Abstract:
The present invention provides an apparatus and method for converting a large bale of hay into a plurality of smaller sized bales having the same nutritional composition and texture as the large bale. The apparatus comprises a first cutting assembly which has a first set of blades which are orthogonally oriented with respect to a second set of blades. The apparatus further comprises a driver head assembly which is used to force a large bale of hay through the first cutting assembly. The apparatus also has a second cutting assembly which comprises a metering knife oriented substantially orthogonal to both the first and second sets of blades of the first cutting assembly. The associated method for processing the large bale fibrous comprises a first step of producing bale sections by pushing the large bale through the first cutting assembly. The method has a second step of producing metered bales through operation of the second cutting assembly. The inventive method further comprises a third step of individually packaging the metered bales.

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 60/135,337 entitled METHOD FOR PACKAGING HAY, filed May 21, 1999. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to devices and methods for converting large bales of fibrous material to smaller, more conveniently sized bales. The invention also relates to the packaging of the bales produced. 
     BACKGROUND OF THE INVENTION 
     There exists a ready market for the production and sale of hay bales designed to meet the needs of low-volume consumers. For example, the owner of a small number of horses demands an efficient means for purchasing feed for his animals. In such cases, the use of small hay bales is cost-effective and convenient. 
     Over the years, hay producers have developed a variety of methods for the manufacture of hay bales. Traditionally, the production of small hay bales took place in the field where both harvesting and baling occurred. Upon formation, the individual small bales were collected, through either mechanical or human effort, and transported to a storage location. 
     With the industrialization of agriculture, hay manufacturers have shifted from small bale production to large bale production. In high volume, large bales of hay are considerably more cost efficient to manufacture, transport and store than traditional smaller bales. Nonetheless, there still exists a market demand for small bales of hay designed for low volume consumption. The Applicants&#39; process involves harvesting large bales of hay that are later processed into smaller, more practical bales. 
     The dietary use of hay demands that each bale of hay exhibit the requisite nutritional quality. During baling, it is critical to include in each bale the essential nutrients found only in the “heads” or leaves of the plant. Frequently, hay producers grind the hay to facilitate packaging. Grinding the hay tends to remove the heads and leaves and thereby deprives the bale of its nutritional content. Grinding hay also reduces the average length of stem material. Because many animals require the ingestion of stem material of sufficient length for proper digestive function, ground hay may be insufficient as a dietary staple. In light of the foregoing, the nutritional, financial, and practical demands placed upon the manufacture of hay bales creates a pressing need for a cost effective means of producing conveniently sized bales of consistent nutritional quality. 
     SUMMARY OF THE INVENTION 
     The present invention provides a cost effective apparatus and method for converting a large bale of hay into a plurality of smaller, more conveniently sized bales having the same nutritional composition and texture as the large bale. In another aspect, the present invention provides an apparatus comprising a first cutting assembly which has a first set of blades which are orthogonally oriented with respect to a second set of blades. The apparatus further comprises a driver head assembly which is used to force a large bale of hay through the first cutting assembly. The apparatus also has a second cutting assembly which comprises a metering knife oriented substantially orthogonal to both the first and second sets of blades of the first cutting assembly. 
     In another aspect, the present invention provides an associated method for dividing the large bale fibrous material packaging into the smaller bales of consistent size and nutritional quality. The method comprises a first step of producing bale sections by pushing the large bale through the first cutting assembly. The method has a second step of producing metered bales through operation of the second cutting assembly. The inventive method further comprises a third step of individually packaging the metered bales. The packaged bales are resistant to rot, mildew and infestation. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an annotated top plan view of an apparatus constructed in accordance with a preferred embodiment of the present invention. 
     FIG. 2 is a side elevational view of the driver head assembly of the apparatus shown in FIG.  1 . 
     FIG. 3 is a top plan view of the driver head assembly of the apparatus shown in FIG.  1 . 
     FIG. 4 is a side elevational view of the driver head assembly, staging area and cutting grate assembly shown in FIG.  1 . 
     FIG. 5 is a top plan view of the driver head assembly, staging area and cutting grate assembly shown in FIG.  1 . 
     FIG. 6 is a front perspective view of the cutting grate assembly shown in FIG.  1 . 
     FIG. 7 is a side elevational view of the cutting grate, compression area, metering knife assembly, metering section and metering limiter assembly shown in FIG.  1 . 
     FIG. 8 is a top plan view of the cutting grate, compression area, metering knife assembly, metering section and metering limiter assembly shown in FIG.  1 . 
     FIG. 9 is a front elevational view of the metering knife assembly and metering section shown in FIG.  1 . 
     FIG. 10 is a top plan view of the bagging assembly shown in FIG.  1 . 
     FIG. 11 is a side elevational view of the bagging assembly shown in FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Construction of the Apparatus 
     Referring first to FIG. 1, shown therein is a top plan view of an apparatus  100  used for converting a large bales  112  of hay into multiple smaller bales (not shown). FIG. 1 provides an overview of the apparatus  100 , directional arrows  110  illustrate the direction of material flow. In the interests of clarity, the function of the apparatus will be discussed with reference to upstream processes and downstream processes. Upstream processes occur toward the beginning of the overall operation cycle with the loading of an unrefined product onto the apparatus. In contrast, a downstream process is defined as a function occurring toward the end of the overall operation cycle, such as packaging. The term “longitudinal” refers to the geometric axis which runs the length of the apparatus  100 . The term “lateral” refers to the axis defined by the width of the apparatus. 
     Continuing with FIG. 1, a large bale  112  is loaded onto and supported by a staging area  114 . There are numerous means for loading the large bale  112  onto the staging area  114 . Such loading means include, but are not limited to, use of stationary hydraulic lifts, conveyor systems and mobile machinery (i.e. forklifts). Typically, the large bale  112  is four feet wide, four feet tall and eight feet long. A bale of this size composed of conventional fibrous material, like hay, will weigh approximately one ton. 
     The large bale  112  is pushed across the staging area  114  by a driver head assembly  116  toward a cutting grate assembly  118 . The cutting grate assembly  118  longitudinally divides the large bale  112  into a plurality of bale sections (not shown). The bale sections (not shown) exit the cutting grate assembly  118  and are forced into a compression area  120 . 
     The longitudinal division imposed by the cutting grate assembly  118  is maintained as the bales pass through the compression area  120 . The bale sections continue moving through the compression area  120  into a metering assembly  122 . The metering assembly  122  acts to laterally divide, or “meter,” the incoming bales at a selected length. Once metered, a sorting assembly  124  forces the metered bales into a bagging assembly  126  for packaging. The specific components and related operations of each of the aforementioned assemblies and areas will be described in greater detail below. 
     Now turning to FIG. 2, shown therein is a side elevational view of the driver head assembly  116 . The driver head assembly  116  includes a base plate  128  that supports a front plate  130  and reinforcement beams  132  all of which ride on upper casters  134  and lower casters  136 . The driver head assembly  116  also includes, and is supported by, a frame assembly  138 . The support frame assembly includes a vertical member  140 , outer I-beams  142  and a center I-beam  144  (FIG.  3 ). One of ordinary skill in the art will recognize that there are a number of configurations for the support frame assembly  138 , all of which are within the scope of the present invention. The support frame assembly  138  should be of sufficient structural strength and rigidity to provide adequate support to all stationary and mobile components of the apparatus  100 . Such support frame assemblies may include, but are not limited to, steel structures and combinations of steel and cement structural elements. 
     Preferably, the six upper casters  134  are oriented such that there are two casters on each side of the driver head assembly  116  and two casters in the center of the driver head assembly  116 . The four lower casters  136  are fixed below the flanges on two outer I-beams  142  on opposite sides of the driver head assembly  116 . 
     The driver head assembly  116  also includes hydraulic cylinders  146  which are rigidly supported at their terminal ends by the vertical member  140 . In a preferred embodiment of the present invention, the hydraulic cylinders  146  are telescopic with five stages and are mounted horizontally. Preferably, the largest stage of the hydraulic cylinders  146  is 7 inches in diameter. The hydraulic cylinders  146  should be of sufficient size and quality to impart between 100,000 and 200,000 pounds of force. 
     As hydraulic pressure is increased, the hydraulic cylinders  146  telescopically expand and thereby move the driver head assembly  116  along the outer I-beams  142  and center I-beam  144  on upper casters  134  and lower casters  136 . In the preferred embodiment of the present invention, the driver head assembly  116  and large bale  112  travel upon a floor (not shown). Preferably, the floor is constructed of channel iron, is substantially smooth and is supported by the center I-beam  144 . 
     In an alternate embodiment, the rolling means of the driver head assembly  116  are disposed below the floor of the apparatus  100 . Enclosing the castors below the apparatus floor reduces the presence of fibrous debris within the castors and benefits operator safety. The benefits proposed by the alternate embodiment of the driver head assembly  116  must be balanced against the additional cost of manufacture. 
     Turning now to FIG. 3, shown therein is a top plan view of the driver head assembly  116  constructed in accordance with a preferred embodiment of the present invention. FIG. 3 shows that the hydraulic cylinders  146  are vertically aligned with one another and with the center I-beam  144 . It will be understood that additional configurations of the hydraulic cylinders  146  exist and are contemplated as within the scope of this invention. Such additional configurations include aligning the hydraulic cylinders  146  in horizontal and diagonal planes. 
     Now referring to FIG. 4, shown therein is a front perspective view of the cutting grate assembly  118 . The cutting grate assembly  118  is comprised of a grate frame  148  that contains a plurality of blades  150 . Preferably, the blades  150  are constructed from ⅜″ metal and are manufactured such that each blade  150  has two leading edges tapered to a single point, designated by reference numeral  151 . The blades  150  are configured such that they intersect one another at right angles and extend across the height and width of the grate frame  148 . In this way, the intersection of the leading edges of the blades  150  form insertion points  153 . Also preferred are blades  150  that self-sharpen through ordinary operation of the apparatus  100 . 
     In a preferred embodiment, the cutting grate assembly  118  is designed for facilitated exchange with alternate cutting grate assemblies. Replacing the cutting grate assembly  118  allows the operator to select the size and shape of the smaller bales produced by the apparatus  100 . Alternate configurations of the cutting grate assembly  118  may depend on specific applications of the apparatus  100  and are contemplated as within the scope of the present invention. 
     In a preferred embodiment, the configuration of the blades  150  divides a large bale into sixteen smaller bale sections of uniform size and composition. Depending on the height of the large bale  112 , a portion of hay is passed between the top row of blades  150  and the bottom of the grate frame assembly  148 . Hay passed above the top row of blades  150  is not used in bale formation and is discarded during downstream processes. For example, a large bale measuring 4.5 ft. high by 4 ft. wide by 8 ft long is divided into sixteen bale sections measuring 1 ft. by 1 ft. by 8 ft. The hay in the large bale  112  which is higher than 4 feet tall is excluded from bale formation to ensure the uniformity of bale section size. 
     Turning now to FIG. 5, shown therein is a side elevational view of the cutting grate assembly  118 , the compression area  120 , and the metering assembly  122 . A separator  152  runs the length of the compression area  120  and is used to maintain the division of the bale sections (not shown) imposed by the cutting grate assembly  118 . The separator  152  comprises a substantially rigid plate extending between the cutting grate assembly  118  and the metering assembly  122 . The separator  152  is supported laterally by sidewalls  154 . In addition to supporting the separator  152 , sidewalls  154  provide stability and compression to the bale sections as they pass through the compression area  120 . 
     The metering assembly  122  comprises a metering limiter subassembly  156  and a metering knife subassembly  158 . The metering limiter subassembly  156  further comprises a limiter head  160 , a limiter spring  162 , a limiter latch  164  and a limiter support  166 . The limiter head  160  consists of a vertical plate mounted for movement along a plurality of tracks (not shown) which extend from the limiter support  166  to the metering knife subassembly  158 . In a preferred embodiment, the limiter spring  162  comprises a coil spring with a range of linear motion greater than two feet. Although the present embodiment suggests the use of a spring mechanism, alternate devices, like hydraulic or pneumatic presses are considered as within the scope of the invention. The limiter latch  164  consists essentially of a latch mechanism controlled by the operation of the metering knife subassembly  158  and is designed to lock the limiter head  160  in a compressed position. The limiter support  166  comprises a vertical steel member which is rigidly attached to the support frame  138 . 
     When not engaged by upstream hay, the limiter head  160  is forced to a position adjacent the metering knife subassembly  158  by the limiter spring  162 . From a discussion of the operation of the metering assembly  122 , it will be understood that the stroke of the metering limiter subassembly  156  determines the length of the “metered” bales (not shown). In a preferred embodiment of the present invention, the metering limiter subassembly  156  has a stroke of two feet which corresponds to the optimal length for the metered bale. 
     Turning now to FIG. 6, the metering knife subassembly  158  comprises a metering knife  168 , a knife press  170  and stationary tracks  172 . Metering knife  168  is preferably constructed of ⅜″ steel, is provided a height equivalent to the cutting grate assembly  118  and is manufactured to have a plurality of jagged leading edges. During operation, the motion of the metering knife  168  is limited to movement in a single geometric plane by the stationary tracks  172 . 
     Continuing with FIG. 6, shown therein is a view of the sorting assembly  124 . The sorting assembly  124  comprises a push-off head  174 , a drop table  176  and a hydraulic cylinder  178 . The push-off head  174  consists essentially of a rigid plate manufactured to be nominally smaller than the profile defined by the length and height of the metered bales (not shown). The push-off head  174  is rigidly attached to, and moves with, the hydraulic cylinder  178 . The drop table  176  is rigidly affixed to the push-off head  174  and comprises a substantially flat piece of metal having a perimeter equivalent to the perimeter defined by the top surface of four adjacent metered bales. 
     The sorting assembly  124  also includes a first retaining wall  180  manufactured to prevent lateral movement of the top three rows of metered bales while permitting the sorting of the bottom row of bales. The first retaining wall  180  comprises a rectangular steel plate having a height equivalent to three stacked metered bales and a width of at least one-half of the selected meter length. The first retaining wall  180  is attached immediately downstream of the metering knife subassembly  158  and opposite the hydraulic cylinder  178 . The first retaining wall  180  is attached such that, in a stack of four metered bales, only the bottom bale passes beneath the first retaining wall  180 . 
     The sorting assembly  124  further includes a second retaining wall  182  manufactured to substantially the same specifications as the first retaining wall  180 . Like the first retaining wall  180 , the second retaining wall  182  is also used to contain metered bales during the sorting operation. The second retaining wall  182  is attached downstream from the metering knife subassembly and opposite the first retaining wall  180 . The second retaining wall  182  should be attached such that the push-off head  174  and drop table  176  pass freely under the second retaining wall  182  during the retraction phase of their operation. 
     Turning now to FIG. 7, shown therein is a top plan view the bagging assembly  126 . The bagging assembly  126  includes a ramp  184 , a deck  186  and a stopper  188 . The ramp  184  is manufactured to have a width nominally larger than the length of the metered bales and a length sufficient to support three metered bales side-by-side. The deck  186  is manufactured to have the same length and width as a metered bale. The stopper  188  is rigidly attached to the deck  186  and consists essentially of a plate or beam extending the length of a metered bale. 
     The bagging assembly  126  also includes a ram  190 , a piston  192 , a bag  194  and a heat sealing device  196 . The ram  190  is preferably a metal plate of sufficient rigidity to controllably force a metered bale from the deck  186  into the bag  194 . The ram  190  is rigidly affixed to, and driven by, the piston  192 . Preferably, the piston  192  is hydraulic or pneumatic and is designed for extended periods of rapid actuation. In a preferred embodiment, the bag  194  is selected to be composed of a plastic with a relatively low melting point. The bag  194  should have a single opening and be reasonably flexible and water-resistant. The bag  194  may bear labels or insignia useful for a desired commercial purpose. 
     The heat sealing device  196  is preferably a metal bar heated through electric resistance to a temperature sufficient temperature to meld shut the open end of the bag  194 . Preferably, the heat sealing device  196  has an operator handle constructed from a thermally non-conductive material, such as rubber. One of ordinary skill in the art will recognize that alternative packaging devices and methods exist and are considered within the scope of the present invention. Such additional devices and methods include the use of baling wire, twine or rope and alternate forms of heat sealed shrink wrap. 
     Use of the Apparatus 
     The following text details the preferred operation of the apparatus  100 . Turning first to FIGS. 8 and 9, shown therein are respective side elevational and top plan views of the cooperative function of the driver head assembly  116 , the staging area  114  and the cutting grate assembly  118 . FIG. 8 shows the driver head assembly  116  in an extended position nearing full stroke as the large bale  112  is pushed through the cutting grate assembly  118  as indicated by directional arrow  198 . The cooperative function of the cutting grate assembly  118  and driver head assembly  116  produces a plurality of bale sections  200 . The bale sections  200  are forced from the cutting grate assembly  118  into the compression area  120 . Excess hay not used in the formation of bale sections  200  is removed from the apparatus during the subsequent metering operation. 
     At full extension, the driver head assembly  116  will be located adjacent to the upstream side of the cutting grate assembly  118 . The substantially flat upstream side of the driver head assembly  116  is unable to clear the cutting grate assembly  118  of hay contained therein. As such, at the end of full stroke, the driver head assembly  116  is retracted to permit the loading of a second large bale (not shown). The driver head assembly  116  is then extended, forcing the second large bale into the cutting grate assembly  118 . The introduction of the second large bale into the cutting grate assembly  118  forces the balance of the first large bale  112  from the cutting grate assembly  118 . It will be understood to one of ordinary skill in the art that each successive bale of hay serves as a plunger for providing downstream movement to previously loaded bales. 
     Turning now to FIG. 10, shown therein is a top view of the cooperative operation of the cutting grate assembly  118 , the compression area  120 , the metering assembly  122  and the sorting assembly  124 . While passing through the compression area  120 , the bale sections  200  are horizontally parted by the separator  152  (FIG.  5 ). As mentioned above, the sidewalls  154  provide lateral support to the bale sections as they are forced through the compression area  120 . 
     The bale sections  200  cross the compression area  120  and into the metering knife subassembly  158  where the bales abut the limiter head  160 . As shown in FIG. 5, before contacting the incoming bales, the limiter spring  162  forces the limiter head  160  to a position adjacent the metering knife subassembly  158 . After contacting the incoming bales, the limiter head  160  is pushed back against the force of the limiter spring  162  to the compressed position shown in FIG.  10 . 
     Once the limiter head  160  is pushed back full stroke and the limiter spring  162  compressed, the forward movement of the incoming bale sections  200  is stopped. Compression in the metering assembly  122  is maintained through the continued application of upstream pressure by the driver head assembly  116  and by the force applied by the limiter spring  162 . The elevated compression facilitates and improves the quality of the subsequent metering of the bale sections  200 . 
     The metering operation is initiated by increasing the hydraulic pressure within the knife cylinder  170 . As the knife cylinder  170  expands, the metering knife  168  is forced through the bale sections  200  and thereby creates a plurality of metered bales  202 . At the end of the metering cut, there are sixteen metered bales  202  of desired height, length and width present in the metering assembly  122  between the extended metering knife  168  and the limiter head  160 . The metered bales  202  are stacked four wide by four high and each bale is preferably 1 ft. high by 1 ft. wide by 2 ft. long. 
     At the close of a metering operation, the function of the sorting assembly  124  begins with the activation of the hydraulic cylinder  178 . Simultaneous with the initiation of the sorting operation, limiter latches  164  engage the limiter head  160 . The limiter latches  164  lock the limiter head  160  in the compressed position and reduce the application of pressure by the limiter head  160  during the sorting operation. 
     As the hydraulic cylinder  178  expands, the push-off head  174  and drop table  176  are moved into contact with the bottom row of metered bales  202 . The push-off head  174  forces the bottom row of metered bales  202  through the metering assembly  122  and into the bagging assembly  126 . 
     During the operation of the sorting assembly  124 , the frictional resistance between the stacked metered bales  202  causes all sixteen bales to move as a single unit. As such, the first retaining wall  180  is needed to restrict the top three rows of metered bales  202  from prematurely entering the bagging assembly  126 . The first retaining wall prevents lateral movement of the top three rows of metered bales  202  while permitting the bottom row of bales to pass under the retaining wall. 
     As the push-off head forces the bottom row of metered bales  202  into the bagging assembly  126 , the drop table  176  moves under the top three rows of end metered bales  202 . The drop table  176  completely supports the top three rows of metered bales  202  at full extension of the sorting assembly  126 . After reaching full extension, the push-off head  174  and drop table  176  are retracted to their initial positions. As the drop table  176  retracts, the top three rows of metered bales  202  are contained within the metering assembly  122  by the second retaining wall  182 . As the drop table  176  passes under the second retaining wall  182 , the drop table  176  is pulled out from under the top three rows of metered bales  202  causing them to sequentially fall onto the metering assembly  122  floor. 
     Upon full retraction of the drop table  176 , all metered bales  202  remaining in the metering assembly  122  are stacked and aligned between the metering knife  168  and limiter head  160 . The push-off head  174  repeats the push-off cycle an additional three times, once for each row of metered bales  202  remaining in the metering assembly  122 . Once all metered bales  202  have been transferred to the bagging assembly  126  and the sorting assembly  124  is fully retracted, the limiter latches  164  are released and the limiter head  160  resets by returning to its initial position adjacent the metering knife subassembly assembly  158 . The metering knife subassembly  158  is then reset by retracting the metering knife  168  to its initial position. 
     After each of the aforementioned assemblies has been reset, the driver head assembly  116  pushes a subsequent length of the bale sections  200  into the metering assembly  122 . It will be understood that, with a large bale of eight feet in length and desired metered bales of two feet in length, the metering operation will be performed four times per single large bale. Accordingly, the sorting assembly  124  must complete sixteen operation cycles per single large bale. 
     Turning now to FIG. 11, after metering, the push-off head  174  forces a row of metered bales  202  onto the ramp  184 . Gravity forces the metered bales  202  down the ramp  184  toward the deck  186 . The lead metered bale  202  comes to rest in abutment with the stopper  188 . The trailing metered bales  202  are stopped against the lead metered bale  202  and remain on the ramp  184 . The ram  190  (shown in FIG. 7) then pushes the lead metered bale  202  from the deck portion  186  into a bag  194 . Once the metered bale  202  is placed within the bag  194 , a heat sealing mechanism  196  closes the bag. The packaged product is then removed from the apparatus  100 . 
     After placing the leading metered bale  202  into the bag  196 , the ram  190  retracts into is initial position. The retraction of the ram  190  permits a subsequent metered bale  202  to slide from its position on the ramp  184  to the deck  186 . The operation of the ram  190  is repeated three additional times for each row of metered bales  202  leaving the metering assembly  122 . Accordingly, the operation cycles of the bagging assembly  126  are repeated sixty-four times per division of single large bale  112 . 
     It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed and as defined in the appended claims.