seated position. It also provides greater certainty in steering the egg to reach a desired final position during initial packaging of the egg. Once the egg has reached its final resting orientation, the railing elements and/or other guidance features of the receptacle may subsequently provide an appropriate amount of friction that resists movement (e.g., rotation, displacement) of the egg out of the resting orientation, for example, during transportation of the container.
Suitable receptacles may also include a number of protrusions as guidance features located near or at the bottom of the receptacle compartment.
Guidance features may be disposed at any suitable location in the space defined by the receptacle. While not so limited, as shown, the railing elements are situated in the receptacle so as to be closer to the rear of the container than the front and the protrusions are located in the receptacle in closer proximity to the front of the container than the rear. However, for some embodiments, railing elements are located closer to the front of the container than the rear. Similarly, protrusions may be located toward the rear of the container rather than the front.
In some embodiments, railing elements do not extend across the entire length of a base surface of the receptacle compartment. For example, railing elements that extend across the entire base surface of the compartment could contact an egg in an uncontrolled manner so as to induce an unfavorable bounce in the egg, leading to misalignment in the final orientation of the egg.
Similar to other guidance features, protrusions situated at or near the bottom of the receptacle compartment may be sufficiently sized so as to resist movement of the egg, yet at the same time, not allowing the top of the egg (e.g., jumbo, large or extra-large sized), when fully settled, to reach past a height such that the egg may be at risk of being damaged when the receptacle is closed. Protrusions may be flexible and suitably able to be compressed depending on the weight of the egg and the amount of surface contact the protrusion has with the egg.
As shown in
As further shown, when the egg has reached its resting orientation, a gap “g” may remain under the egg, which may provide for a degree of tolerance during handling of the container so as to avoid impact on the egg which may lead to detrimental damage (e.g., cracking, piercing). For some embodiments, the bottom surfaces of eggs are held slightly away from the inner base surface of the receptacle compartments, allowing space for the compartments to be compressed before contact, and potential damage, is made with the egg surface. Incorporation of compressible protrusions in the receptacles may help to provide tolerance in this respect. In some embodiments, when positioned in the resting orientation, the gap g between the bottom of an egg and the inner surface of the base of the compartment may be between about 0.01 inches and about 0.1 inches, between about 0.02 inches and about 0.08 inches, between about 0.03 inches and about 0.05 inches, or about 0.04 inches.
As discussed above, receptacles may have any appropriate number of guidance features that direct an egg falling into the receptacle compartment into a suitable resting orientation, by gravity alone or with some slight agitation. In addition, once the egg is settled into the resting orientation, such guidance features may also serve to resist movement of the egg away from the resting orientation. Guidance features may include, but are not limited to railing elements and protrusions disposed in the compartment of the receptacle.
Various features of the container such as the lid, receptacles and guidance features may comprise any suitable material. Suitable materials include, but are not limited to, a foamed material (e.g., Styrofoam), plastic, polymer (e.g., polyurethane, polyester, polystyrene), paper (e.g., molded pulp, recycled paper), elastomer (e.g., rubber), cardboard or combinations thereof. Guidance features may comprise the same or a different material than that of the receptacles and in the case of molded containers, may be incorporated into the molds.
In some embodiments, stabilizing features may be positioned over the entrance to the receptacles so as to gently hold the eggs in their respective resting orientations. For example, stabilizing features may include small flexible finger-like elements that apply low pressure contact to the surface of the egg so that the egg is pressed against guidance features, such as protrusions or railing elements, disposed on the opposite side of the egg. Such gentle contact between opposing features of a receptacle serves to substantially prevent movement (e.g., rotation) of the egg due to vibration, agitation, or loss of contact between the surface of the receptacle and the egg that would otherwise occur. These various features around the entrances to the receptacles further are intended not only for stabilizing but also to contact the egg when it is falling into the receptacle, imparting a slight drag on that side of the egg, causing the egg to tilt to a preferred angle during the process of falling before reaching the bottom of the receptacle.
Stabilizing features may include any suitable material, such as any of the materials listed above with respect to the lid, receptacles and guidance features. Stabilizing features may be flexible enough so as not to induce cracking in the egg upon contact For example, stabilizing features may be flexible to provide appropriate levels of force to accommodate different sizes and shapes of eggs. In some cases, stabilizing features can be suitably flexible with respect to the egg by matching the material thickness of the stabilizing feature with the shape of the egg. That is, the material of the stabilizing feature may be constructed to be thicker at regions of the egg where the egg has greater strength and thinner where the egg is more fragile.
In some embodiments, stabilizing features such as finger-like elements 62a are flexibly adapted (e.g., elastomeric) to return back to an original configuration despite being deformed or stretched out of position. For example, as shown in
Receptacles 50 shown in
As discussed above, stabilizing features optionally may be provided as part of a lid on an upper portion of the container, for closing the container
In some embodiments, the container design may permit the omission of stabilizer fingers to hold the egg still during the marking process. By using a receptacle that holds the egg in a specific position, additional stabilization may no longer be needed. In such embodiments additional material considerations may be made, including, within containers manufactured from PET and other low friction materials, features of thinly drawn material that may effectuate a gripping action around the girth of the egg. When higher friction materials are used to manufacture the container, tapered snug receptacles with less longitudinal elasticity may be required in some areas of the receptacle.
As discussed above, eggs may be marked with information which may include, for example, a freshness date, a traceability code and/or advertising. It has been recognized that in order for a means of marking eggs with indicia suitable for repacking purposes to be both widely commercially viable and economically feasible, it is important for a large percentage of the eggs processed to have clear, legible, consistent markings. One reason for this is that, in many circumstances, eggs that are mismarked with such indicia must be discarded, for one reason or another. Such a concern is the subject, in part, of the International Publication No. WO 2011/091011 (the '011 Publication), which is incorporated herein by reference in its entirety.
Once the quality and reliability of egg marking such that large percentages of eggs are have clear, legible and consistent markings on them (whether evaluated objectively or subjectively) is addressed, it may be advantageous to incorporate within egg marking systems the ability to manipulate eggs so as to be oriented in container packages in a particular (uniform) manner in advance of or after the printing process.
Accordingly, eggs may be placed in a container having receptacles incorporating appropriate guidance and/or stabilizing features such that, upon entry of an egg into a receptacle, the egg is automatically guided by force of gravity (with optionally slight agitation) by the path determined by the guidance and/or stabilizing features into a preferred resting orientation. As a result, all of the eggs in a container may be centered and tilted slightly backwards, uniformly where a relatively large surface area of the egg will be immediately visible to a consumer (or an inspector, vendor, or other person) who opens the package. By so orienting the eggs in the package prior to the printing process, the amount of “visible” surface area made available to the laser (and ink head, if used), for marking, may be increased. In addition, the information that is actually marked on the eggs (expiration dates, tracking codes, advertisements, etc.) will be readily communicated to the consumer (or an inspector, vendor, or any other person who might subsequently open the package) immediately upon opening the package. As an example, a consumer opening a container (e.g., carton) of eggs may immediately be presented with neatly arranged, uniformly oriented rows of eggs, each having information such as a company's logo and/or an expiration date prominently displayed at the same location and directly facing the customer.
In addition, once the eggs in a container are positioned uniformly in their resting orientations so as to allow a person to readily view the information marked on the eggs, various features of the receptacles also resist movement of the eggs from the resting orientation during shipping or handling. During transit, individual eggs are often subject to substantial vibration or agitation that induces rotation or displacement of the eggs to a position that is different than that of the other eggs held within the container. Aspects of the present disclosure significantly increases the probability that eggs held within a container and positioned in an orientation that enables a person to easily view the information marked on the eggs upon opening the container will maintain such an orientation despite being subject to shipping and handling. Eggs placed in containers described herein will maintain their resting orientation where information marked on the eggs remains prominently displayed before, during and after transit. It can be appreciated that systems and apparatuses described herein, including containers with tilted receptacles having appropriate guidance features, may be readily incorporated with existing egg packing equipment functions without requiring substantial modification to the equipment or any modification at all
The following describes a system where eggs are both marked and placed within containers. It can be appreciated that packages used in cooperation with systems described below may incorporate containers having receptacles in accordance with aspects of the present disclosure. For example, suitable embodiments of containers discussed herein may be implemented with an orienter(s) contemplated for uniformly urging eggs into a suitably presentable resting orientation, such as those orienters described in the '011 Publication.
In the example shown, the conveyor 202 first moves the package 204 to a primary location A within the egg loading section 206 of the egg packing apparatus 200. As shown, when the package 204 stops at this section, a number of eggs 205 corresponding to the number of receptacles in the package 204 (e.g., twelve, eighteen, or more) are disposed into the package 204. As noted above, the eggs may be loaded one row (e.g., six eggs) at a time, with the conveyor 202 advancing the package 204 slightly to allow for subsequent rows to be loaded.
Next the conveyor moves the package 204 to a location B where, if an orienter is employed, an operation is performed to orient the eggs to a desired position for laser marking as well as for display to a consumer who ultimately opens the package 204, or perhaps to an inspector or an employee of a retailer or distributor who later examines the eggs for inspection and/or repacking purposes. As shown, if a container as shown herein is not employed, the eggs 205 may be oriented in a somewhat haphazard manner within the package at the time they reach the location B. Once they reach the location B, however, an egg orienter 112 may be operated so as to reorient the eggs into the desired position. Even if the improved container discussed herein is used, it still may be advantageous to employ an orienter apparatus to “fine tune” egg positioning. The egg orienter 112 may be any of numerous devices capable of reorienting the eggs within the package, and the invention is not limited to any particular device or structure for performing such a function. One illustrative example of an egg orienter 112 suitable for this purpose is shown in
As illustrated by arrows 113 adjacent the egg orienter 112 in
With an egg orienter alone (i.e., without the improved container disclosed herein), preferably stabilizer fingers (discussed elsewhere in this disclosure) preferably are provided to stabilize the positions of the eggs after they have been oriented. However, the herein disclosed container obviates the need for such stabilizer fingers.
As illustrated by arrows 115 in
In some embodiments, moreover, an egg orienter mechanism may be operated, and operate on the eggs, while the carton (container) is moving, so long as the orienter device moves faster than the carton is moving. As shown in
An example of a driving mechanism 122 that may be used to move the egg orienter 112 in a desired manner (e.g., as indicated by the arrows 113, 115 in
As shown in
As shown in
In alternate embodiments, driving mechanism 122 may include linear motors as an electromagnetic drive mechanism replacing the requirement for pneumatic cylinders.
In the embodiment shown, the egg orienter 112 further includes a set of tubes 120 disposed between nooks of the scallop-shaped aluminum member 118 and the frame 114. As shown, the tubes 120 may be arranged such that a pair of them straddles each egg 205 as the egg orienter 112 is swept across the tops of the eggs 205 in the package 204. Advantageously, a high-velocity air source (not shown) may be connected to the tubes 120 such that air may be blown onto and around the eggs 205 as the egg orienter 112 sweeps over the eggs 205 to reposition them. Blowing air over and around the eggs in such a fashion can help dry the surface of the eggs 205 uniformly prior to laser marking them and may also help overcome the friction between the bottoms of the eggs 205 and the package receptacles by creating a slight cushion of air between them.
In the illustrative embodiment shown, after the egg orienter 112 has repositioned the eggs 205 within the package 204, the conveyor 202 moves the package 204 to a location C at which a laser marking operation may be performed.
As shown, as a result of the processing by the egg orienter 112, the eggs 205 may be arranged uniformly within the package 204, with each egg 205 being tilted slightly toward the back 228 of the package 204 (see
As shown in
When the eggs 205 are oriented within the package 204 in such a manner, the surface of the egg 205 that is immediately apparent to someone opening the package is neither an end nor the middle of the egg 205, but rather a section of the egg somewhere between those two locations.
In some embodiments, eggs may be oriented in each package and information may be marked on the eggs in such a way that the information marked on all of the eggs in each package can be viewed immediately upon opening the package, without requiring a human being to manipulate any of the eggs to allow such information to be viewed. In some embodiments, the eggs may be oriented in each package in an alternating fashion, either by row, pocket, pair of pockets, or the like, to increase the number of angles from which the information marked on the at least some of the eggs may be visible upon the opening of the package, without requiring a human being to manipulate any of the eggs to allow that information to be viewed.
It is known that a significant percentage of the eggs that are produced have the salmonella virus on them. For this and other reasons, various regulations exist governing when and how eggs may be manipulated. Allowing inspection of laser marked information on all of the eggs in a given package without needing to manipulate any of the eggs in the package can thus provide significant advantages.
Turning to
An orienter 310 as described herein may be used to position the eggs in the package before printing is performed, so that eggs do not shift position very much between the two printing stations. In this embodiment of an orienter, a series of resilient or sweeping members 311, depending from a support structure, urge the eggs into a tilted backward orientation. Thus, the desired relative printing positions for the two stations can be achieved without requiring complicated registration mechanisms.
The above-described package conveying and egg printing arrangements may be modified in various respects. Among them is an arrangement, shown schematically in
An orienter station 310 may then operate upon the eggs in the carton to achieve the above-described orientation. From the orienter, conveyor 334 carries the egg carton to an ink jet printing station 304, if used, and thereafter into a lasing station 302. (Or to a lasing station first and then to an ink printing station. There are advantages and disadvantages to both sequences. Moreover, each of the printing stations may be considered optional as printing may be limited to only laser printing or only ink printing, in some embodiments.) At the output of the lasing station, a closer mechanism 344 pivots the lid 328 to close the carton. The conveyor 334 may discharge the closed egg cartons onto a flat surface which is stationary, or onto another conveyor, from which the cartons may be removed and packed into boxes or crates.
The lasing station may include a housing 312 in which a non-volatile environment is maintained by appropriate apparatus, not shown. The laser devices may be contained within housing 312 or be external to that housing, with the laser beams conducted into the housing 312 via an enclosed path to which the ink volatiles are excluded.
Once the eggs are tilted backwardly in the cartons by the orienter, the upward slant of conveyor 334 provides an additional force urging the eggs to stay tilted back even while the conveyor jostles the packages. This approach is particularly helpful with respect to small eggs, and when the stopping and starting of the conveyor imparts enough force to overcome the friction between an egg and the carton. On a horizontal surface, such an egg might fall forward in the carton, out of aligned orientation.
The type of embodiment shown in
The egg orienting operation is not limited to the above-discussed embodiment, but also may be performed by alternative apparatus. It may also be noted that it may be desirable to break the operation into two stages: (1) to orient, loosen and tilt the eggs and (2) to straighten the eggs from side to side. One apparatus can perform both operations or separate apparatus can be used for each.
If the eggs are on the small side, which is common, and the conveyor is horizontal or only tilted a small amount, then as the carton is moved from one location into the next location (which may be the next station or just the next row or next carton printing position) gravity and friction may not be enough to hold the eggs in their rest orientation; they can jostle or even fall forward as the conveyor chain stops suddenly. Optionally, therefore, there may be included in some embodiments of the orienter apparatus, with or without the above-described embodiment, two semiflexible (resilient) rods 352, 354 (
In another type of embodiment, the suspended resilient members of the orienter may comprise a plurality of suspended brushes or weighty, flat textile strips hanging down from a frame which drags them against the eggs in a motion similar to that employed in the above-described embodiment, to urge the eggs into the desired parallel tilted positioning.
The orienter mechanism and process have been shown as applied to eggs, but it should be appreciated that it may be desirable to perform a similar operation on other objects, whether printing on them or not. For example, one might desire to orient other food objects similarly for packaging and/or labeling. These food objects might include produce such as apples and pears or bell peppers or any of a number of other fruits or vegetables. They might also include manufactured food products such as chocolates and candies that the manufacturer wishes to place uniformly into packages, or non-food products such as Christmas tree ornaments.
An egg container may include a number of other features that may be incorporated in combination with aspects described herein. An egg container may include any number of receptacles. For example, an egg container can be provided as a 36-pack, 30-pack, 24-pack, 20-pack, 18-pack, 15-pack, 12-pack, 10-pack, 9-pack, 8-pack 6-pack, 4-pack or 2-pack. Some egg containers are slightly larger in dimensions so as to accommodate jumbo or extra-large sized eggs.
In addition to various guidance features such as railing elements or protrusions, the receptacle compartment within which the egg may sit may include grooves, for example, disposed in the corners or sides of the receptacles. Such grooves may allow for some degree of expansion of the compartment, for example, when an oversized egg is placed in the receptacle compartment and the external dimensions of the container are to be maintained. Grooves may also allow for more air circulation than railing elements alone in the space around the egg, which can be beneficial when eggs are subject to condensation on the surface or are heated and left to cool.
Egg containers may include tall sharp ridges disposed between the receptacle compartments. Such ridges may serve to prevent eggs from touching one another, particularly when eggs are dropped into compartments during the packing process and also during shipping.
The bottom of each receptacle external to the compartment may include a slight indent (off the bottom plane of the carton) which may provide a cushioning gap underneath the compartment, allowing the bottom of the compartment to flex when eggs are dropped during packing. Such an indent from the external side may also provide some level of flexibility and protection at the base of the receptacle during shipping and handling. Additionally and alternatively, a slight bump (protrusion) may be formed in the interior of the bottom of the compartment, to raise a smaller egg within the compartment and position it for the best height for the marking operation. Such a bump may be located, for example, around the expected axis of the tilted egg.
Egg containers may include a number of features at the edges of the receptacles. For example, stiffener ribs may be located at the ends of the containers so as to provide stiffness against excessive flexing of the container. Edges of the receptacles may also be uneven in height so as to provide cushioning for the container to be compressed. Uneven edges along receptacles of the container may provide space where fingers (e.g., de-nester fingers) may enter into so as to be helpful to assist in removing nested containers from one another. Similarly, the lid of the container may include a slight gap for a finger to be inserted so that the container may be easily opened. Additionally, edges between receptacles may provide air ventilation when the container is closed or slightly compressed.
The upper portion of a container may include a lid having substantially flat faces so that useful information may be printed thereon. For example,
The container may include a lid having retaining holes that permit the container to remain in a closed configuration. The portion of the 11d surrounding the retaining holes may be reinforced with an added amount of thickness in material on the lower side of the lid so as to provide strength for mitigating the possibility for the lid to tear through the retaining hole.
A lid of the container may include a stabilizer bar extending down toward the lower portion of the container for substantially preventing collapse of the container when a weight is applied on top of the container. In some cases, edges or corners of the receptacles may have a height that reaches up so as to come into contact with the stabilizer bar. Accordingly, edges or corners of the receptacle that match the geometry of the stabilizing bar may provide support between the upper and lower portions of the container so as to prevent crushing of the eggs held within the container.
The container may include a tucker flap having a score line so that the tucker flap can be folded and positioned in the space between the eggs and the lid. The tucker flap may provide for added protection of the eggs situated in the receptacles of the container. The score line of the tucker flap may provide for consistent and easy closing of the container. In addition, a ridge along the length of the tucker flap may provide a barrier that stops the lid when the container is being closed, further preventing crushing of the eggs. In addition, the interior of the tucker flap may include one or more thinned regions that provide clearance for the eggs when the container is being closed and when closed,
To provide for easy, cost-effective shipping and storage of empty containers, containers may be constructed to nest with one another. For example, ridges located between receptacles may support nesting. In some cases, egg cartons nest at a spacing of approximately 0.3 inches between one another. During nesting, the container may include lug features disposed at various locations around the exterior of the container, which act as spacers to prevent over-compression of nested containers and for maintaining a desired separation when containers are stacked.
Having thus described certain embodiments of systems and methods for practicing aspects of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. For example, in embodiments wherein open egg packages are fed in the opposite direction onto the conveyor 202 shown in
Turning to
Turning to
Turning to
It is appreciated that all of the examples of the container may be constructed of transparent material so as to allow consumers to view the contents and labeling of the eggs in the container without having to open the container.
Both the carton configurations and the orienter discussed above may be used to optimize the tilt angle of the eggs in order to make the positions of the eggs more consistent prior to the lasing process, resulting in more consistent marking performance. For instance, prior to lasing, the orienter (
The maximum printable image area, or tapestry, is constrained as follows: The top limit is defined by the image limit where the beam incidence angle approaches the tangent of the crown. The effect is a rapid fading of the image. The natural curvature of the shell may elongate and distort characters as the crown is approached prior to total image loss. The width limit is defined by the curvature, which limits the image at the sides. Some carton designs have pillars which interfere with the lasing of the image. Some cartons therefore cannot be used where the maximum tapestry is required. Depending on the configuration of eggs in the carton, the egg in front of the target egg may shadow the potential print area and thereby provide the effective lower limit to the tapestry. Some cartons have a pocket profile that would therefore limit the lower tapestry.
Different egg sizes have a distribution of diameters and heights. To achieve maximum mark contrast and controlled depth-of-mark on all eggs, all eggs of a specific size (weight) are positioned at a known throw distance from the laser lens. Although the eggs are different sizes, and therefore the exact throw distance from the laser lens can vary between eggs, by optimizing the throw distance in consideration of the size and curvature distributions, maximum possible performance can be achieved across all eggs of a given size (weight). In some embodiments according to the present disclosure, to optimize or improve the throw distance when processing a different size of egg, the carton of eggs is stopped at a slightly different position on the lasing conveyor. This technique positions the eggs for optimum throw distance from the laser marking system's lens to the center of the size distribution for the egg size being processed.
As a consequence of stopping the carton closer or farther from the nominal position, adjusting the Y-axis of the center of the mark is performed to position the mark area in the ideal location on the egg for minimum curvature and minimal depth of field around the curved egg surface, i.e. maximum tapestry as discussed above. The size distribution of the eggs of a given weight also results in an optimum lean-back angle for the eggs within the pockets of the carton (in a vertical plane parallel to the motion of the cartons). The size distribution of the eggs of a given weight also results in an optimum angle for the laser beam relative to the flow of the cartons. Typically smaller sized eggs (which weigh less) are shorter than larger eggs. Due to the (approximately) 55 degree angle between the laser beam and egg axis, the surface of a shorter egg is positioned farther from the lens, reducing the effectiveness of the laser marking system (see the description of tapestry constraints based on egg shape below). Additionally, laser marking systems have optimum throw distances from laser lens to the surface of the product being marked, at which plane (the “focal plane”) the beam is focused to a certain tightness of beam. Moving the substrate (in this case, the egg surface) away from that ideal focal plane reduces the beam intensity at the egg surface, thereby degrading the quality and crispness of the mark, as well as potentially requiring that the marking process be slowed down to accommodate that less intense beam.
One possible solution to this problem would be to move the eggs up, or the lasers down, or some combination of the two, to have the lasers remain in focus for the smaller size of eggs. This solution is widely used, but it requires an axis of controlled motion to be provided so that the relative height of the eggs and lasers can be adjusted appropriately.
According to the systems methods of at least some of the embodiments of the present disclosure, those systems and methods avoid the need for an additional controlled axis of movement, instead using the two existing axes of movement already required and therefore already present within the core system. Firstly, the throw distance can be adjusted not by raising/lowering the eggs or lasers, but instead—due to the 55 degree angle—by stopping the eggs at an earlier or later point on the existing conveyor carrying the eggs and egg cartons under the laser system. In some embodiments, the conveyor already has controls capable of stopping the cartons at a specific computer-controlled location. This “conveyor offset” based on egg size can be stored in a database and recalled based on the combination of carton and egg size being processed. In some embodiments, sensors or barcode scanners or other suitable means known in the art can be employed to determine the combination of carton and egg size being processed. In other embodiments, this information is predetermined and provided to a processor, which then queries the correlated conveyor offset information from the database, and applies the conveyor offset information to the servo control of the conveyor position. It is appreciated that different conveyor offsets may be required for eggs situated in the front row, any of the middle rows, or the back row of the carton, depending on carton design. Therefore multiple conveyor offsets for a specific combination of carton and egg size may be required to be stored in and retrieved from the database, and then such offsets may be applied sequentially as successive rows in cartons of eggs pass under the laser marking system for marking.
However stopping the conveyor earlier or later, also impacts the height of the mark on the egg, since the beam now intersects with the egg surface at a different height above the base of the carton/bed of the conveyor. Therefore a Y-axis offset adjustment is also required for the laser beam, so that the marks on the egg are at the appropriate height to maximize tapestry size and mark quality. This Y-axis adjustment is already required in order to make the markings on the egg (the X and Y computer-controlled movement of the beam is what forms the characters and graphical elements within the marking).
It is appreciated that multiple Y-offsets may be stored in and retrieved from the database, corresponding to multiple rows of eggs within a carton.
The optimum angle of the eggs in the pockets, and the incident angle of the laser beam to the egg, results in minimum variation in throw distance from the laser lens across the entire extent of the egg surface to be marked. This in turn results in optimum mark consistency and controlled depth-of-mark. The capability to adjust the center of the marking field in both X and Y axes allows different carton designs to be readily accommodated by the system. For example, a Jumbo carton has eggs on a 2″ pitch, compared with 1⅞″ for X-Large and Large egg cartons. With a simple programmed X-offset, the laser marks can be optimally positioned on the eggs in the jumbo carton, without requiring that the laser lens or marking head be moved in any way. Additionally certain carton designs may position the eggs higher or lower than others. By adjusting the Y-axis of the marking area accordingly, the optimum mark area (tapestry) on the egg can be accessed by the laser.
Smaller eggs (such as Medium eggs) have tighter curvature than the larger egg sizes. Therefore the available marking area may be smaller on such eggs. Smaller eggs (such as Medium eggs) will sit lower in a carton than the larger eggs, therefore the Y-offset of the center of the marking field is generally lower for optimum performance. Similarly larger eggs may sit higher in a carton and therefore the optimum marking area can be accessed by increasing the Y-offset accordingly.
Eggs are typically packed with the tight-radius end at the bottom, touching the base of the carton. This exposes the end of the egg with less curvature to the laser for marking, which is advantageous for the reasons noted above (less curvature results in a larger mark tapestry, all else being equal).
Eggs that are inverted (tight-radius end upwards) result in a smaller tapestry and additionally because of how those eggs sit in the pockets of the egg carton, potentially a different height compared with the same egg when not inverted.
Certain egg packing machines are less effective at packing eggs with the tight-radius end down. Certain egg packing machine types may require a specific set of offsets and tapestry size settings on a per-carton basis, due to the frequency of incorrect egg orientation and the business requirement for maximum consistency in quality and depth of mark. In some packers, as many as 50% of the eggs are delivered in an inverted position.
Referring to
Referring to
In some embodiments of the present disclosure, the eggs not yet processed (closer to the laser lens) have not yet been oriented and remain leaning away (down the incline) from the eggs being marked, thereby increasing the potential mark area (tapestry) on the eggs being marked by reducing the potential for shadowing of the eggs being marked by the eggs in front.
In some embodiments of the present disclosure, the X, Y and Conveyor Stopping-point Offset values can be stored as a set in a database in the cloud or on a server, each set corresponding to a specific carton design and egg size. The set of values can be automatically transferred into the control mechanisms for the laser and conveyor when the specific carton is being processed with the specific egg size in question.
In some embodiments of the present disclosure, the tapestry is optimized for large eggs because the majority of eggs to be marked will be sized large (including extra large).
In at least one embodiment of the present disclosure, any suitable means for determining the size and positioning of the eggs, including physical or optical sensors, may be employed to determine any variance of size between eggs in a single carton. When possible, the eggs may be reoriented to provide for optimal tapestry size. Using parameters known in the art, provided in this disclosure, or calculated based on prior data stored in the server or cloud, on the fly adjustments may be made to the laser settings to optimize marking on the variant tapestry sizes.
Referring to
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Referring to
It is to be understood that any suitable mathematical means, including the use of tilting vectors may be employed to achieve optimal marking.
In some embodiments of the present disclosure, average inversion rates, egg sizes, tilt, and the like for an individual packer are analyzed to determine an average optimal laser configuration for optimal tapestry marking for what is likely to be the most number of eggs in the cartons packed by the packer. In some embodiments, data is shared to allow for aggregation of information from many packers to aid in the modeling of proper laser settings for an individual packer. In at least some embodiments, the final markings are examined through any suitable means so that the data may be employed to further optimize the marking process.
In at least some embodiments, the eggs are manipulated by the orienter, the carton shape, or both one or more times to optimize tapestry marking.
In some embodiments the upper surface of the carton lid is deliberately designed with flat surfaces to allow an exterior label to be affixed using common self adhesive labels while in other embodiments the upper lid of the carton contains detents to allow the carton to retain a card label or paper label on the inside without adhesive. In each of these supplemental design variants additional shape is introduced to the vertical surfaces of the carton, as viewed in a closed state, by the addition of contours visible in such vertical surfaces of the carton for the purpose of introducing additional rigidity to the carton.
As noted above, it may be advantageous for marks on eggs to be distributed between front-facing and rear-facing directions, with reference to the position of the hinge opening in a carton. Referring to
In some embodiments, the spacing between the laser sources can be adjusted so that one or more eggs in one row of a carton can be marked, concurrently with one or more eggs in a second row of the same carton. Such marks could be front-facing or rear-facing, depending on computer control. Such configuration choices and selections may be made with reference to the required speed of processing and types of cartons being processed.
In a preferred embodiment, the beam tubes have a built-in adjustment for length, without compromising the required alignment features at either end of the tube. In this context ‘length’ refers to the dimensions noted in
Such length adjustment can be used to adjust for small variations in laser lens focus, caused by slight variations in laser beam parameters and/or lens form and function. Additionally the length adjustment may be needed to adjust for manufacturing tolerances in the laser source mounting brackets, the laser source housings, and all other sub-assemblies and components of the laser marking system including the laser source.
In food processing facilities, equipment cleaning must be carried out frequently, typically at least once per day. Such cleaning is required to remove debris and other materials that accumulate on and in the equipment due to breakage of food products, damaged food packaging and cartons, and the like. Uncleaned equipment can be a source of bacterial buildup and consequently food safety can be compromised. Typically (but not exclusively) the debris will accumulate on flat surfaces, including the floor. Cleaning processes can include the use of chemicals, power washer systems, and the like. In egg processing facilities in particular, egg contents and other debris is typically removed from the floor using power washing equipment.
For effective cleaning of the floor, it is preferred that floor-mounted equipment have as large a clearance above the floor as possible, within the constraints of the equipment and required flow of food products through the food processing equipment.
In a preferred embodiment, the laser control electronic systems and other required electronic controls including but not limited to those for conveyor motion, laser safety guarding, and operator controls, may be located in a sealed cabinet located above the conveyor. In this location, exposure of the sensitive electronics to harsh cleaning processes is minimized, and access under the conveyor, for cleaning, maintenance and the like, remains as unobstructed as possible.
One advantage of such laser source and marking system arrangements is that all the associated laser electronics can be arranged vertically between the laser sources associated with the laser marking systems. The weight of such systems applies vertically, parallel to the axis of the laser sources 4802, which makes the design of the supporting members less complex because resulting forces are minimized in a direction perpendicular to the axis of the laser sources 4802.
In a configuration where eggs are marked concurrently on both the front-facing and rear-facing directions, it is not possible to simultaneously accommodate egg sizes (as discussed above) by stopping the conveyor in a different location, since one or other direction of facing would be significantly disadvantaged as the other is better accommodated. Therefore with this configuration of lasers, and choice of mark directions, it may be necessary to adjust the distance (relative height) of the eggs relative to the laser marking systems, using a mechanical means. In some embodiments the depth of field of the laser systems may be great enough to accommodate the egg and carton size variations without requiring a mechanical means; in such systems only a ‘Y-offset’ of the laser mark position may be required.
One embodiment of a suitable means for such adjustment is shown in
In alternative embodiments, the conveyor may be translated in a vertical direction, or the laser marking systems translated in a vertical direction, or a combination of both, to achieve the same change in relative height between the egg and the laser marking system.
In an alternate embodiment to that depicted in
In the embodiments in which the entire conveyor or laser marking system assembly is translated in a direction not perpendicular to the conveyor angle (such as a vertical movement of an angled conveyor), the egg carton after translation may be incorrectly positioned for optimum lasing from either marking direction, therefore a change in the stopping point of the conveyor (offset) is also required. This additional control requirement adds complexity and may require sensors measuring the vertical adjustment in order to calculate the correct conveyor stopping point offset for a specific carton and egg size.
A second alternative embodiment to that depicted in
A third alternate embodiment to that depicted in
In some embodiments according to the present disclosure, being able to mark eggs in all rows of a carton concurrently may save time by reducing the time incurred in moving from one row to the next, and this may result in overall improvements in machinery throughput rates. It should be noted that, in using this configuration, all egg pockets in the front row of the carton would lean backwards, and all egg pockets in the back row of a carton would be required to lean forwards. This alternate arrangement of egg pockets is provided as additional embodiment in this disclosure.
In a preferred embodiment, the laser sources are configured such that they are offset relative to the eggs being marked. This offset allows equipment to be installed onto parallel egg packing lanes that are closer together than the overall width of the laser sources for the 6 marking systems.
In an alternate embodiment according to the present disclosure, the laser marking systems are configured as described above but such that up to twelve eggs are marked using six laser marking systems. Each laser marking system marks up to two of the twelve eggs consecutively.
In an alternate embodiment according to the present disclosure, the laser marking systems are configured such that two laser marking systems can each mark three eggs, thereby concurrently marking all six eggs in a typical row of eggs. In an alternate embodiment a second pair of laser marking systems may be added, each of which may mark the reverse side of a set of three eggs, concurrently with the laser marking systems that mark the front side of the two sets of three eggs.
In an alternate embodiment, the laser source may be connected via at least one beam delivery to at least one galvanometer in turn connected via at least two beam deliveries to at least two laser marking assemblies and associated lenses and other components. Further such a laser marking system may be configured to mark sequentially in two separate locations on a single conveyor. Further in alternate embodiments the two locations may be two separate conveyors associated each with two separate packers. The advantage of such a system may be that marking can occur via one laser marking assembly while products are moved into position for marking under the second laser marking assembly. Then the galvanometer position is switched such that the laser beam is directed to the second laser marking assembly and the mark is made, during which time the product is moved under the first laser marking assembly.
It is understood that multiple laser sources connected as discussed to multiple galvanometers and thereon to multiple laser marking assemblies may be configured in order to effect marking concurrently on multiple objects in at least two separate containers, or in a single container.
In an alternate embodiment, the power available from a single laser source may be sufficient to mark at least two products simultaneously. In this embodiment, a beam splitter and mirrors, or equivalent optical devices, may be employed to direct a proportion of the laser beam via a beam delivery to one laser marking assembly and associated lens and other components, with the remainder of the laser beam directed via a beam delivery to an additional laser marking assembly with associated lens and other components, or via a beam delivery to a second beam splitter where the laser beam is again split into two or more beams and onwards via beam deliveries to additional laser marking assemblies with lenses and associated components. Multiple beam splitters in series may be included if the laser source power is capable of marking more than two products simultaneously.
It is understood that multiple laser sources connected as discussed to beam splitters and thereon to multiple laser marking assemblies may be configured in order to effect marking concurrently on multiple objects in at least two separate containers, or in a single container.
It will be understood that various aspects or details of the invention may be changed without departing from the scope of the invention. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 62/107,499 filed on Jan. 26, 2015 and U.S. Provisional Application No. 62/107,544 filed on Jan. 26, 2015, the contents of which are incorporated herein by reference in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62107499 | Jan 2015 | US | |
| 62107544 | Jan 2015 | US |
