Abstract:
A loader device for a hopper-fed processing machine has a top plate pivotally secured to a bottom plate. The plates are attached between the processing equipment throat and the material hopper, or vacuum receiver/reservoir. As the top plate pivots upon the other, ports that extend through the plates control the flow of material from the hopper into the throat of the machine. The pivot design, a purge funnel, and a drain tube are additional features that save time, labor, and make switching of processing material quick and convenient without the use of tools.

Description:
TECHNICAL FIELD OF THE INVENTION 
   This invention relates generally to machines where a hopper or vacuum receiver feeds material into the machine throat for processing and, more particularly, to a processing machine loader device and method of using the same. 
   BACKGROUND OF THE INVENTION 
   Hoppers, or vacuum receivers are usually mounted to the processing machine throat; and, the processing material, which is typically in the form of pellets or other flowable solid, is fed or free to flow by way of the hopper as needed into the machine where it is processed. Extruded plastics are a common example of such apparatus. In many applications, the same machine is used to produce different products. Since different products require different starting materials, the processing materials have to be changed often. 
   Another reason for frequent material changeover is due to short runs. Obviously, in certain instances only a small amount of product may be desirable. A constant switching of the processing material, therefore, goes hand-in-hand with machine operation. The exchange of material and set up are slow and produce machine downtime. The hopper must be removed allowing remaining material to be returned to the Gaylord, bag, or barrel. Tools are required, and remaining material is often wasted due to spillage during the changeover. Spilled material makes the work area dangerous and causes machine parts to bind and stick. 
   Hence, there remains a need for a processing machine loader device that saves time, material, and labor. The present invention is directed toward meeting this need. 
   SUMMARY OF THE INVENTION 
   The present invention relates to a loader device for a processing machine of the type wherein material is typically delivered to the throat of the machine by way of a hopper or vacuum receiver. The device includes a first plate adapted for supporting the hopper or vacuum receiver and a second plate adapted for securing to the machine. At least one port extends through the first plate, and at least one port extends through the second plate. The plates are pivotally secured together so that the first plate is free to pivot relative to the other plate between an operating position and a purging position. 
   In another aspect, the device includes securing means for securing the plates in the operating position, the purging position, or therebetween. 
   In yet another aspect of the invention, the device includes an arcuate cutout formed in the first plate. A shaft is secured to the second plate, and the cutout serves as a passage for the shaft when the first plate pivots relative to the second plate. 
   In still another aspect, the invention includes a method of feeding material into a processing machine of the type wherein the material is typically delivered to the throat of the machine by way of a hopper or vacuum receiver, and unused material is returned to a Gaylord, or barrel. The method includes the steps of securing between the vacuum receiver and machine throat at least a pair of plates. The plates are secured together by a pivot, and each plate has at least one port through which the material can flow. One of the plates is pivoted relative to the other into an operating position so that the ports are aligned, and material is free to flow from the vacuum receiver, through the ports, and into the throat of the machine. The plates are maintained in the operating position until a process is complete. The pivotal plate is pivoted between the operating position and a purging position so that the ports are not aligned, and the material cannot flow from the vacuum receiver, through the ports, and into the throat of the machine. 
   One object of the present invention is to provide an improved loader device for a hopper-fed processing machine. Related objects and advantages of the present invention will be apparent from the following description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an elevated perspective view of the processing machine loader device shown in the operating position. The processing machine is shown schematically in fragmented view beneath the invention. 
       FIG. 2  is an elevated perspective view of the processing machine loader device shown in the purging position. The processing machine is shown schematically in fragmented view beneath the loader device. 
       FIG. 3  is an elevational perspective view of the processing machine loader device shown disassembled. 
       FIG. 4  is a bottom plan view of an embodiment of the top plate of the invention taken along lines  4 - 4  of  FIG. 3 . 
       FIG. 5  is a top plan view of an embodiment of the bottom plate of the invention taken along lines  5 - 5  of  FIG. 3 . 
       FIG. 6  is a partial side plan view of the loader device of  FIG. 1  taken along lines  6 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   For the purposes of promoting an understanding of the principles of the invention and presenting its currently understood best mode of operation, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, with such alterations and further modifications in the illustrated device and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
   With reference to the figures, the processing machine loader device  20  is for a processing machine  10  of the type wherein material is typically delivered to the throat of the machine by way of a hopper or vacuum receiver  30 . One such machine, for example, is a plastics extrusion machine. 
   The loader device  20  includes a first top plate  40  and a second bottom plate  60  secured together by a pivot  70 . The invention contemplates the use of additional plates stacked upon each other and secured together by pivot  70 . One such plate assembly includes at least one additional plate positioned between the first and second plates. The same pivot  70  secures all three plates together such that the top two plates can pivot independently of each other relative to the bottom plate. In that embodiment, the two pivotal plates are each respectively adapted to support a corresponding hopper or vacuum receiver like the single plate configuration of  FIGS. 1 and 2 . 
   In another embodiment, the size of the top plate may be enlarged so as to accommodate an additional hopper or vacuum receiver. In each case, it should be recognized that the size and number of plates may be manipulated to fit a desired application. 
   In a preferred embodiment, the plates  40 ,  60  are formed from a rigid noncorrosive material that does not stain and wears well. In a more preferred embodiment, the plates are made of steel and have anti-friction portions  65  on at least one contacting surface, which permits one of the plates to easily slide against the other. 
   In the most preferred embodiment, the plates  40 ,  60  are formed from high quality cast fixture plating having a finish of 20 micro inches typical on both sides, and anti-friction portions  65  embedded in the top surface of the bottom plate  60 . In that embodiment, anti-friction portions  65  are formed from Ultra High Molecular Weight (UHMW) polyethylene. Other anti-friction substances and coatings are also contemplated within the scope of the invention. One example of such material is commonly sold under the trademark “TEFLON.” 
   Referring to  FIGS. 4 and 5 , first port  42  and a second port  44  extend through the top plate  40 . A first port  62  and a second port  64  extend through the bottom plate  60  as well. Ports  44  and  62  include concentric inserts  50  formed from stainless steel, which prevents staining, corrosion, and wear. The diameter of ports  44  and  62  is accurately determined by the inserts  50  and may be customized for individual machines. 
   The top plate  40  includes an arcuate cut out  45 , as shown in  FIG. 4 . A pivot bore  75  for receiving pivot  70  extends through the top plate  40 . In the preferred embodiment, pivot action of the top plate  40  relative to the bottom plate  60  is achieved by way of pivot  70 , which includes a threaded shaft  72  on which resides a bushing  74 . A locking handle  90  secures the pivotal plate  40  in an operating position ( FIG. 1 ), a purging position ( FIG. 2 ), or therebetween. 
   The shaft  92  of the locking handle  90  extends through the cut out  45  and is received by threaded locking handle bore  95  in the bottom plate  60 , as shown in  FIG. 3 . Accurate spacing between the handle and the top surface of the top plate  40  is achieved using washers  93 . 
   Bolts  103  secure a handle  80  and a purge funnel mount  102  to the top plate  40 . The purge funnel  100  rests in the mount  102 . 
   Referring to  FIG. 5 , the bottom plate  60  includes a pivot bore  75 ′ for receiving pivot  70 . Mounting bores  63  are custom machined and extend through the bottom plate  60  to secure it to the processing machine  10  by known means. A drain tube  120  is secured underneath the second port  64  of the bottom plate  60  using screws  121  received by threaded holes  123 . Passages  68  for retrieving waste material extend through the bottom plate  60  on both sides of locking handle bore  95 . A chamfer  69  is formed around the lip of each of the passages  68 . 
   The loader device  20  is secured between the processing machine throat (not shown) and the vacuum receiver  30 , as shown in  FIGS. 1 and 2 . In operation, the user grasps handle  80  and pivots the top plate  40  into the operating position, as shown in  FIG. 1 . The bearing  74  on the pivot shaft  72  between the plates produces smooth and easy single-handed transfer of the top plate  40  from one position to another. In the preferred embodiment of the invention, the plates  40 ,  60  are sized such that the pivot radius of plate  40  accommodates machine specifications and thus, reduces the degree to which the loader  20  intrudes into the workspace. The pivot design also eliminates the chance of the plates binding and sticking. Additionally, the vacuum receiver  30  and drain tube  120  are closer to the machine as a result, which improves the ease of material changes. 
   Referring to  FIGS. 1 ,  2 , and  3 , in the operating position, ports  42 ,  62  are aligned. Locking handle  90  is rotated and brought to bear against the top surface of the top plate  40  preventing movement of the top plate  40 . Processing material is then free to flow from the vacuum receiver, through the ports  42 ,  62 , and into the throat of the machine. The top plate  40  is maintained in the operating position as desired until a process is complete. 
   Once done, the locking handle  90  is loosened allowing the pivotal plate  40  to be moved into the purging position, as shown in  FIG. 2 . In the purging position, ports  42  and  64  are aligned so that remaining processing material is free to flow from the vacuum receiver, through the ports  42 ,  64 , and out the drain tube  120  where it is recovered and returned to the Gaylord, or other vessel. In the drain position, the hopper is closer to the edge of the machine for safety and convenience during cleaning. No tools are needed to change the processing material, and once drained, the hopper can be loaded with a different processing material and the steps repeated for another separate process. Time, material, and labor are saved as result. 
   Additionally, the purge funnel  100  can be used to capture extra material during the purging operation, or it can be conveniently used for short processing runs. For short runs, the purge funnel  100  is positioned over the throat of the machine, as illustrated in  FIG. 2 , which shows the purging position. In that position, material loaded by hand in the purge funnel can flow freely through ports  44  and  62  and into the throat of the processing machine  10 . Machine down time for short runs is eliminated as a result. 
   With reference to  FIG. 6 , in the event that any processing pellets  31  collect in the arcuate cut out  45  during material changeovers, there is a built-in cleaning system for ridding the cut out of the pellets. This is important because the plates could bind and stick if the material is not removed. As the top plate  40  pivots on top of the bottom plate  60 , notches  46  formed at both ends of the cut out collect the pellets  31  and deliver them to the passages  68 . Upon contact with the shaft  92  of the locking handle  90 , which is threaded  91  in the handle bore  95 , the pellets are made to flow through the passages  68  where they may be reclaimed, as shown in  FIG. 6 . 
   While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nearly infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the invention are desired to be protected.