Apparatus for Packing Leafy Produce into a Tray

Abstract

packing leafy produce into a tray involving a plunger, the plunger having an actuator arm and a footpad, the footpad having an upper surface and a lower surface, being in moveable relation to the actuator arm, for contacting the leafy produce.

Description

PRIORITY CLAIM

[0001]This application is a continuation in part of application Ser. No. 11/232,830, entitled "Automated Plunger assembly, Machine and Method" filed on Sep. 21, 2005 (retitled "Apparatus for Packing Leafy Product into a Tray" by examiner's amendment), and claims priority thereto. The parent application and all amendments thereto are hereby expressly incorporated by reference. Claims 1 through 8 herein were previously allowed in the parent application. Claims 9 through 16 are new.

TECHNICAL FIELD

[0002]The present invention relates to mechanized processing and packaging of agricultural products and produce.

BACKGROUND ART

[0003]The currently existing art involves several machines for packing leafy produce, such as "spring mix," spinach, lettuce, endive, arugula, and the like. One such instance of existing art is a packing machine that fills a container with leafy produce then fits a lid onto such container having the produce, but damages the leafy produce at the rim of the container, thereby shortening the shelf life of the product. This problem in the related art occurs, because the leafy produce has a tendency to spring back upon loading into the container, to overhang the rim of the container, and to be subsequently damaged during fitting of the lid. To counteract this adverse result, agricultural processors have used manual labor for "post-packing"the leafy produce, e.g., using a production line of approximately six gloved workers who manually reposition the leafy produce in the container prior to thereon fitting the lid. Thus, a long-felt need is seen to exist for an automated apparatus for efficiently packing leafy produce, eliminating damage thereto, and minimizing processing time.

DISCLOSURE OF THE INVENTION

[0004]The present inventive concept pertains to the mechanized packing of a product, such as leafy produce, into a tray without damage and minimizing processing time. In a preferred embodiment, an automated machine for packing leafy produce into a tray generally comprises: one or more transfer chutes for receiving the portions and guiding each tray-sized individual portions into one of the trays; flop gates within the chutes to control the flow of produce through the various chutes; a conveyor for moving the trays into a position below the transfer chute's discharge opening to receive the tray-sized portions; a plunger assembly with at least one linear plunger having a first footpad for moving the portions through the transfer chute discharge opening into the tray, a ram, cylinder and piston rod, a retracted first position with the footpad outside of the transfer chute and an extended second position with the footpad inside the transfer chute proximal to the discharge opening. Mechanized moving parts, including the flop gates and plunger assembly, are coupled with automated actuators to allow automation and sequencing of movement.

[0005]Advantages of the present inventive concept include the promotion of increased production levels, minimization of rejected product, and minimization of the number of workers required in the production line. Other features of the present inventive concept and its embodiments are disclosed, or are apparent, in the section entitled "Detailed Description of the Invention," disclosed, infra.

BRIEF DESCRIPTION OF THE DRAWING

[0006]For a better understanding of the present invention, reference is made to the below-referenced accompanying Drawing. Reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the Drawing.

[0007]FIG. 1 is an upward perspective view of an automated packing machine, in accordance with the present invention, with a plunger assembly comprising two plungers per transfer chute.

[0008]FIG. 2 is a downward perspective view of the automated packing machine, as shown in FIG. 1, in accordance with the present invention, with a plunger assembly comprising two plungers per transfer chute.

[0009]FIG. 3 is an upward perspective view of an automated packing machine, shown without the support frame for clarity only, in accordance with the present invention, with a plunger assembly comprising two plungers per transfer chute.

[0010]FIG. 4 is a downward perspective view of a plunger assembly comprising two plungers per transfer chute with a mounting bracket, and without the support frame for clarity only, in accordance with the present invention.

[0011]FIG. 5 is a downward perspective view of a plunger assembly comprising two plungers per transfer chute an automated plunger assembly, shown without a mounting bracket and without the support frame for clarity only, in accordance with the present invention.

[0012]FIG. 6 is side view of a plunger assembly comprising two plungers per transfer chute, wherein at least one plunger is disposed outside a transfer chute and a funnel, shown without a mounting bracket and without the support frame for clarity only, in accordance with a first embodiment of the present invention.

[0013]FIG. 7 is side view of a plunger assembly comprising two plungers per transfer chute, wherein at least one plunger is disposed inside a product transfer chute and a funnel, shown without a mounting bracket and without the support frame for clarity only, in accordance with a second embodiment of the present invention.

[0014]FIG. 8 is a front view of an automated packing machine, being serially disposed in an assembly line, in accordance with an embodiment of the present invention.

[0015]FIG. 9 is an upward perspective view of an automated packing machine, in accordance with the present invention, with a plunger assembly comprising one plunger per transfer chute.

[0016]FIG. 10 is a downward perspective view of the automated packing machine, as shown in FIG. 9, in accordance with the present invention, with a plunger assembly comprising one plunger per transfer chute.

[0017]FIG. 11 is an upward perspective view of an automated packing machine, shown without the support frame for clarity only, in accordance with the present invention, with a plunger assembly comprising one plunger per transfer chute.

[0018]FIG. 12 is a downward perspective view of a plunger assembly comprising one plunger per transfer chute with a mounting bracket, and without the support frame for clarity only, in accordance with the present invention.

[0019]FIG. 13 is a downward perspective view of a plunger assembly comprising one plunger per transfer chute an automated plunger assembly, shown without a mounting bracket and without the support frame for clarity only, in accordance with the present invention.

[0020]FIG. 14 is side view of a plunger assembly comprising one plunger per transfer chute, wherein the plunger is disposed outside a transfer chute and a funnel, shown without a mounting bracket and without the support frame for clarity only, in accordance with an embodiment of the present invention.

[0021]FIG. 15 is side view of a plunger assembly comprising one plunger per transfer chute, wherein the plunger is disposed inside a product transfer chute and a funnel, shown without a mounting bracket and without the support frame for clarity only, in accordance with an embodiment of the present invention.

MODES FOR CARRYING OUT THE INVENTION

[0022]FIG. 1 illustrates, in a perspective view, an automated packing machine 1000, comprising a plunger assembly, in accordance with the present invention. The plunger assembly 100 for packing leafy produce 10 into a tray 20, comprises at least one plunger 30, each at least one plunger 30 having at least one actuator arm 40 and at least one footpad 50, the at least one footpad 50 having an upper surface 50a and a lower surface 50b, being in moveable relation to the at least one respective actuator arm 40, for contacting the leafy produce 10. The moveable relation comprises a structure 40a (not shown) for articulating the at least one footpad 50 about each respective at least one actuator arm 40. The articulating structure 40a is disposed at a location selected from a group consisting essentially of a periphery of the footpad 50 at the upper surface 50a, a centerline of the footpad 50 at the upper surface 50a, and a location between a centerline of the footpad 50 and a periphery of the footpad 50. The machine 1000 is shown in FIG. 1 with a set of plungers 30, e.g., primary plungers, with a support frame 1001, with a hopper 80, comprising a primary chute 1002 and a secondary chute (pant-leg chute) 1003 for facilitating filling of two trays at a given filling interval, and a feeder 90, comprising a feature such as a product transfer (funnel) 120, for clarity and by example only. The primary chute 1002 comprises a flop gate 1002a and a flop gate actuator 1002b, as shown in FIG. 12 which is described, infra, and a flop gate control device 1002c, such as a solenoid switch, for controlling the flop gate actuator 1002b.

[0023]By example only, the articulating structure 40a comprises a feature selected from a group consisting essentially of a hinge, a pin, and a ball and socket combination. The at least one footpad 50 comprises a corrugated surface 50c at the lower surface 50b for minimizing surface tension of the leafy produce 30 which facilitates release of the leafy produce 10 from the footpad 50 when the plunger 30 retracts, The corrugated surface 50c comprises a configuration such as a sinusoidal profile and a square wave profile, the sinusoidal profile being preferred. The at least one actuator arm 40 comprises a structure for adjusting stroke (not shown), wherein the stroke is effected by programmable logic control (PLC), such as a magnetic read switch disposed on the actuator arm 40 and a PLC-defined dwell time. The actuator arm 40 comprises an actuator arm housing 40b such as a hollow tube. The at least one footpad 50 comprises a structure for adjusting size (not shown), especially the platform size. The footpad size adjusting structure comprises a feature such as at least one retractable footpad portion and a set of interchangeable footpads 50 which are interchangeable by loosening a fitting 41a at a proximal end of a guide-rod 41 and a fitting 50d at the upper surface 50a of the footpad 50, wherein each footpad 50 of the set comprises a distinct size.

[0024]Plunger 30 is angularly disposed in relation to the tray 10. The plunger 30 is activated, i.e., deployed by a feedback and control unit comprising sensor 110 (discussed, infra), upon sensing the presence of a tray 20 and retracted upon packing the tray 20 with the leafy produce 10. The apparatus 100 comprises a primary plunging mechanism 31, as shown and described, infra, with respect to FIG. 12. The footpad 50 is preferably selected to fit the size of the opening of the tray 20. In particular, as the footpad 50 reaches the bottom of the stroke, a puff of gas, such as air and nitrogen (N₂), as well as an inert gas, such as helium (He) and argon (Ar), is administered through a manifold disposed at the periphery of the upper surface 50a of the footpad 50. After the dwell period has lapsed, the plunger 30 retracts; and the filled tray 20 is stepped forward by the conveyer 60 for applying the lid 130.

[0025]FIG. 2 illustrates, in a downward perspective view, the automated packing machine 1000, as shown in FIG. 1, comprising the automated plunger assembly 100, in accordance with the present invention.

[0026]FIG. 3 illustrates, in an upward perspective view, an automated packing machine 1000, comprising an automated plunger assembly 100, shown without the support frame 1001 for clarity only, in accordance with the present invention.

[0027]FIG. 4 illustrates, in a downward perspective view, an automated plunger assembly 100, shown in relation to a feeder 90, such as a product transfer chute 120 and a funnel, with a mounting bracket 32, and without the support frame 1001 for clarity only, in accordance with the present invention. A set of plungers 30 are lowered into the product transfer chute 120 by the primary plunging mechanism 31.

[0028]FIG. 5 illustrates, in a downward perspective view, an automated plunger assembly 100, shown without a mounting bracket 32 and without the support frame 1001 for clarity only, in accordance with the present invention.

[0029]FIG. 6 illustrates, in a side view, an automated plunger assembly 100, wherein at least one plunger 30 is disposed outside a feeder 90, such as a product transfer chute 120 and a funnel, shown without a mounting bracket 32 and without the support frame 1001 for clarity only, in accordance with a first embodiment of the present invention.

[0030]FIG. 7 illustrates, in a side view, an automated plunger assembly 100, wherein at least one plunger 30 is disposed a feeder 90, such as a product transfer chute 120 and a funnel, shown without a mounting bracket 32 and without the support frame 1001 for clarity only, in accordance with a second embodiment of the present invention.

[0031]FIG. 8 illustrates, in a front view, an automated packing machine 1000, comprising automated plunger assemblies 100, 100', being serially disposed in an assembly line, wherein the second apparatus 100' acts as a secondary set of plungers, in accordance with a fifth embodiment of the present invention. The primary chute 1002 comprises a flop gate 1002a, a flop gate actuator 1002b, and a flop gate control device 1002c, such as a solenoid switch, for controlling the flop gate actuator 1002b. The flop gate 1002a limits the amount of leafy produce 10 which is packed at a given packing interval.

[0032]Referring to both FIGS. 1 and 8, the automated machine 1000 for packing leafy produce 10 into a tray 20, comprises a conveyor 60 having a stepper 70 for accommodating and moving at least one tray 20, a tray filler generally comprising a hopper 80 for channeling the leafy produce 10 and a feeder 90 for receiving the channeled leafy produce 10 and for filling the leafy produce 10 into the at least one tray 20, and an automated plunger assembly 100 for packing the leafy produce 10 into a tray 20, the apparatus 100 comprising at least one plunger 30, each at least one plunger 30 having at least one actuator arm 40 and at least footpad 50, the at least one footpad 50 having an upper surface 50a and a lower surface 50b, being in moveable relation to the at least one respective actuator arm 40, for contacting the leafy produce 10.

[0033]Machine 1000 further comprises a sensor 110 for detecting the presence of the at least one tray 20 and for supplying an electronic signal to the feeder 90 to effect its opening for filling the at least one tray 20 with the leafy produce 10 (a designated amount thereof). The feeder 90 includes a product transfer chute 120 or a funnel being disposed into the at least one tray 20 upon receipt of the electronic signal from the sensor 110. In the alternative, the plunger 30 is disposed within the product transfer chute 120.

[0034]FIGS. 9 though 16 similarly depict a packing machine and its components with a preferred configuration, having a plunger assembly comprising only one plunger per transfer chute. This embodiment has the advantage of fewer moving parts, with consequent added simplicity in coordinating and automating the plunger actuation as well as being easier to clean, maintain and sanitize.

[0035]Information as herein shown and described in detail is fully capable of attaining the above-described object of the invention, the presently preferred embodiment of the invention, and is, thus, representative of the subject matter which is broadly contemplated by the present invention. The scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and is to be limited, accordingly, by nothing other than the appended claims, wherein reference to an element in the singular is not intended to mean "one and only one" unless explicitly so stated, but rather "one or more." All structural and functional equivalents to the elements of the above-described preferred embodiment and additional embodiments that are known to those of ordinary skill in the art are hereby expressly incorporated by reference and are intended to be encompassed by the present claims.

[0036]Moreover, no requirement exists for a device or method to address each and every problem sought to be resolved by the present invention, for such to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. However, various changes and modifications in form, material, and fabrication material detail may be made without departing from the spirit and scope of the inventions as set forth in the appended claims should be readily apparent to those of ordinary skill in the art. No claim herein is to be construed under the provisions of 35 U.S.C. 112, sixth paragraph, unless the element is expressly recited using the phrase "means for."

INDUSTRIAL APPLICABILITY

[0037]The present invention industrially relates to agricultural apparatuses, machines, and methods. More particularly, the present invention industrially relates to agricultural apparatuses, machines, and methods for processing produce. Even more particularly, the present invention industrially relates to agricultural apparatuses, machines, and methods for packing processed produce.

Claims

1. An apparatus for packing leafy produce into a tray, comprising:a. A primary chute for receiving and apportioning the leafy produce into individual portions;b. A transfer chute, having two sidewalls, two end walls and a discharge opening, for receiving the portions and guiding each of said tray-sized individual portions through a discharge opening into one of the trays;c. a means for conveying said trays to a position below said discharge opening of said transfer chute to receive said tray-sized individual portions.d. A first linear plunger having a first footpad for moving the portions through the transfer chute discharge opening into the tray, said plunger having a retracted first position with the footpad outside of the transfer chute and an extended second position with the footpad inside the transfer chute proximal the discharge opening, said first plunger having a first ram, cylinder and piston rod; ande. A second linear plunger having a second footpad for moving the portions through the transfer chute discharge opening into the tray, said second plunger being oriented to said first plunger at an acute angle, and having a second ram, cylinder and piston rod, said first and second footpads further each having a manifold for dispersing a puff of gas as the linear plungers reach the extended position.

2. The apparatus as in claim 1 wherein at least one of the first and second footpads is detachably coupled to the respective first and second linear plungers by a coupling.

3. The apparatus as in claim 2 wherein the coupling is at a position selected from the group of positions consisting of a periphery of the footpad at an upper surface, a centerline of the footpad at an upper surface, and a location between the centerline and the periphery.

4. The apparatus as in claim 3 wherein at least one of the first and second footpads has a corrugated surface on the side contacting the portion in the tray.

5. An apparatus as in claim 1, wherein the primary chute includes a secondary chute, wherein the primary chute further includes a flop gate for limiting the amount of leafy produce to be filled in two trays, a flop gate actuator, and a flop gate control device for controlling the flop gate actuator, and wherein the secondary chute includes at least two chute branches for facilitating filling of at least two trays simultaneously.

6. An apparatus as in claim 1 further having at least one footpad manifold for dispersing a puff of gas.

7. An apparatus as in claim 1, wherein said means for conveying said trays comprises a conveyor having a stepper for disposing and moving the trays below said discharge opening.

8. An apparatus, as recited in claim 1, wherein at least one of the footpads traverses a path substantially along one of the sidewalls of the transfer chute.

9. An apparatus for packing leafy produce into trays comprising:a. A primary chute for receiving and apportioning the leafy produce into individual tray-sized portions;b. At least two transfer chutes, having two sidewalls, two end walls, and a discharge opening, for receiving the portions and guiding each of said tray-sized individual portions through said discharge opening into one of the trays;c. A linear plunger having a first footpad for moving the portions through the transfer chute discharge opening into the tray, said plunger having a retracted first position with the footpad outside of the transfer chute and an extended second position with the footpad inside the transfer chute proximal to the discharge opening, said plunger having a ram, cylinder and piston rod.

10. The apparatus as in claim 9 wherein at least one of the footpads is detachably coupled to the respective plunger by a coupling.

11. The apparatus as in claim 10 wherein the coupling is at a position selected from a group on positions consisting of a periphery of the footpad at an upper surface, a centerline of the footpad at an upper surface, and a location between the centerline and the periphery.

12. The apparatus as in claim 11 wherein at least one of the footpads has a corrugated surface on the side contacting the portion in the tray.

13. An apparatus as in claim 9 wherein the primary chute includes at least one secondary chute, wherein the primary chute further includes a flop gate for limiting the amount of leafy produce to be filled in two trays, a flop gate actuator, and a flop gate control device for controlling the flop gate actuator, and wherein the at least one secondary chute includes two chute branches for filling of at least two trays simultaneously.

14. An apparatus as in claim 9 further having at least one footpad manifold for dispersing a puff of gas.

15. An apparatus as in claim 9 wherein said means for conveying said trays comprises a conveyor having a stepper for disposing and moving said trays below said discharge opening.

16. An apparatus as in claim 15 wherein at least one of the footpads traverses a path substantially along one of the sidewalls of the product transfer chute.

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