RELATED APPLICATIONS This application is a divisional of U.S. patent Ser. No. 10/738,547, filed Dec. 17, 2003 which claims the benefit of priority of U.S. Provisional Patent Application Ser. No. 60/508,609, filed Oct. 3, 2003, the contents of which are hereby incorporated by reference as if recited in full herein, and this application is a continuation-in-part of U.S. patent application Ser. No. 10/339,910, filed Jan. 10, 2003, directly and/or via continuation application U.S. patent application Ser. No. 10/782,552, filed Feb. 19, 2004, each of which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/347,477, filed Jan. 11, 2002.
FIELD OF THE INVENTION The present invention relates to apparatus that can enclose products in packaging materials, and may be particularly suitable for enclosing products in clippable netting material.
BACKGROUND OF THE INVENTION Certain types of commodity and/or industrial items can be packaged by placing the desired product(s) in a covering material and then applying a closure clip or clips to end portions of the covering material to secure the product(s) therein. For non-flowable piece goods, the piece goods can be held individually in a respective clipped package, or as a group of goods in a single package. The covering material can be any suitable material, typically a casing and/or netting material.
Generally described, when packaging a piece good product in netting, the product is pushed through a netting chute. The product can include, by way of example, a non-flowable semi-solid and/or solid object such as a meat product including whole or half hams, turkeys, chickens, and the like. The netting chute holds a length of a netting sleeve over the exterior thereof. A first downstream end portion of the netting is typically closed using a first clip. As the product exits the netting chute, it is covered with the netting. The netting can be held relatively tight (typically stretched or in tension) over the product. The open end of the netting (upstream of the product) is then gathered and another clip can be applied to the gathered netting, typically using a double clipper apparatus. A clip attachment apparatus or “clippers” are well known to those of skill in the art and include those available from Tipper Tie, Inc., of Apex, N.C., under product numbers Z3214, Z3202, and Z3200. Examples of clip attachment apparatus and/or packaging apparatus are descried in U.S. Pat. Nos. 3,389,533; 3,499,259; 4,683,700; and 5,161,347, the contents of which are hereby incorporated by reference as if recited in full herein.
The double clipper concurrently applies two clips to the netting proximate the open (upstream) end of the package. One clip defines the leading end portion of the next package and the other defines the trailing or second end portion of the package then being closed. A cutting mechanism incorporated in the clipper apparatus can sever the two packages before the enclosed package is removed from the clipper apparatus. U.S. Pat. No. 4,766,713 describes a double clipper apparatus used to apply two clips to a casing covering. U.S. Pat. No. 5,495,701 proposes a clipper with a clip attachment mechanism configured to selectively fasten a single clip or two clips simultaneously.
SUMMARY OF EMBODIMENTS OF THE INVENTION Embodiments of the present invention provide netting product chutes with non-circular cross-sectional cavities that can be used to automatically and/or manually package a product in a covering material to which clips may be applied thereto.
In certain embodiments, the product can be manipulated and packaged so that at least one clip is automatically applied to enclose the product in the covering material after it exits the product chute. Particular embodiments automatically introduce and/or push a discrete object or objects through the chute and into netting and then automatically clip the netting holding the enclosed product to thereby automatically package the product(s).
Some embodiments are directed to netting/product chutes having an outer wall defining an interior cavity extending therethrough, the outer wall including an exterior surface adapted to hold netting thereon, the chute having a cavity with a non-circular cross-section.
In particular embodiments, the netting/product chute may include a primary body and an entry segment attached thereto. The entry segment can have a flared portion with a first cross-sectional area that tapers into an adjacent downstream portion proximate the primary body to have a smaller second cross-sectional area thereat. The chute may include a generally planar floor.
In some embodiments, the non-circular shape can be a generally pentagonal cross-sectional shape. In other embodiments the cavity cross-sectional shape comprises an upper triangular portion. In yet other embodiments, the cavity cross-sectional shape is generally oval while in other embodiments the product chute has a cavity cross-sectional shape with a generally curvilinear upper portion that terminates into a generally planar lower floor portion.
Certain embodiments are directed to systems for enclosing a semi-solid or solid product (or products) in a covering material. The systems include: (a) an elongate product chute having a generally planar floor, and an outer wall defining opposing receiving and discharge end portions and an interior cavity extending therethrough, the cavity having a non-circular cross-sectional shape; and (b) a clipper mechanism disposed downstream of the product chute. The clipper mechanism is configured to apply at least one clip to a covering material that resides over and encloses a product discharged from the product chute.
Other embodiments are directed to methods of packaging an object or objects in netting. The methods include: (a) pushing at least one object through a product chute having a floor and a non-circular cross-sectional shape; (b) pulling netting material downstream of the product chute off of an exterior surface of the product chute to automatically enclose the object in the netting material as the object exits the product chute; and then (c) applying at least one clip to the netting material to secure the object in the netting material.
These and other objects and/or aspects of the present invention are explained in detail in the specification set forth below.
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 is a front perspective view of an apparatus/system used to automatically advance objects through a product chute and then automatically apply a clip(s) via a clipper mechanism according to embodiments of the present invention.
FIGS. 2A-2D are front views of a manual packaging system illustrating a sequence of operations that can employ the netting chutes of the present invention according to embodiments of the present invention.
FIG. 3 is a side perspective view of a product chute according to embodiments of the present invention.
FIG. 4 is a front view of the product chute shown inFIG. 3.
FIG. 5 is a rear view of the product chute shown inFIG. 3.
FIG. 6A is a side perspective view of the product chute shown inFIG. 3 illustrating an exemplary object therein in preparation for packaging with the product chute held substantially horizontally during operation according to embodiments of the present invention.
FIG. 6B is a side perspective view of the product chute shown inFIG. 3 with the product chute held tilted relative to horizontal during operation according to other embodiments of the present invention.
FIG. 7 is a front perspective view of a product chute according to other embodiments of the present invention.
FIG. 8 is a front view of the product chute shown inFIG. 7.
FIG. 9 is a side perspective view of another product chute according to yet other embodiments of the present invention.
FIG. 10 is a side view of the product chute shown inFIG. 9.
FIG. 11 is a front view of the product chute shown inFIG. 9.
FIG. 12 is a rear end view of the product chute shown inFIG. 9.
FIG. 13 is a side perspective view of another product chute according to additional embodiments of the present invention.
FIG. 14 is a side view of the product chute shown inFIG. 13.
FIG. 15 is a front view of the product chute shown inFIG. 13.
FIG. 16 is a rear end view of the product chute shown inFIG. 13.
FIG. 17 is a side perspective view of the product chute shown inFIG. 13 with an exemplary object entering therein for packaging according to embodiments of the present invention.
DESCRIPTION OF EMBODIMENTS OF THE INVENTION The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations, unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the claims unless specifically indicated otherwise. Where used, the terms “attached”, “connected”, “contacting”, “coupling” and the like, can mean either directly or indirectly, unless stated otherwise. The term “concurrently” means that the operations are carried out substantially simultaneously. In addition, as used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.
In the description of the present invention that follows, certain terms are employed to refer to the positional relationship of certain structures relative to other structures. As used herein, the term “front” or “forward” and derivatives thereof refer to the general or primary direction that the product travels for packaging and closure; this term is intended to be synonymous with the term “downstream,” which is often used in manufacturing or material flow environments to indicate that certain material traveling or being acted upon is farther along in that process than other material. Conversely, the terms “rearward” and “upstream” and derivatives thereof refer to the directions opposite, respectively, the forward and downstream directions.
Embodiments of the present invention are particularly suitable for applying closure clips to discrete objects held in a covering material. The covering material may be natural or synthetic and may be a casing material that can be sealed about a product or may be netting. The casing can be any suitable casing (edible or inedible, natural or synthetic) such as, but not limited to, collagen, cellulose, plastic, elastomeric or polymeric casing. The term “netting” refers to any open mesh material in any form including, for example, knotted, braided, extruded, stamped, knitted, woven or otherwise. Typically, the netting is configured so as to be elastic and/or stretchable in both axial and lateral directions (isotropically elastic).
Netting or other covering material may be used to package discrete meat products such as loaves of meat, boned ham, spiral-sliced ham, deboned ham, turkey, turkey loaves held in molds, or other meat items; the packaging may be performed on the item or items alone or with the item or items held in subcontainers and/or wraps such as molds, trays, boxes, bags, absorbent or protective sheets, sealant, cans and the like. Other embodiments of the present invention may be directed to package other types of food such as cheese, bread, fruit, vegetables, and the like. Examples of non-food items that may be packaged using embodiments of the present invention include living items such as flora, trees, and the like, as well as inanimate objects. Additional examples of products include discrete, semi-solid or solid non-flowable objects such as firewood, pet food (typically held in a container if the wet type), recreational objects (such as balls), or other solid or semi-solid objects. The product may be a packaged for any suitable industry including horticulture, aquaculture, agriculture, or other food industry, environmental, chemical, explosive, or other application. Netting may be particularly useful to package ham or turkeys, manufactured hardware such as automotive parts, firewood, explosives, molded products, and other industrial, consumable, and/or commodity item(s).
Generally stated, embodiments of the present invention are directed to the packaging of piece goods or discrete items by forcing them through a product chute, wrapping or enveloping the objects at the other end of the chute in a covering material, such as netting, then clipping the covering material with a closure clip or other attachment means to close the covering and hold the object or objects inside of the covering material. As noted above, clippers are available from Tipper Tie, Inc., of Apex, N.C. Examples of suitable clips include metallic generally “U”-shaped clips available from Tipper Tie, Inc., in Apex, N.C. Other clips, clip materials, and clip configurations or closure means may also be used.
FIG. 1 illustrates an exemplary automaticclipping packaging apparatus10 according to embodiments of the present invention. As shown, theapparatus10 includes a product pusher assembly ormechanism20, aproduct chute30, and aclipper40. It is noted that theclipper40 may be referred to herein as a clipper apparatus, clipper mechanism, and/or clipper assembly, but each term may be used interchangeably with the others. As shown, theapparatus10 may optionally include aninfeed conveyor50. In the embodiment shown, theapparatus10 can be described as a horizontal automatic clipping packaging apparatus as the product is primarily moved, processed, clipped and packaged in a horizontal plane. However, certain components, features or operations may be oriented and/or carried out in other planes or directions and the present invention is not limited thereto. For example, theproduct chute30 may be tilted from horizontal, typically so that the discharge oregress end30dis closer the ground than the product entry oringress end30e(as generally illustrated byFIG. 6B). The direction of travel of an exemplary product undergoing packaging is illustrated by the broken line arrows in thisFIG. 1. Non-automated systems may have a generally straight path axially aligned with that of the chute axis as is known to those of skill in the art.
This positioning of the product in the flow path and/or alignment with theproduct chute cavity30ccan be carried out substantially automatically as will be discussed further below. However, a target product undergoing packaging can also be manually introduced or placed into the flow path and subsequently processed as in an automatic or manual in-feed operation.
In operation, theproduct pusher assembly20 linearly retracts and advances to push a product through theproduct chute30 so that the product is positioned proximate theclipper40 and then retracts to a resting state upstream of theproduct transfer zone60. As described above, a sleeve of coveringmaterial100c(FIG. 2B) can be positioned about the external surface of theproduct chute30 and configured to be drawn downstream thereof so as to automatically encase the product as the product emerges from thedischarge end30dof theproduct chute30. A supplemental sleeve material holder may also be used if desired instead of placing the sleeve of casing material on the product chute. The supplemental sleeve holder can be configured to surround a downstream portion of the product chute (not shown). The sleeve of covering material may be sized to stretch to substantially conform to the external wall or surface of theproduct chute30 or may be more loosely held thereon. The cavity of theproduct chute30cmay be sized to snugly contact or squeeze opposing portions of the product (side to side and/or top to bottom) as the product is pushed therethrough or may be oversized with respect to the product so that the product loosely travels therethrough.
In some embodiments, the shape, size and/or type of product can determine a suitable netting diameter to provide a desired tightness of netting and, hence, influence the product chute design factor.
In operation, the sleeve of covering material may be clipped, welded, fused, knotted or otherwise closed at a leading edge portion thereof. When the product exits theproduct chute30, it is held in the covering material as the covering material is drawn downstream. The covering material is typically loaded onto theproduct chute30 and the leading edge portion closed before theproduct chute30 is mounted to theapparatus10. Additional description of a suitable automatic apparatus is described in co-pending, co-assigned U.S. Provisional Patent Ser. No. 60/508,609, filed Oct. 3, 2003, the contents of which were incorporated by reference above.
FIGS. 2A-2D illustrate a manual orsemi-manual system11 with a series of operations that can be used to package atarget product100 or products using aproduct chute30 and a desiredcovering material100c.FIG. 2D illustrates a clipped100clpackage of netting enclosing theproduct100.
FIGS. 3-6B illustrate one embodiment of aproduct chute30 that can be used with automatic and/or manual packaging systems. As shown, theproduct chute30 includes anouter surface30s, acavity30c, and afloor30f. As shown, thefloor30fcan be substantially planar and disposed at the lower portion of acurvilinear wall30w. In certain embodiments, thechute30 is configured so that thecurvilinear wall30wterminates or merges into thefloor30fto together define a non-circular cross-sectional shape of thecavity30c.
Thus, theproduct chute30 has a cross-sectional profile that is non-circular. As shown inFIG. 4, theproduct chute30 may be configured with acavity30chaving a generally oval profile. In this embodiment, the cavity shape can be described as having a substantiallyplanar bottom portion30b, generallysemi-circular side30aportions, and a substantially planarupper portion30u. Other cross-sectional profile configurations may also be used, including, but not limited to, circular, oval, triangular, rectangular, square and the like, and combinations thereof, examples of which will be described below.
As is also shown inFIGS. 3 and 4, theproduct chute30 may include an outwardly flaringforwardmost edge portion34 that gradually tapers into the primary chute body. This flaring segment orportion34 can be described as a funnel-like guide that may help direct objects into the primary body of thechute30. Thus, theproduct chute30 can include a larger front-end cavity area relative to the intermediate and/or dischargingportion30d, i.e., thechute cavity30cnarrows in the pushing/product travel direction. Thus, theproduct chute30 can include a primary body and a larger upstream guide portion that narrows into the shape of the primary body.
Theproduct chute30 can include ahandle35 or other suitable gripping means thereon to facilitate operator handling. In addition, theproduct chute30 may include a mountingbracket36 that allows thechute30 to be secured to a mounting frame during operation. In particular embodiments, theproduct chute30 mountingbracket36 is configured to releasably attach to a frame of an apparatus (such as that shown asreference number10 inFIG. 1). As shown inFIGS. 3-6B, the mountingbracket36 can be configured with an axially extendingfinger bracket37bwith at least one aperture37 (shown as two) that can be used to hold a safety proximity or interlock sensor to inhibit operation of the clipping and/or product/pusher system when the product chute is not in proper position. An exemplary sensor is a two-part magnetic switch, one part of which can be positioned onchute bracket37bas shown inFIG. 3 and the other part held on a mounting frame that holds thechute30. When the two matable parts of the switch engage, thechute30 is determined to be in proper position. Other types and/or additional sensors may also be used as suitable as is known to those of skill in the art.
In particular embodiments particularly suitable forautomated systems10 shown inFIG. 1, when aproduct100 is detected in thetransfer zone60, the activation of theproduct pusher assembly20 may be based on whether theproduct chute30 is determined to be in proper position using data from the sensor held onbracket37b(FIG. 3), and/or on a portion of the mounting frame holding thechute30. In operation, a controller/processor (such as a Programmable Logic Controller) may be configured to monitor a signal from the proximity sensor and deactivate the product pusher assembly (release cylinder pressure) automatically whenever aproduct chute30 position-error is noted at any time during the process. The signal can be automatically monitored through a Safety Circuit Computer Module. If theproducts chute30 is missing or out of position, theapparatus10 can be held in a low energy state that removes power to air supplies and controls to inhibit machine operation. To reinitiate the procedure, an operator may press a restart or reset button. In certain embodiments, theclipper40 may be operated on override even when thechute30 is absent. Once theproduct chute30 is in location and the stop is reset, power air can be applied to the machine control valves and electric power can be applied to the control (PLC) outputs. After the PLC determines the positions of the moveable components, such as theproduct pusher assembly20, theclipper40, a product holding member (where used), and the like, an automatic reset can be performed and those components automatically moved to a respective home position as needed.
In operation, as shown inFIG. 6A, a supply of coveringmaterial100ccan be placed on or about thechute30, arranged to surround the exterior surface of at least a portion of theproduct chute30 and stretch in tension in the downstream direction to cover the product100 (tenting in the axial direction) as the product exits the discharge end portion of theproduct chute30d. In certain embodiments, the coveringmaterial100cis configured and sized to stretch in at least the lateral direction and typically in both the lateral and axial directions as it is held on and dispensed from theproduct chute30. The covering (typically netting) can be pulled to package successive objects until the sleeve is depleted.
FIG. 6A illustrates that theproduct chute30 may be held substantially horizontal during operation.FIG. 6B illustrates that the product chute may be held tilted with respect to horizontal during operation. The tilt may be selected so that the chute extends angularly down at between about 30-60 degrees.
Although theproduct chute30 is shown as having a continuous outer surface or wall, other configurations may also be used. For example, the chute wall or walls may include a slot or apertures and may not be a closed configuration, typically depending on the application. However, thechute30 should be configured to provide sufficient structural support for the covering material (typically sized and configured to hold the covering stretched in both lateral and longitudinal directions) and to allow the product to enter the product material as it exits theproduct chute30.
FIGS. 7 and 8 illustrate another embodiment of aproduct chute30. In this embodiment, theproduct chute30 has a cavity that has a truncated circular profile. As shown inFIG. 8, the upper profile shape (when viewed from the end) is circular and is truncated by a generallyplanar floor30f. As before, theforwardmost entry portion30ecan include a flaredsegment34.
FIGS. 9-12 illustrate yet another embodiment of aproduct chute30. As shown, thecavity30chas a profile that is a generally elongate flattened oval. In this embodiment, the oval shape is more compressed than that ofFIG. 3, with the cross-sectional shape of thecavity30chaving shortercircular sides30awith relatively longer generally planar top andbottom segments30u,30b. However, similar toFIG. 3, the upper andlower portions30u,30b, respectively, of theproduct chute30 can be generally planar, while the opposingside portions30aare substantially semicircular (typically arcuate). Again, the forwardmost portion may include a flaredentry segment34. However, in this embodiment, the flaredsegment34 has a discontinuous perimeter. That is, the flaredsegment34 is attached to the primary body of thechute30 and defines agap space34gproximate thefloor30fof the entry portion of theproduct chute30.
FIG. 10 illustrates that thedischarge end30dof thechute30 can be configured with anangular shape39 when viewed from the side. This configuration can also apply to other chutes described herein (see, for example,FIG. 14). Thedischarge end30dof the product chute may be configured so that a top axially extending length of the chute is shorter than a bottom axially extending length of the chute. As shown, the discharge end of thechute30dis angled from top to bottom, typically at about 10-45 degrees.
FIGS. 13-17 illustrate yet another embodiment of achute30 according to the present invention. As shown, thechute30 includes a generally triangularupper portion30t. The generally pentagonal cross-sectional shape of thecavity30cis shown inFIGS. 15 and 16. As shown inFIG. 15, when the chute is held horizontally, the upper generally triangulatedportion30tmerges into opposing substantially downwardly extending (shown as vertical) side segments30v1,30v2, which merge into a bottom30bsubstantially planar (shown as horizontal)floor segment30f.
Thechute30 may be formed as a unitary member or a series of attached members (not shown). In certain embodiments, the product chute body may include a single continuous wall that defines the shape of thecavity30c. In other embodiments, the product chute body can be formed with a plurality of walls. In some embodiments, theproduct chute30 is fabricated from stainless steel. The interior surface or portions thereof may be coated with an anti-stick coating and/or lubricant. For example, the interior of thechute30 may comprise TEFLON® polymer. In particular embodiments, a single sheet of metal can be formed to provide the desired curvilinear product chute body shape (at least the upper portion above the floor).
Thechutes30 can vary in length depending on the target object or objects and the netting or covering material used, and the like. In particular embodiments, the chutes can have lengths of between about one (1) foot-eight (8) feet long, and more typically between about 2-6 feet long.
Although shown with a single object in a netting package, other embodiments of the invention use theproduct chutes30 to package groups of objects (not shown).
Theproduct chute floor30fmay be a stationary floor as shown. However, it is also rioted that theproduct chute30 may include a moving floor. Thechute30 may be sized relative to theproduct100 so that theproduct100 extends across a major portion of the width of the cavity, and in certain embodiments, extends across at least about 75% of the width of the cavity. In certain embodiments, theproduct100 andchute cavity30care sized so that the sides and/or top and bottom of theproduct100 are pressed against the sidewalls of the chute cavity as the product is pushed therethrough.
As described above, theproduct chute30 can be configured to mount on a mountingbracket36 that fits into a frame on such asapparatus10,11 (FIGS. 1, 2).FIGS. 7-17 illustrate a mountingbracket36 with a different configuration from that shown inFIGS. 3-6B. Thebracket36 shown inFIGS. 3-6B can include aplanar platform30b1(typically mounted substantially horizontal) that is connected to an upwardly extendingsegment30b2(typically substantially vertical) with a recessed contour configured to receive the contour of the bottom of theproduct chute30b3.
FIGS. 7-17 illustrate a substantiallyplanar platform30b1′ that is attached to the planar bottom surface of achute30 and merges into a downwardly extendingsegment30b2′.
In any event, the mountingbracket36 can be configured to relatively easily attach to and be removed from the frame of the apparatus (such as10,11,FIGS. 1,2) so as to be releasably mountable thereto. The mountingbracket36 can hold theproduct chute30 in alignment with theclipper mechanism40 downstream and, where used, theproduct pusher mechanism20 upstream. In certain embodiments, thesystem10,11 can include a first product chute and a respective first mountingbracket36 and asecond product chute30 releasably mountable to theapparatus frame10,11 at the same position (interchangeable chutes) using a respective second mountingbracket36 that can be configured substantially the same as the first mountingbracket36. In other embodiments, theproduct chute30 can be lifted off of the mounting bracket36 (leaving the mounting bracket in place) and anotherchute30 placed thereon. The second product chute may be sized and configured the same as thefirst product chute30 and loaded with a second supply of covering material. The covering material may be the same as that of the first product chute or different. Thus, the respective first and second mountingbrackets36 can be configured as quick disconnect components (merely loosening and/or releasing attachment hardware) to allow the first andsecond product chutes30 to be interchanged on a system in under 5 minutes, and more typically in under about 2 minutes, to allow an operator to employ at least one of a different size product chute, a different configuration product chute, different packaging material dispensed by the product chute.
The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. In the claims, means-plus-function clauses, where used, are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.