SYSTEM AND METHOD FOR MANUFACTURING PACKAGED ICE

TECHNICAL FIELD

The technical field generally relates to ice manufacturing, and more particularly to automatically bagging and stacking ice in a storage unit.

SUMMARY

According to a first aspect, a bagging mechanism for packaging ice into plastic bags is provided. The bagging mechanism includes a chassis, a roll support operatively connected to the chassis for supporting a roll of plastic having first and second layers, a feeding unit operatively mounted to the chassis for feeding a predetermined length of plastic from the roll of plastic along a feeding path, a sealing unit positioned along the feeding path for sealing the length of plastic across a width thereof to define a bottom and a top of the plastic bag, a breaching unit positioned along the feeding path downstream from the sealing unit, for breaching at least one of the first and second layers of the length of plastic, and defining an opening at a top of the plastic bag; and a spreading unit positioned along the feeding path downstream from the breaching unit, the spreading unit including a plurality of elongated fingers adapted to extend between the first and second layers of the plastic through the opening, and to hold the top of the plastic bag open while it is filled with ice.

According to a possible embodiment, the roll support includes a roll support arm pivotally connected to the chassis and operable to pivot away from the chassis to facilitate installation and replacement of the roll of plastic.

According to a possible embodiment, breaching mechanism includes a cutting blade having a plurality of axially aligned teeth for perforating the plastic bag and defining a perforated line along the width of the plastic.

According to a possible embodiment, the breaching unit further includes a tearing roller adapted to tear the first layer of the plastic bag along the perforated line.

According to a possible embodiment, the breaching unit further includes a rubber plate positioned to maintain the second layer in place while the first layer is torn via the tearing roller.

According to a possible embodiment, the feeding unit includes a first and a second pair of rollers for feeding the length of plastic, further wherein the breaching unit is positioned between the first and second pair of rollers.

According to a possible embodiment, the sealing unit includes first and second sealing mechanisms for respectively sealing a bottom end and top end of the plastic bags.

According to a possible embodiment, the spreading unit further includes one or more blowers for blowing air between the first and second layers of the plastic through the opening formed by the breaching unit.

According to a possible embodiment, the spreading unit includes a first and a second pair of elongated fingers, each pair being independently movable with respect to the other.

According to a possible embodiment, each finger of the first pair of elongated fingers is adapted for pivotal movement toward and away from each other.

According to a possible embodiment, each finger of the second pair of elongated fingers is adapted for pivotal movement toward and away from the first pair of elongated fingers.

According to a possible embodiment, the elongated fingers include a ribbed section to prevent the plastic bag from slipping.

According to a possible embodiment, the bagging mechanism cooperates with a support plate positioned below the chassis for supporting the bag while it is being filled, the support plate being operable to move up or down relative to the chassis.

According to a possible embodiment, the bag support includes a load cell to measure the weight of the plastic bag supported thereon.

According to a possible embodiment, the feeding unit includes at least one pair of rollers, further wherein the chassis includes a top jaw section and a bottom jaw section separable from one another, a first one of the pair of rollers being mounted to the top jaw section, and the second one of the pair of rollers being mounted to the bottom jaw section.

According to a second aspect, a stacking mechanism for stacking packaged ice into stacks within a storage unit is provided, The stacking mechanism includes a frame operatively mounted within the storage unit, a bag support connected to the frame for supporting the packaged ice, stacking arms rotatably mounted to and extending from opposite sides of the bag support along a longitudinal axis, the stacking arms being shaped and sized to receive the packaged ice from the bag support and adapted to transfer the packaged ice at a stack location within the storage unit; and at least one motor operatively connected to the frame and/or stacking arms, the at least one motor being operable move the stacking arms along first and second axes in the storage unit, and/or to rotate the stacking arms about the longitudinal axis.

According to a possible embodiment, the stacking mechanism further includes at least one height sensor positioned within the storage unit for determining a height of the stacks of packaged ice.

According to a possible embodiment, the frame includes support rails fixedly mounted to opposite walls of the storage unit and a mobile frame supported by the rails, further wherein the bag support is positioned on the mobile frame to allow movement of the stacking arms along the first and second axes.

According to a possible embodiment, the bag support includes a load cell to measure the weight of the plastic bag supported thereon.

According to a third aspect, a method of packaging ice into a plastic bag is provided. The method includes the steps of:

a) feeding a length of plastic having first and second layers from a roll of plastic;

b) fusing the first and second layers of the length of the plastic at a first location to form a sealed bottom end of the plastic bag;

c) cutting at least one of the first and second layers of the length of plastic to create an opening at a top end of the plastic bag;

d) inserting fingers between the first and second layers through the opening to retain the plastic bag in an open configuration;

e) filling the plastic bag with ice; and

f) sealing the top end of the plastic bag.

According to a possible embodiment, step c) includes perforating the first and second layers of the length of plastic along a width thereof.

According to a possible embodiment, step d) further includes blowing air between the first and second layers of the length of plastic through the opening at the top end of the plastic bag.

According to a possible embodiment, step e) includes:

- i) filling the plastic bag with ice at a first flow rate;

ii) while the plastic bag is being filled, weighing the plastic bag; and

iii) once an intermediate weight threshold has been reached, filling the plastic bag at a second flow rate until a final weight threshold is reached.

According to a possible embodiment, the method further includes the step of blowing air into the plastic bag after step e), prior to sealing the plastic bag during step f).

According to yet another aspect, a method of stacking bags of ice within a storage unit using a stacking mechanism having first and second stacking arms is provided. The method includes the steps of:

a) determining a desired stacking location in the storage unit;

b) receiving a bag of packaged ice;

c) determining whether the stacking location is accessible via the first stacking arm or via the second stacking arm;

d) transferring the packaged ice to the appropriate stacking arm;

e) transporting the packaged ice above the chosen stack location; and

f) dropping the packaged ice onto the chosen stack location.

According to a possible embodiment, the storage unit includes a grid of possible stacking locations, said grid includes a front grid section and a back grid section, each grid section having a corresponding height sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of an ice packaging system according to an embodiment.

FIG. 2 is a detail view of the ice packaging system of FIG. 1, showing a bagging mechanism.

FIG. 3 is a perspective view of a portion of the bagging mechanism of FIG. 2, showing a roll support supporting a roll of plastic.

FIG. 4 is a detail view of the bagging mechanism of FIG. 2.

FIG. 5 is a perspective view of the bagging mechanism, showing a jaw system in an open configuration, according to an embodiment.

FIG. 6 is a perspective view of the bagging mechanism, showing a jaw system in a closed configuration, according to an embodiment.

FIG. 7 is a perspective view of a sealing unit of the bagging mechanism, according to an embodiment.

FIG. 8 is a flowchart of a method of operating the bagging mechanism, according to an embodiment.

FIG. 9 is the flowchart of FIG. 8, detailing various steps thereof in additional steps, according to an embodiment

FIG. 10 is a flowchart of a step of the method of FIG. 8, according to an embodiment.

FIG. 11 is a perspective view of a stacking mechanism mounted within a storage unit, according to an embodiment.

FIG. 12 is a schematic view of a storage area divided in a grid, according to an embodiment.

FIG. 13 is a perspective view of a stacking mechanism, showing the cooperation of the various frames thereof, according to an embodiment.

FIG. 14 is a side elevation view of the stacking mechanism shown in FIG. 13.

FIG. 15 is a front elevation view of the stacking mechanism shown in FIG. 13, showing stacking arms extending in opposite directions, according to an embodiment.

FIG. 16 is a flowchart of a method of operating the stacking mechanism, according to an embodiment.

FIG. 17 is a flowchart of a step of the method of FIG. 16, according to an embodiment.

FIG. 18 is a flowchart of a step of the method of FIG. 16, according to an embodiment.

DETAILED DESCRIPTION

In the following description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures are optional, and are given for exemplification purposes only.

In addition, although the optional configurations as illustrated in the accompanying drawings comprise various components and although the optional configurations of the ice packaging system as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the ice packaging system, and corresponding parts, as briefly explained and as can be easily inferred herefrom, without departing from the scope of the disclosure.

As will be explained below in relation to various embodiments, a system for manufacturing, packaging and storing ice is provided. For simplicity, the system is referred to in the present disclosure simply as an ice packaging system, although it is appreciated that such a term can encompass a system with other functionalities as well, including manufacturing and storage of ice, among others. The present disclosure also provides corresponding methods for manufacturing, packaging and storing ice.

Broadly described, the system can include an ice distributor for producing ice, a bagging mechanism for packaging ice into bags, a storage unit for refrigerating and storing the bags of ice, and a stacking mechanism for stacking the bags of ice within the storage unit. In some embodiments, the stacking mechanism is installed within the storage unit to facilitate stacking operations and is adapted to receive bags of packaged ice from the bagging mechanism. In some embodiments, the ice packaging system can be fully autonomous.

In the present disclosure, components of the ice packaging system, associated accessory(ies)/component(s)/part(s) thereof and/or steps of the method(s) described herein could be modified, simplified, altered, omitted and/or interchanged, without departing from the scope of the present disclosure, depending on the particular applications it is intended for, and/or the desired end results, as briefly exemplified herein and as also apparent to a person skilled in the art.

Referring to FIGS. 1 and 2, an ice packaging system 10 is shown according to an embodiment. The system 10 includes an ice distributor 100 configured to make and distribute ice, a bagging mechanism 200 in operatively connected to the ice distributor 100 for packaging the ice into bags, a storage unit 300 for storing the bags of ice, and a stacking mechanism 400 operatively mounted within the storage unit 300 for stacking the bags of ice within the storage unit 300. In this embodiment, the ice distributor 100 includes two ice makers 102 capable of producing ice cubes for example, as is well known in the art. It is appreciated, however, that a different number and configuration of ice makers is also possible. In the present embodiment, the ice distributor 100 includes a distribution/transport mechanism for receiving ice from the ice makers 102 and distributing said ice to the bagging mechanism 200 below via a discharge mechanism 105, such as a chute. In the present embodiment, the distribution/transport mechanism comprises hoppers 104 positioned below the ice makers 102 for receiving ice therefrom, and transporting the ice via augers (not shown) to a funnel 106 adapted to transfer the ice to the discharge mechanism 105.

In the present embodiment, the storage unit 300 is temperature-controlled to safely store the ice over an extended period, while avoiding loss, for example due to melting. The storage unit 300 comprises a freezer 301 adapted to store bags of ice within a storage area 302 in a manner that will be described further below. The storage area 302 can include sensors, such as temperature sensors for monitoring the inner temperature of the storage unit 300 and determine if the temperature requires adjustment. The storage unit 300 is coupled to the bagging mechanism 200 and adapted to receive bags of ice therefrom through one or more openings defined in the storage unit 300. Additionally, the storage unit 300 can include one or more doors operable between open and closed configurations to allow access to the packaged ice 50 stored within the storage area 302.

As previously mentioned, the bagging mechanism 200 is installed below the hoppers 104 and funnel 106, as illustrated in FIG. 2, and is operatively connected therewith so as to receive ice for packaging. More particularly, the packaging system 10 includes a bagging compartment 20 for housing the bagging mechanism 200 therein, the bagging compartment 20 being installed below the distributor 100. In some embodiments, the bagging compartment 20 can have one or more doors allowing access to the bagging mechanism 200 for maintenance, troubleshooting and/or any other operation(s). However, it is appreciated that the bagging mechanism 200 can be installed as a separate unit from the ice distributor 100 if needed. In such embodiments, transportation mechanisms such as conveyors can be used to carry ice from the distributor 100 to the bagging mechanism 200 for example.

With reference to FIGS. 3 and 4, in addition to FIG. 2, the bagging mechanism 200 includes a chassis 202 slidably mounted within the bagging compartment of the packaging system 10, allowing access to the parts and components of the bagging mechanism 200 to facilitate maintenance thereof when required. In the present embodiment, the chassis 202 is mounted on sliding rails 204, allowing the bagging mechanism 200 to be slid in and out of the bagging compartment 20. However, it is appreciated that other configurations of rails are possible and/or that other displacement means can be used for moving the bagging mechanism 200 in a manner that allows access to the required parts and components (e.g., pivots, levers, etc.).

In the present embodiment, the bagging mechanism 200 includes a roll support 210 coupled to the chassis 202 for supporting a roll of plastic 211. The roll support 210 can be movably connected to the chassis 202 and thus displaceable in a position facilitating, among others, installation and/or replacement of the roll of plastic 211. More specifically, in the present exemplary embodiment, the roll support 210 includes a support arm 212 pivotally connected to the chassis 202 at a first end thereof, and a support rod 214 extending from the pivoting arm 212 at a second end thereof for carrying the roll of plastic 211. It should be understood that the roll of plastic 211 comprises at least one sheet of plastic 216 rolled around the support rod 214 to form the aforementioned roll 211. In this embodiment, the roll of plastic 211 includes a double-layered sheet of plastic 216, sealed along the lateral edges and rolled around the support rod 214. However, it is appreciated that the roll support 210 can include any suitable displacement means, such as sliding rails for example, to allow clearance of the plastic roll 211 from the rest of the bagging mechanism 200.

In some embodiments, and as illustrated in FIG. 4, the bagging mechanism 200 can include a plurality of components and/or units, such as a feeding unit 220 adapted to feed plastic from the plastic roll 211, a sealing unit 230 for sealing the plastic in a manner to form plastic bags, a breaching unit 240 for creating an opening in the plastic bag and/or an spreading unit 260 for holding the opening of the plastic bag open as the bag is filled with ice.

Still referring to FIGS. 3 and 4, the feeding unit 220 can be adapted to feed plastic from the roll of plastic 211 through the bagging mechanism 200 along a feeding path. In the present embodiment, the feeding unit 220 is operatively mounted to the chassis 202 and is adapted to cooperate with the roll of plastic 211, and more particularly with the sheet of plastic 216, so as to pull the plastic sheet 216 from the roll 211 and feed it through the bagging mechanism 200. In other words, the feeding unit 220 can effectively feed plastic (i.e., unroll the roll of plastic 211) through the bagging mechanism 200 to ultimately form a plastic bag which can be filled with ice. It should thus be understood that the feeding unit 220 can be configured to feed a predetermined length of plastic 216 through the bagging mechanism 200, which substantially corresponds to the length of a single plastic bag. In the present embodiment, the feeding unit 220 comprises a pair of rollers 222a, 222b positioned adjacent one another in a parallel configuration to allow the plastic sheet 216 to be fed therethrough. It should be understood that the rollers 222a, 222b can be configured to rotate in opposite directions so as to feed the sheet of plastic 216 forward along the feeding path.

In some embodiments, the rollers 222a, 222b can be rotatably mounted to the chassis 202 proximate the roll of plastic 211 to facilitate cooperation with the sheet of plastic 216, and adapted to rotate about their respective longitudinal axis to pull the plastic 216 from the roll 211. In some embodiments, when operating the bagging mechanism 200, the rollers 222a, 222b can be in contact with one another when rotating to increase pressure on the plastic sheet 216 to hold the sheet therebetween and «drag» it from the roll 211 (i.e., pull the sheet to unroll the roll).

In some embodiments, the feeding unit 220 can comprise two or more pairs of rollers. For example, in the present embodiment, rollers 222a, 222b are a first pair of rollers, and feeding unit 220 further comprises a second pair of rollers 224a, 224b rotatably mounted on the chassis proximate a front end thereof. The second pair of rollers 224a, 224b are positioned along the feeding path, downstream from the first pair of rollers 222a, 222b. It is appreciated that the plastic sheet 216 can be fed via each pair of rollers, and thus at two separate locations, increasing efficiency of the feeding unit 220 at maintaining the plastic sheet 216 aligned along the feeding path as it is fed through the bagging mechanism 200. Furthermore, the feeding unit 220 can include a feeding guide 228 extending outwardly from the front end of the bagging mechanism 200 and being shaped and sized to guide the sheet 216 toward the spreading unit 260. In the present embodiment, the feeding guide 228 includes a plurality of curved prongs 229 adapted to guide the sheet 216 downwardly as it exits from between the second pair of rollers 224.

Now referring to FIGS. 5 and 6, in addition to FIGS. 3 and 4, the chassis 202 of the bagging mechanism 200 can include a jaw system 204 operable between an open configuration 204a (FIG. 5) and a closed configuration 204b (FIG. 6). Therefore, it should be understood that the jaw system 204 can allow the chassis 202 to be opened and separated in a top jaw section 205 and a bottom jaw section 206. In an exemplary embodiment, the bottom jaw section 206 can be pivotally connected to the chassis 202 and can thus be configured for pivotal movement towards and away from the top jaw section 205. However, it is appreciated that the jaw sections 205, 206 can be mounted on rails to allow separation thereof, or have any other suitable configuration allowing the jaw sections to be separated. The jaw system 204 can facilitate maintenance of the bagging mechanism 200 and associated parts and components by allowing easy access to said components when in the open configuration 204a. Additionally, it should be noted that in the present embodiment, each pair of rollers 222, 224 includes a first roller mounted on the top jaw section 205, and a second roller mounted on the bottom jaw section 204b. As illustrated in FIG. 5, the rollers 222a and 224a are mounted on the top jaw section 205, while the rollers 222b and 224b are mounted on the bottom jaw section 206. Therefore, it will be understood that operating the jaw system 204 from the closed configuration 204b to the open configuration 204a effectively separates each pair of rollers 222, 224 and can thus facilitate the initial installation of the sheet of plastic 216 between the first and/or second pair of rollers.

With reference to FIG. 7, in addition to FIGS. 5 and 6, the sealing unit 230 can be operatively mounted to the chassis 202 and adapted to seal the sheet of plastic 216 at least at two separate locations so as to form a plastic bag. It should be understood that forming a plastic bag from the sheet of plastic 216 includes sealing both layers of the sheet together across a width thereof between the lateral edges, thus defining a top end and a bottom end of the bag. In an exemplary embodiment, the sealing unit 230 can include one or more sealing stations 232 adapted for sealing the plastic sheet 216 across a width thereof. In the present embodiment, each sealing station 232 is adapted to seal the plastic sheet 216 once, although it is appreciated that a single sealing station 232 can seal the plastic sheet 216 at various locations as the sheet 216 is fed along the feeding path. In some embodiments, the sealing stations 232 can include sealing elements 233 adapted to effectively seal the plastic sheet 216. For example, the sealing elements 233 can seal the plastic sheet 216 using glue, heat, mechanical fasteners or any other suitable fastener/sealing method or combination thereof.

In the present embodiment, the sealing unit 230 includes a first sealing station 234 positioned along the feeding path upstream from at least one of the pairs of rollers 222, 224, and a second sealing station 236 positioned along the feeding path downstream from at least one of the rollers 222, 224. However, it is appreciated that the sealing stations 234, 236 can be positioned at any suitable location along the feeding path for sealing the plastic sheet 216 as it is fed through the bagging mechanism 200. In an exemplary embodiment, the first sealing station 234 has a first sealing mechanism for sealing the plastic sheet 216 at a first location and define the bottom end of the plastic bag. Similarly, the second sealing station 236 has a second sealing mechanism for sealing the sheet 216 at a second location and define the top end of the bag. It should be understood that the bottom end should be sealed first to allow ice to fill the bag, and that the top end should be sealed only once the bag has been filled, effectively producing a bag of ice (i.e., packaged ice 50). However, it is appreciated that other sealing configurations and methods are possible.

In an exemplary embodiment, the first sealing mechanism comprises a strip heater 235 mounted on the chassis 202, spanning across a width thereof along the feeding path (as seen in FIG. 7). More specifically, the strip heater 235 spans across the bottom jaw section 206 of the chassis 202 and is adapted to fuse the layers of the sheet 216 together to create a seal. Similarly, the second sealing mechanism also comprises a strip heater 237 mounted on the chassis 202, spanning across the width of the bottom jaw section 206 at a front end thereof. The first and second sealing mechanisms further comprise a clamp element, such as a press-plate 238, adapted to effectively press or clamp the plastic sheet 216 along the strip heater 235 or 237. In the present embodiment, press-plate 238 is mounted on rails on either side of the second sealing element 237, allowing axial movement thereof toward and away from the strip heater. It is appreciated that the press-plate can be operated via any suitable manner, such as rotating gears or a pneumatic cylinder for example.

Still referring to FIG. 7, in addition to FIG. 4, the breaching unit 240 can be adapted to create an opening in the bag being formed to allow ice to enter and fill the bag. In the present embodiment, the breaching unit 240 is operatively mounted to the chassis 202 and is adapted to at least partially cut the plastic sheet 216 across a width thereof. More specifically, the breaching unit 240 includes a cutting assembly 241 having a cutting blade 242 adapted to at least partially cut across the width of at least one layer of the plastic sheet 216. The cutting blade 242 is mounted on the top jaw section 205 of the chassis 202 between the first and second pair of rollers 224, 226 above the feeding path, although other configurations are possible. In the present embodiment, the cutting assembly 241 is operatively connected to the chassis 202 and is operable to move downwardly toward the plastic sheet 216 in order to cut it. The cutting assembly 241 can be operated via an actuating mechanism, such as a piston for example, adapted to displace the cutting assembly 241 toward the plastic sheet 216 to allow the cutting blade 242 to cut said plastic sheet 216. After cutting the plastic sheet 216, the cutting assembly 241 is moved away from the plastic sheet 216, thus retracting the cutting blade 242 to allow the plastic sheet 216 to be fed forward via the feeding unit.

In some embodiments, the cutting blade 242 can be configured to cut perforations through one or more layers of the plastic sheet 216. Still with reference to FIG. 7, in the present embodiment, the cutting blade 242 includes a plurality of perforating teeth 248 spanning at least the width of the feeding path so as to perforate both layers of the plastic sheet 216, and define a perforated line spanning the width thereof. The perforating teeth 248 are axially aligned to define a substantially straight perforated line across the plastic sheet 216.

However, it is appreciated that the cutting blade 242 can be any suitable cutting apparatus (e.g., a single elongated blade, longer and/or wider perforating teeth, etc.) disposed in any suitable configuration so as to at least partially cut across the width of the plastic sheet 216. It should be understood that the perforating teeth 248 are configured for perforating the plastic sheet 216 at a location corresponding to the top end of the plastic bag being formed, and that the perforated line is configured to facilitate opening the plastic bag and tearing the plastic bag to separate it from the roll once it has been filled.

In the present embodiment, the cutting assembly 241 further includes a retractable pressure-plate 249 operatively mounted on the chassis 202 adjacent the cutting blade 242 for applying pressure on the plastic sheet 216 during operation of the cutting blade 242. In other words, the retractable pressure-plate 249 is adapted to hold the plastic sheet 216 in place as the cutting blade 242 extends through and retracts from the plastic sheet 216. In some embodiments, the retractable pressure-plate 249 is spring-loaded to facilitate reverting back to an initial position after each cut of the cutting blade 242. During operation, the cutting assembly 241 is lowered to have the cutting blade 242 and retractable pressure-plate 249 contact the plastic sheet 216. Then, the perforating teeth 248 extend through the plastic sheet 216 as the retractable pressure-plate 249 effectively retracts upwardly as the cutting assembly 241 further descends. Finally, the cutting assembly 241 is raised from the plastic sheet 216, retracting the perforating teeth 248 therefrom as the retractable pressure-plate 249 holds the plastic sheet 216 in place prior to also reverting back into its initial position.

In some embodiments, the breaching unit 240 can be further adapted to tear open the plastic bag along the perforated line realized by the cutting blade 242. In other words, the breaching unit 240 can include a tearing assembly 250 configured for separating the first layer of plastic from the second layer by tearing the first layer along the perforated line, thus defining an opening through which ice can enter the bag. In the present embodiment, the tearing assembly 250 includes a tearing roller 252 rotatably mounted to the chassis 202 and being operable to tear open the first layer of the plastic bag via rotation of the tearing roller 252. More specifically, the tearing roller 252 is mounted on the top jaw section 205 and is adapted to contact the first layer (i.e., the top layer) of the plastic sheet 216 subsequent to operations of the cutting assembly 241. Once in contact with the first layer, the tearing roller 252 can rotate, dragging and tearing the first layer along the perforated line, defining the plastic bag opening. In some embodiments, the tearing assembly 250 includes a bottom pressure-plate 254 mounted on the bottom jaw section 206 and adapted to apply pressure on the plastic sheet 216 to facilitate/induce contact with the tearing roller 252. It should thus be understood that the bottom pressure-plate 254 is adapted to move upwardly in order to push the plastic sheet 216 into the tearing roller 252. In the present embodiment, the tearing assembly 250 can further include an actuator, or actuating mechanism, adapted to cooperate with the bottom pressure-plate 254 to impart linear motion thereto in order to push it upwardly. The actuator can be any suitable device and/or mechanism, such as a solenoid for example, configured to impart the aforementioned linear motion to the bottom pressure-plate 254. Additionally, the bottom pressure-plate 254 can have an adhering top surface adapted to facilitate the tearing operation of the tearing roller 252. In other words, the actuator pushes the bottom pressure-plate 254 to contact the second layer (i.e., the bottom layer) of the plastic sheet 216 in order for the adhering surface to hold said second layer in place while the first layer is torn via the tearing roller 252.

In the present embodiment, the pressure applied on the sheet 216 via the bottom pressure-plate 254 can simultaneously allow the strip heater of the first sealing station 234 to effectively seal the layers of the sheet 216 together. As such, it is appreciated that the cutting operation of the cutting assembly 241 can be performed simultaneously as the sealing operation of the first sealing station 234.

As can be appreciated, the bottom pressure-plate 254 can be mounted along the feeding path, downstream from the first sealing station 234, as illustrated in FIG. 7. In this configuration, during operation of the breaching unit 240, the first sealing station 234 can effectively seal the layers of the plastic sheet 216 together above the perforated line, defining the bottom end of a subsequent plastic bag.

Referring back to FIGS. 4 to 6, once the breaching unit 240 has defined the opening, the bag can be fed forward via the feeding unit 220 in order to reach the spreading unit 260. In this embodiment, the spreading unit 260 is adapted to spread and align the opening of the bag with the discharge opening 105 of the distribution/transport mechanism. As illustrated in FIG. 6, the spreading unit 260 is operatively mounted to the front end of the chassis 202 and includes a plurality of elongated fingers 262 adapted to extend within and hold the plastic bag open. Each elongated finger 262 has a first end operatively connected to the top jaw section 205 and a free end, opposite the first end, operable to extend within and open the plastic bag. In some embodiments, each elongated finger 262 is pivotally connected to the chassis 202 and is adapted to pivot away from one another within the plastic bag to spread the opening wide, therefore holding the bag open. In the present embodiment, the spreading unit 260 includes a first pair of elongated fingers 264 and a second pair of elongated fingers 266, each pair being independently movable with respect to the other pair. However, it is appreciated that the spreading unit 260 can include any suitable number of elongated fingers 262 (e.g., three, five, etc.), movable in any suitable manner to hold the bag open.

In the present embodiment, the fingers 262 of the first pair of elongated fingers 264 are spaced apart at the front end of the chassis 202, and are configured for pivotal movement toward and away from each other. Similarly, the fingers 262 of the second pair of elongated fingers 266 are also spaced apart at the front end of the chassis 202, and are configured for pivotal movement toward and away from the front end of the chassis 202. As seen in FIG. 6, the second pair of elongated fingers 266 can be positioned between the first pair of elongated fingers 264. Therefore, once each finger 262 is inserted within the plastic bag, the second pair of fingers 266 can rotate outwardly and spread open the opening of the plastic bag. In some configurations, each finger of the second pair of fingers 266 can pivot about a common axis substantially simultaneously upon operation of the spreading unit 260. For example, the fingers of the second pair of fingers 266 can be fixedly connected to a rod 267 rotatably mounted at the front end of the chassis 202. Therefore, upon rotation of the rod 267, each finger 262 of the second pair 266 can pivot toward or away from the front end of the chassis 202 simultaneously. It is appreciated that other configurations of the elongated fingers 262 are possible for extending within and spreading the opening of the bag.

It should be appreciated that the spreading unit 260 can be adapted to hold the bag proximate the second sealing station 236, between the second sealing element 237 and the press-plate 238. As such, the top end of the plastic bag can be aligned with the second sealing element 237 and can thus be sealed upon operation of the press-plate 238 once the bag as been filled with ice for example.

In some embodiments, one or more fingers 262 of the spreading unit 260 can have a ribbed section 268 adapted to increase the grip of the finger 262 (i.e., prevent the plastic from slipping off the finger 262) while ice fills the interior volume. However, it is appreciated that other methods of increasing the grip of the fingers 262 are suitable for this application, such as ridges and/or spikes surrounding a portion of some or all of the fingers 262.

In some embodiments, the spreading unit 260 can include an inflation system adapted to at least partially inflate the bag to keep it open and facilitate insertion of the fingers 262. For example, the inflation system can include one or more air blowers configured to produce a jet of air, and positioned to direct the jet of air into the opening in the plastic bag. It should be noted that the air jet system can be further adapted to dry the plastic bag prior to sealing the top end of the bag thus facilitating sealing operations.

In some embodiments, and as will be described in more detail below, the bagging mechanism 200 can cooperate with a bag support for supporting the plastic bag while it is being filled with ice. The bag support can be position below the chassis 202, and more precisely below the spreading unit 260 so as to reduce stress applied on each finger 262 from holding the bag. Additionally, the bag support can be adapted to move upwardly towards the spreading unit 260, further reducing the stress applied on the fingers 262, and downwardly as the bag is filled. In some embodiments, the bag support can include a load cell for measuring the weight of the bag as ice fills the interior volume and communicating the information to a controller operating the bagging mechanism. As such, the controller can determine if the weight of the bag exceeds a weight threshold, and send a signal to one or more units of the bagging mechanism 200 in response thereto, for example to prevent the bag from being filled further. In some embodiments, the second sealing station 236 can be activated when the weight threshold is reached, therefore indicating that the plastic bag is full and ready to be sealed. Once sealed, the packaged ice 50 can be transferred to the stacking mechanism 400 to be stacked and stored within the storage unit 300.

Now referring to FIG. 8, with continued reference to FIGS. 1 to 7, a method of bagging ice 800 and corresponding steps are provided. As can be appreciated, the system described above can comprise a control unit operatively connected to the bagging 200 and/or stacking 400 mechanisms for the controlling the same. Accordingly, the bagging 200 and/or stacking 400 mechanisms can be operated automatically to bag and stack ice according to the method 800. In the present embodiment, the method 800 includes, at step 810, feeding a length of plastic 216 from a roll of plastic 211 and, at step 820, sealing the length of plastic at a first location to form a plastic bag. It should be understood that sealing the length of plastic at a first location effectively defines the bottom end of the plastic bag. The method further includes, at step 830, at least partially cutting the plastic bag at a top end thereof, followed by, at step 840, opening the plastic bag via the previously cut top end. Once opened, the method includes, at step 850, filling the bag with ice and finally step 860 of sealing the top end of the plastic bag.

In some embodiments, as illustrated in FIG. 9, in addition to FIGS. 1 to 8, step 830 can include punching holes across the width of the plastic bag, defining a perforated line. Furthermore, step 840 can include step 840a of tearing a first layer of the plastic bag along the perforated line, thus defining an opening, followed by step 840b of feeding the plastic bag forward such that the perforated line moves below the elongated fingers 262 of the spreading unit 260. Then step 840c can include blowing air at the top end of the plastic bag, proximate the perforated line so as to blow open the plastic bag. The bag can then, at step 840d, be retracted via the feeding unit 220 operating in reverse, to allow the elongated fingers 262 to extend through the opening of the bag. Step 840 can include a recovery sequence for when the elongated fingers 262 fail to enter the plastic bag. More specifically, when the elongated fingers 262 fail to enter the plastic bag, steps 840b, 840c and 840d cyclically repeat until the fingers 262 extend within the bag. Finally, once the elongated fingers 262 have entered the bag, step 840e includes opening the bag via the expansion of the fingers 262.

In some embodiments, steps 820 and 830 can be performed substantially simultaneously. However, it is appreciated that these steps can be performed one after the other. Additionally, and with additional reference to FIG. 10, step 850 can include step 850a of filling the plastic bag with ice at a first flow rate and measuring, at step 850b, the weight of the plastic bag. Step 850c includes determining if the weight of the bag has reached an intermediate weight threshold. If it has not, then ice keeps filling the bag at the first flow rate and steps 850a to 850c cyclically repeat until it is determined that the intermediate weight threshold as been reached. If it is determined, at step 850c, that the intermediate weight threshold as been reached, then, in step 850d, the bag is filled with ice at a second flow rate, which is slower than the first slow rate. Then, in step 850e, the weight of the bag is measured once again, followed by determining, in step 850f, if a final weight threshold as been reached. If the final weight threshold as not been reached, then steps 850d to 850f cyclically repeat until it is determined, at step 850f, that the final weight threshold has been reached. If the final weight threshold has been reached, then, at step 850g, the flow of ice is stopped. In this embodiment, the method 800 can include step 852 of shaking the plastic bag prior to step 850d, once it has been determined that the intermediate weight threshold has been reached at step 850c. Shaking the bag (step 852) can help settle the ice within the bag, which can increase the precision of step 850e (i.e., weighing the bag). Finally, the method 800 can include, at step 855, blowing air at the top end of the plastic bag following step 850g in order to dry the plastic prior to step 860.

Referring back to FIGS. 1 and 2, and further referring to FIGS. 11 and 12, the stacking mechanism 400 is illustratively positioned below the bagging mechanism 200 is operatively connected therewith to receiving packaged ice 50. More specifically, the storage unit 300 can include a top opening 310 (FIG. 11) through which packaged ice 50 from the bagging mechanism 200 can access the stacking mechanism 400, and thus the storage area 302. In the present embodiment, the stacking mechanism 400 is operatively mounted within the storage unit 300 and is adapted to stack packaged ice 50 at various stack locations 305 within the storage area 302. In an exemplary embodiment, as illustrated in FIG. 12, the storage area 302 can include a plurality of stack locations 305a-305l in which packaged ice 50 can be effectively stacked in a manner that will be described further below.

In some embodiments, and as illustrated in FIG. 13, in addition to FIGS. 11 and 12, the stacking mechanism 400 can include a frame 410 operatively mounted within the storage unit 300, and a bag support 440 connected to the frame 410 for receiving and supporting the packaged ice 50. In some embodiments, the frame 410 is displaceable within the storage area 302, effectively carrying the bag support 440 along. Additionally, the stacking mechanism 400 can include stacking arms 450 connected to the bag support 440 for transporting the packaged ice 50 during operation of the stacking mechanism 400. The stacking arms 450 can further be operable to stack the packaged ice at one of the various stack locations 305 within the storage area 302. It should thus be understood that the stacking arms 450 can be adapted to receive the packaged ice 50 from the bag support 440 prior to stacking the bag. It should be further understood that the stacking mechanism 400 can be operated via one or more motors adapted to effectively engage the various components of the stacking mechanism 400.

In some embodiments, and as mentioned above, the frame 410 can be operable to move within the storage area 302. In the present embodiment, the frame 410 comprises a fixed portion 412 fixedly connected to inner walls of the storage unit 300, and a mobile portion 414 movably connected to the fixed portion 412 for moving the bag support 440 and stacking arms 450 within the storage area. It should thus be understood that the bag support 440 is connected to the mobile frame 414, and that the mobile frame 414 can be operatively connected to one or more motors, or any other suitable mobility means, for transporting/moving the bag support 440 and stacking arms 450.

In the present embodiment, the fixed portion 412 includes support rails 416 extending along a first axis direction 413 between opposite inner walls of the storage unit. The support rails 416 can be fixedly mounted to the walls of the storage unit 300 using any suitable fastener or fastening means (e.g., nails, screws, glue, tape, etc.). The mobile portion 414 includes outer rails 418 supported by the support rails 416, and extending therebetween along a second axis direction 415 substantially perpendicular to the first axis 413. The outer rails 418 are operable to move along the fixed rails 416 (i.e., in the first axis direction 413). Additionally, the mobile frame 414 can include inner tubes 420 operatively connected to and extending between the outer rails 418. The inner tubes 420 can be operable to move along the outer rails 418 following the second axis direction 415. In this embodiment, is should be apparent that the bag support 440, being connected to the inner tubes 420 of the mobile frame 414, can move in the first and second axis directions 413, 415. In other words, operating the outer rails 418 effectively moves the inner tubes 420, and therefore the bag support 440, in the first axis direction 413, and that operating the inner tubes 420 effectively moves the bag support 440 in the second axis direction 415, allowing substantially full coverage of the storage area 302 by the bag support 440.

In the present embodiment, as illustrated in FIGS. 13 to 15, the outer rails 418 extend substantially transversely between the fixed rails 416, with each end of the outer rails 418 being connected to one of the fixed rails 416. In some embodiments, the outer rails 418 can include roller wheels 422 positioned at each end thereof for resting on the fixed rails 416, thereby allowing axial movement of the outer rails 418 via rotation of the roller wheels 422. It should be understood that the roller wheels 422 can be operatively connected to motor(s) of the stacking mechanism 400 to engage the outer rails 418 in translation. However, in the present embodiment, the outer rails 418 are connected to a belt and pulley system adapted to effectively displace the outer rails 418 along the first axis direction 413. The outer rails 418 can be provided with a belt drive mechanism 425 including a driving belt (not shown) for engaging and displacing the outer rails 418 linearly along the first axis direction 413. However, it is appreciated that other configurations of the outer rails 418 and/or displacement mean thereof are possible for this application.

In a similar fashion, the inner tubes 420 illustratively extend transversely between the outer rails 418, and are thus parallel to the fixed rails 416. It should thus be understood that the inner tubes 420 keep the outer rails 418 spaced apart from one another at a fixed distance. Each end of the inner tubes 420 can connect with one of the outer rails 418 in a manner allowing axial movement along the second axis direction 415. In the present embodiment, the inner tubes 420 include roller wheels 422 adapted to roll along the outer rails 418 upon operation of the mobile frame 414. It should thus be understood that the inner tubes 420 can also be connected to a corresponding belt and pulley system to allow axial movement of the inner tubes 420 along the second axis direction 415. The inner tubes 420 therefore include a corresponding belt drive mechanism 426 adapted to operate as previously described in relation to the outer rails 418. However, it is appreciated that other configurations of the inner tubes 420 and/or displacement mean thereof are possible for this application.

Still referring to FIGS. 13 to 15, in addition to FIG. 12, the stacking arms 450 are shaped and sized to carry packaged ice 50, and are rotatably connected relative to the bag support 440 such that rotation of the stacking arms 440 effectively drops (i.e., stacks) the packaged ice 50 at a stack location 305. In the present embodiment, the stacking arms 450 include a left stacking arm 450a and a right stacking arm 450b axially extending from opposite sides of the bag support 440 along a longitudinal axis. It should be noted that the stacking arms 450 can be adapted to rotate about the longitudinal axis but can alternatively rotate about any other suitable axis which would allow unloading of the stacking arms 450. In some embodiments, as illustrated in FIGS. 14 and 15, each stacking arm 450 can include an elongated receptacle 452 connected to a rod 454 extending from the bag support 440 along the longitudinal axis. It should be understood that the rods 454 can be adapted to rotate about the longitudinal axis, thus rotating/flipping the elongated receptacle 452. In the present embodiment, each elongated receptacle 452 is connected to the same rod 454 extending through the bag support 440 and on either side thereof. As such, it should be understood that rotating the rod 454 effectively rotates both elongated receptacles 452 simultaneously. Additionally, it should be understood that the receptacles 452 are configured for transporting/carrying at least one bag of packaged ice 50. In this embodiment, and as best seen in FIG. 14, the elongated receptacles 452 can have a substantially U-shaped cross-section, having sidewalls 455 extending upwardly from a bottom surface 456. It is appreciated that, for the purpose of carrying packaged ice 50, the sidewalls 455 and/or bottom surface 456 can be either curved or substantially flat.

In some embodiments, the stacking mechanism 400 can include one or more sensors 460 (FIG. 11) for monitoring the system 10 and the various components thereof. In the present embodiment, the sensors 460 include height sensors 462 adapted to determine if the stack locations 305 of the storage area 302 are full of packaged ice 50. More specifically, the height sensors 462 can be adapted to determine a height threshold of the stacks of packaged ice stored within the storage area 302 and transfer that information to the system controller. In the present embodiment, the height sensors 462 comprise optical sensors (e.g., lasers or beams of light) positioned on the inner walls of the storage unit 300 and configured to detect when a height of stacked packaged ice 50 has exceeded a predetermined threshold. If a stack reaches the height threshold, the bags will break the beam of light, thus sending a signal to the stacking mechanism 400 to prevent any further bags of ice being stacked at the corresponding stack locations 305. In the present embodiment, the height sensors 462 are positioned on lateral sidewalls of the storage unit 300 and aligned with expected stacking rows of the packaged ice 50. However, it is appreciated that different types of sensors can be used, and that they can be positioned at different locations, including the ceiling of storage unit 300, on the stacking mechanism 400, or a combination thereof. The height sensors 462 can be operatively coupled to controller in a manner such that when it is determined that one of the stack locations 305 is full, the controller can operate the stacking mechanism 400 to stack ice at a different location. As can be appreciated, if it is determined that all stack locations 305 are full, the controller can halt bagging and/or ice manufacturing.

It should be noted that, during operation of the mobile frame 414, the outer rails 418 and inner tubes 420 can be adapted to move substantially simultaneously, displacing the bag support 440 along both the first and second axis directions at the same time, thus reducing operation time of the stacking mechanism 400. In some embodiments, and as illustrated in FIG. 11, the frame 410 can have an initial position where the bag support 440 is positioned below the top opening 310 of the storage unit 300, ready to receive packaged ice 50 from the bagging mechanism 200. In this embodiment, the bag support 440 of the stacking mechanism 400 can correspond to the bag support of the bagging mechanism 200 and can therefore include all the features and functionalities described hereinabove. In other words, the plastic bags can be lowered through the top opening 310 and supported by the bag support 440 of the stacking mechanism 400 during operation of the bagging mechanism 200.

Still with reference to FIG. 11, the initial position of the bag support 440 is configured to keep a portion of the plastic bag in the storage unit 300 (i.e., the bottom end), and a remaining portion of the plastic bag in the bagging compartment 20 (i.e., held by the spreading unit 260). Therefore, once the bag is filled and sealed, the mobile frame 414 can be operated to displace the bag support 440 within the storage area 302, causing the packaged ice 50 to abut on an edge of the top opening 310 and tip over, therefore transferring it onto one of the stacking arms 450. Moreover, during transfer of the packaged ice 50 from the bag support 440 to one of the stacking arms 450, the second layer of plastic is torn along the perforated line defined by the cutting blade, effectively separating the packaged ice 50 from the plastic sheet still connected to the roll of plastic. However, it is appreciated that other methods/means of separating the filled plastic bag from the plastic sheet 216 can be suitable, such as a blade cutting the layer of plastic for example. It is further appreciated that the packaged ice 50 can be transferred to one of the stacking arms 450 via any suitable means, such as being pushed and/or pulled by an actuation assembly (not shown) mounted within the storage area 302.

Referring back to FIG. 12, and as previously mentioned, the storage area 302 can include a plurality of stack locations 305a-305l which can be arranged in a grid 306 of rows and columns. The grid 306 can include a front section 306a and a back section 306b. In the present embodiment, the front section 306a includes stack locations 305a, 305b, 305c, 305d, 305e, 305f, 305g and 305hj, and the back section 306b includes stack locations 305i, 305j, 305k and 305l. However, it is appreciated that the grid can include more rows and/or columns, and that the front and back sections can thus include any suitable number of stack locations 305. As such, when choosing a stack location for stacking the packaged ice 50, the controller controlling stacking mechanism 400 can determine in which section of the grid 306 (i.e., front or back) the stack location is positioned. Once the section is determined, the mobile frame 414 can be operated to move the bag support 440 to have the packaged ice 50 be transferred to the appropriate stacking arm 450 and finally be stacked at the chosen stack location 305. In other words, if the stack location 305 is determined to be in the front section 306a, then the packaged ice 50 is transferred to one of the stacking arms 450 prior to being transferred to the stack location 305. In the present embodiment, the stacking mechanism 400 is adapted to stack bags of packaged ice at the stack locations following the alphabetical order thereof. In other words, a first bag will be stacked at stack location 305a, followed by a second bag stacked at stack location 305b, and so on. It is appreciated that the stacking mechanism 400 will follow the alphabetical stacking sequence as long as the height threshold is not reached. For example, if the height threshold is reached (e.g., the beam of light is broken) at the front section 306a, then the stacking sequence will skip to a stack location 305 located in the back section 306b, and vice-versa.

Now referring to FIG. 16, with continued reference to FIGS. 11 to 15, a method of stacking packaged ice 900 within a storage unit 300 and corresponding steps are provided. The method includes, at step 910, choosing a stack location 305 among the various stack locations 305 and, at step 920, receiving a bag of packaged ice 50. The method further includes, at step 930, carrying the packaged ice 50 above the chosen stack location 305 and finally, at step 940, stacking the packaged ice 50 at the stack location 305.

With reference to FIG. 17, in addition to FIGS. 11 to 16, step 910 can include step 910a of choosing the stack location following the alphabetical order of the previous chosen stack location 305, and step 910b of keeping said chosen stack location 305 if the height threshold of the corresponding section of the grid has not been reached. Otherwise, if the height threshold has been reached, the method includes step 910c of choosing a stack location in the other one of the grid sections following the alphabetical order of the stack locations 305, followed by step 910d of keeping the newly chosen stack location if the height threshold has not been reached in the corresponding grid section. It is appreciated that if the height threshold has been reached in both grid sections, the stacking process can be stopped, as the storage area is at or nearing full capacity.

In alternate embodiments, it is appreciated that other methods of choosing a stack location can be suitable for such an application, such as choosing the stack location furthest to, or nearest to, the initial position of the frame 410. It should thus be understood that, in the above described embodiments, the packaging system 10 can be configured to run continuously until the storage area 302 is full of packaged ice 50.

It should be appreciated that in some embodiments, it may not be possible to have an accurate measurement of the height of each stack. Accordingly, the method can comprise keeping track of where bags have previously been stacked and, upon each stacking cycle, selecting a stacking location to evenly distribute the bags within the storage area. During each stacking cycle, the desired stacking location can be selected from a list of available stacking locations. Stacking locations can be removed from the list if a height sensor in the row and/or column corresponding to the stacking location has detected that the stacking height has exceeded a predetermined threshold. The stacking location can be added again to the list of available stacking locations if the sensor detects that the height threshold is no longer exceeded.

In the present embodiment, as illustrated in FIG. 18, in addition to FIGS. 11 to 17, step 930 of the method 900 can include, at step 930a, determining the location of the chosen stack location 305 from step 920. Once determined, step 930b includes moving the bag support 440 away from the chosen stack location 305 along the first axis direction 413, causing the packaged ice 50 to transfer to one of the stacking arms 450. For example, if the chosen stack location 305 is determined to be positioned in the last two columns of the grid 306 (i.e. in a right section), then the bag support 440 will be moved towards the left side of the storage area. Finally, step 930c includes carrying the packaged ice above the chosen stack location 305, followed by step 940a of step 940, which includes rotating the rod 454 to effectively drop and stack the packaged ice 50.

As described above, the ice packaging system 10 can include a controller, for example comprising a processor and memory. The controller can monitor the status of the components (i.e., the bagging and stacking mechanisms, among others), their activities and/or various statistics such as «number of bags stacked», «average weight of each bag», or any other suitable features to be monitored. It is appreciated that the system 10 can be equipped with a user interface 60 and a payment interface 70 (FIG. 1) allowing customers to buy bags of packaged ice, and allowing for self-service.

It will be appreciated from the foregoing disclosure that there is provided an ice manufacturing and packaging system, which can operate generally autonomously to produce bags of packaged ice and stack the bags inside a storage unit. As can be appreciated, the system can run continuously with minimal maintenance to keep the unit filled with packaged ice. The system can be installed in any location where ice is to be sold and can allow for ice to be manufactured on site without requiring regular deliveries.

SYSTEM AND METHOD FOR MANUFACTURING PACKAGED ICE

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)