Method and apparatus for filling a radially flexible container

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DESCRIPTION

Procedure and apparatus for filling a radially flexible container.

Background of the invention

1. Field of the invention

The invention relates to a method and apparatus for filling a container configured to contain a plurality of articles, and, more particularly, a radially flexible container with means for containing the contents so that a current or acceleration does not damage the contents.

2. Description of Related Art

Items can be contained and transported in flexible containers such as bags. It may be desirable to limit the movement of individual articles in the flexible container relative to one another to reduce the likelihood of the articles being damaged and increase the likelihood that the container will maintain a relatively rigid shape. Several different methods have been proposed to limit the movement of the individual articles in the flexible container relative to each other. For example, it is known to fill a flexible container and hot-dip the filled container. The system for removing air from the flexible container to define a vacuum is known, in which vacuum sealing can substantially limit the movement of the articles in the container relative to each other. Also known is the system for compressing a flexible container filled with pressurized air to compress the air in the flexible container and substantially limit the movement of the articles in the container relative to each other.

The present inventors previously made the invention of a Transportable Bulk Product Container and Container Forming Procedure, US Patent 6,494,324. A radially flexible container is filled with a filling system and the diameter of the container is reduced by the fill level while the fill level is increased.

Description of the invention and advantages

According to a first aspect of the present invention, there is provided a method for filling a container with a plurality of particles comprising the steps of: radially stretching a radially flexible container; filling the radially stretched container through a larger diameter with the plurality of particles to a fill level; and reducing the larger diameter of the radially flexible container to a fill diameter substantially less than the fill level as the fill level increases during filling of the flexible container.

According to a second aspect of the present invention, there is provided an apparatus for filling a container with a plurality of particles, wherein a filling system fills a radially flexible container through a larger diameter with the plurality of particles to a fill level, and a diameter reduction system reduces the larger diameter of the radially flexible container to a substantially smaller fill diameter at the fill level when the fill level increases during filling of the flexible container, wherein the diameter reduction system is characterized by: a stretching device to radially stretch the container before filling.

One embodiment of the invention provides an improvement over the prior diameter reduction system, in which the diameter of the container at the fill level is reduced by first stretching the container to fill and release a portion of the container stretched substantially at the fill level. . An appliance that includes a plurality of arms can receive the container in a substantially unstretched or relaxed configuration and stretch the container for filling. A larger diameter of the stretched container receives the particles and is released from the stretched configuration substantially at fill level at a smaller fill diameter. Release of the stretched portion of the container generates circumferential forces and promotes controllable contact between the particles.

Accordingly, the invention provides an alternative to template stretching to reduce the diameter of the container. The amount of material required to pack the particles is reduced by eliminating template stretching. The amount of waste material relative to the packaging material used is reduced by eliminating template stretching.

Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.

Brief description of the drawings

Figure 1 is a schematic side view of the flexible container being filled, according to the present invention;

Figure 2 is a simplified flow chart illustrating steps performed by one embodiment of the present invention;

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Figure 3 is a schematic side view of a flexible container that is received relative to a plurality of arms;

Figure 4 is a schematic side view of the flexible container shown in Figure 3 stretched by movement of the plurality of arms; Y

Figure 5 is a schematic side view of an alternative embodiment of the present invention, in which a support for the flexible container is movable between a receiving station and a filling station.

Detailed description of a preferred embodiment

Throughout the present specification and claims, the phrase "filling material" is used as an abbreviated version of the wide range of products that can be packaged using the present invention. The terms filling material, articles, and particles can be used interchangeably. The present invention finds use in the packaging of any material that is packaged. These items can encompass large packaged bulk pieces, as well as bulk packaged pieces with a very small volume. Examples of smaller filling materials include, but are not limited to, the following: agricultural products such as seeds, rice, grains, vegetables, fruits: chemicals such highly refined chemicals, parapharmaceuticals, crude chemicals, fertilizers; Elastics such as plastic resin pellets, plastic parts, rejected plastic parts, machined plastic parts; cereals and cereal products such as wheat; a variety of machined parts of all kinds; wood products such as wood chips, landscaping, peat moss, dirt, sand, gravel, rocks, and cement. The present invention also finds use in bulk packaging of larger filling material including, but not limited to: prepared meals; partially processed foods such as frozen fish, frozen chickens, other frozen meats, and meat products; manufactured items such as textiles, clothing, footwear; toys such as plastic toys, partially metal parts, metal parts, stuffed animals, stuffed animals, and other toys and toy products. All of these types of materials and bulk packaged materials and the like are intended to be encompassed by the present specification and claims by this phrase.

The present invention can be applied in combination with any of the features described in US Patent 6,494,324. Some of the features described in US Patent 6,494,324 that can be applied in combination with the present invention are briefly described below.

Referring now to Figure 1, The present invention provides a method and apparatus 10 for filling a container 12 with a plurality of particles 14 comprising the steps of filling the radially flexible container 12 through a larger diameter 16 with the plurality of particles 14 to a fill level. 18 and reduce the larger diameter 16 of the radially flexible container 12 to a smaller fill diameter 20 substantially at the fill level 18 while the fill level 18 increases during the Filling of flexible container 12. The six-major diameter is reduced by radially stretching container 12 prior to filling and, after filling substantially at fill level 18, releasing a stretched portion or stretch 22 of container 12 substantially adjacent to fill level 18. In other words, the container 12 can be expanded to define a larger diameter 16 to receive the particles 14. The apparatus may include a stretching device 24 for radially stretching the container 12 prior to filling. Container 12 can be a flexible elastic bag.

Reducing the major diameter 16 at fill level 18 by releasing a stretched portion 22 of container 12 at fill level 18 generates circumferential forces that apply slight pressure to fill material 14, helping to support and firm it. Circumferential forces stabilize the filling material 14 by promoting controllable contact between the elements of the filling material 14 that are loaded into the container 12, thus promoting connection between the components of the filling material 14. For example, when the filling material 14 being loaded is a bulk cereal in the form of fluffy dough or flakes, the circumferential forces promote the connection between the pieces of cereal, thus reducing the relative movement between the pieces and immobilizing the cereal in the interior of the container 12. By adjusting the extent of the contraction, the circumferential forces can be adjusted to the type of filling material 14 that is inserted into the container 12. The circumferential forces allow a very compact and rigid container, which does not allow the filling material 14 to move or break inside the container 12. The container 12 is filled without any internal frame or support means, since the subsequent removal of this frame or these support means would cause the circumferential forces to dissipate and would also cause displacement of the filling material 14 which could cause part of the filling material 14 will be crushed.

A process that can be performed by an embodiment of the present invention is illustrated in the simplified flow diagram of Figure 2 and the schematic side views of Figures 1 and 3 to 5. The process begins at step 26. At step 28, device 24b as shown in figure 5 can be placed in a receiving station of container 30. In step 32.1 container 12a, as shown in figure 3, can be coupled relative to a support 24a. The container 12a may be in a collapsed and pulled configuration from a roll 34 at a receiving station 30a. As shown in Figures 3 and 5, a roll 34, 34a can be arranged above or below the device 24a, 24b.

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Referring now especially to Figure 3, device 24a may include a plurality of arms 36, 38 for receiving container 12a. The container 12a can be pulled off the roll 34 and opened with an opening device 40. The plurality of arms 36, 38 can be movable relative to one another between at least two positions. Figure 3 shows the arms 36, 38 in a first closed position. The container 12a can be received by the device 24a when the arms 36, 38 are in the closed position in step 32. The closed position can be defined by the arms 36, 38 in contact with each other, or by the arms 36, 38 separated from each other. The arms 36, 38 can be separated from each other in the closed position to improve the interlocking of the container 12a with the arms 36, 38. For example, arms 36, 38 can be spaced apart to allow relatively easy, but positive interlocking, between arms 36, 38 and container 12a.

Referring now to Figures 3 and 4, the device 24a may include one or more roller mechanisms 42, 44 positioned individually with respect to a corresponding arm 36, 38 to improve the interlocking of the container 12 with the respective arm 36, 38 Each roller mechanism 42,44 may include a wheel or roller 46,48, respectively, positioned adjacent the surfaces 50, 52 of the arms 36, 38. During interlocking of container 12a with surfaces 50, 52, rollers 46, 48 may rotate away from roll 34 and move container 12a in a fanned-out orientation. For example, roller 46 can rotate counter-clockwise in Figure 3 and roller 48 can rotate clockwise to lock container 12a relative to device 24a. A controller 54 (shown in Figure 1) can control the movement of the rollers 46, 48 according to a control program stored in memory.

Referring now to Figures 2 and 4, the process continues at step 56 and the arms 36, 38 move to a second open position. The arms 36, 38 can be moved relative to each other with a motor 58. Movement of the arms 36, 38 to the open position stretches the container 12a to the larger diameter 16a.

Also in step 56, the device 24a is moved to receive the particles (such as the particles 14 shown in Figure 1). Referring now to Figure 5, the device 24a is movable between the container receiving station 30 and a particle receiving station 60 with a motor 62. Motor 62 can be driven to rotate or lift device 24b such that device 24b is in an upward-facing orientation (shown in solid line) at the container receiving station 30 and in a downward-facing orientation (shown in dotted lines) at the particle receiving station 60. In addition, the motor 62 can move the device 24b vertically. A controller (substantially similar to controller 54 shown in FIG. 1) can control motor 62 in accordance with a control program stored in memory.

Referring now to Figures 1 and 2, the process continues at step 64 and the predetermined length 22 of container 12 is released relative to device 24. Alternatively, at the start of the filling process, nothing from container 12 can be released and Filling can begin with container 12 in the orientation shown in Figure 4.

Referring now to Figures 1 and 2, the process continues to step 68 and a plurality of particles 14 can be transferred to container 12. The particles 14 can be transferred to container 12 with a filling system that includes a conveyor belt 70 The particles 14 move along the conveyor belt 70 and may fall through a passage 72 defined by the device 24. The conveyor belt 70 can be an articulated conveyor belt, which can rotate about an axis of rotation. Controller 54 can control conveyor 70 including the speed with which particles 14 move in passage 72 and articulation of conveyor 70.

Step 74 monitors whether the fill level 18 has changed. The fill level 18 can be detected by a sensor 76. The sensor 76 can be an infrared sensor. The invention may include an array of infrared sensor emitters 78 supporting a plurality of infrared emitters 80 along a path that extends parallel to the vertical axis of container 12. Each emitter 80 can emit infrared radiation substantially transverse to the vertical axis of container 12. Sensor 76 can be horizontally aligned with at least one of the plurality of infrared emitters 80 during filling of container 12. When level When filling changes, the infrared radiation communicated between the emitter 80 and the sensor 76 can be blocked by the particles 14. In response to a change in fill level, sensor 76 can output a signal to controller 54. Controller 54 can control motor 62a to move sensor 76 vertically so that sensor 76 can receive infrared radiation from one of the plurality of emitters 80. The sensor 76 can be associated in an immovable way with respect to the device 24, so that the motor 62a moves the sensor 76 and the device 24 at the same time.

In alternative embodiments of the invention, sensor 76 may include an ultrasound transmitter and receiver, which applies sound waves to monitor the fill level 18 of material 14 in container 12. In another embodiment, a lower support member, such as the support member 25 shown in Figure 1, for supporting the flexible container 12 includes a scale and the release of the stretched portion 22 from the flexible container 12 is coordinated with the measured weight. of the fill material 14, thus allowing the portion 22 to remain substantially at the fill level 18. In other embodiments, the system includes a timing mechanism that coordinates the incremental release of the stretched portion 22 based on the known fill rate of the container 12.

For certain types of filling material 14, it may be advantageous to deposit the filling material 14 while filling the flexible container 12. To accomplish this, the support member 25 may include a vibratory shaker, thus allowing the support member 25 to deposit filling material 14 while filling container 12.

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In alternative embodiments of the invention, support member 25 and device 24 are vertically movable. In these embodiments, during the initial stages of filling the container 12 the support member 25 is positioned in close proximity to the device 24. As the container 12 is filled, the support member 25 is moved away from the device 24, in one direction downward to accommodate the accumulation of filling material 14 in the container 12. The advantage of this system is that brittle materials have a shorter fall distance from conveyor 70 into container 12. Movement of support member 25 can be accomplished by any of a variety of mechanisms including platform legs. in scissors, hydraulic pistons, pneumatic pistons, or a gear mechanism.

As used herein, the fill level is the highest level at which the particles occupy substantially an entire cross-sectional area of ​​the container 12. The plurality of particles may define a ridge 82 and the fill level 18 may be by below peak 82. Communication between sensor 76 and a corresponding emitter 80 can be blocked by peak 82. Sensor 76 can be separated from rollers 46, 48 by a distance substantially similar to the distance between crest 82 and fill level 18. Alternatively, sensor 76 and rollers 46, 48 can be substantially aligned with crest 82 Preferably, the release of the container 18 is maintained roughly within 12 inches of the ridge 82.

Referring now to Figure 2, if the fill level has not changed in step 74, the process returns to step 68 and a plurality of particles 14 are transferred to container 12. If the fill level has changed, the process continues to step 84 and the fill extent of container 12 is monitored. If the container 12 is full in step 84, the process ends in step 86. If container 12 is not full in step 84, the process continues in step 88 and device 24 moves upward. Device 24 can be moved with motor 62a. Motor 62a can be controlled by controller 54.

After upward movement of device 24, the process returns to step 64 and a predetermined length 22 of container 12 is released relative to device 24. During the filling process, predetermined length 22 can be selected based on the speed of fill. For example, a greater length of container 12 can be released in response to a high fill rate. Alternatively, the length can be selected based on the density of the material. For example, a greater length of container 12 may be released in response to higher density fill material. The flexible container 12 can be incrementally released from the bundled orientation or released continuously.

After length 22 is released, the major diameter 16 of container 12 will shrink to fill diameter 20 at fill level 18. Contraction of container 12 can generate circumferential forces to stabilize the plurality of particles 14 and promote contact. that can be controlled between individual particles. In a preferred embodiment, the circumferential forces generated are approximately 6900-20700 pascals (1-3 pounds per square inch). The contraction of the container 12 can be relatively gentle to couple the individual particles together. In any particular cross section, the coupled particles can form a mesh that reduces the probability of movement of the particles relative to each other and improves the structural rigidity of the container 12. The lock between the particles 14 resulting from the application of the circumferential force on the fill level 18 by increasing the fill level 18 can also reduce the likelihood that a bump or acceleration will damage the particles 14.

Referring now to Figure 1, in operation, controller 54 can control conveyor 70 to fill container 12 with particles 14. In particular, controller 54 can move articulated conveyor 70 to a downward position and control that conveyor belt 70 moves particles 14 through passage 72. Device 24 and sensor 76 can be immovably associated with each other and positioned below articulated conveyor 70. Container 12 can be supported in a fan-out orientation by device 24. Articulated conveyor 70 can moving a plurality of particles 14 that are received in container 12. Sensor 76 can receive infrared radiation from one of a plurality of emitters 80 disposed along array 78. When the fill level 18 increases so that the sensor 76 is blocked from receiving infrared radiation from a corresponding emitter 80, the sensor 76 can output a signal corresponding to a change in the fill level 18 to the controller 54. In In response, controller 54 may control motor 62a to move device 24 vertically upward. Controller 54 can also control articulated conveyor 70 to move upward, to prevent device 24 from contacting articulated conveyor 70. Controller also controls rollers 46, 40 to rotate and move container 12 away from conveyor belt 70, releasing portion 22 from the bundled orientation.

The top of the container 12 can be closed or left open after filling, depending on the filling material 14. For example, certain filling material 14 such as wood chips, sand, gravel, and other filling material 14, may not require the open top to close. The open top can be closed in any of a variety of ways known in the art including, but not limited to: ultrasonic or heat welding on the open top, closure of the open top with a draw loop of plastic, open top closure with wire or rope, open top closure with a clamp, and other closure means known in the art. In embodiments where continuous tubular rolls and open top ultrasonic or heat welding are used, the process of sealing the top of one container 12 can also create the bottom of the next container 12.

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It may be advantageous that once container 12 is filled with fill material 14 to include the additional step of placing a nylon strap net over container 12. The net may include a series of loops at the top or bottom. from the network to allow the resulting load to be handled like a Super Sack^®. Moving the unit with the loops more than the bottom platform or bracket will be advantageous in loading cargo ships with a very stable load with the least amount of cost associated with packaging material.

The above invention has been described in accordance with relevant legal standards, thus, the description is by way of example rather than limiting in nature. Variations and modifications to the described embodiment may be apparent to those skilled in the art and are within the scope of the invention. Accordingly, the scope of legal protection achieved by this invention can only be determined by studying the following claims.