Abstract:
A material disposal system ideally suited for use in container filling operations and includes a cover member and a hopper having a lower door operable relative to the hopper by pneumatic or other actuating means for opening and closing the passage disposed above a drum or other container to be filled. The cover member and hopper are fixedly attached to each other. The cover member forms a seal around the inside of the container opening such that air and other gases escaping from the container by the filling or other material handling operation are directed through filter means which separate airborne particulates therefrom. The material disposal system is adaptable for covering and sealing a wide variety of containers. The filter means is adaptable for filtering a wide variety of materials and particulate sizes for removal of noxious gases, vapors and other airborne effluents.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to material disposal systems and more particularly to a device and system for effectively and economically controlling odor and other airborne materials that result from material handling operations involving noxious solid waste. 
     The handling of solid waste poses a special problem, due to the potential exposure to those loading the waste into disposal containers. Currently, 55-gallon disposal drums have a flat steel cover. Any time something is disposed of, the cover must be lifted and the contents, including fumes and odors, are exposed to the work environment. While protective gear may be worn, it is preferable to prevent any release to avoid contaminating not only the worker but the waste generating or waste disposal facility. 
     Numerous devices for controlling odor during container filling and other material handling operations involving pulverulent solids including a variety of means for sealing a container to be filled and for filtering airborne particulates from the flow of air created by the handling operation are well known in the art, but all are relatively complicated devices. 
     It is therefore a principal object of the present invention to provide a material disposal system which filters airborne particulates from air and other gases escaping from a material handling operation. 
     Another object is to provide a material disposal system having odor purging means. 
     Another object is to provide a material disposal system which is relatively simple and inexpensive to manufacture, install and operate and which is adaptable for use with a wide variety of material handling operations and with containers of different sizes and shapes. 
     These and other objects and advantages of the present invention will become apparent to those skilled in the art after considering the following detailed specification in conjunction with the accompanying drawings wherein. 
     SUMMARY OF THE INVENTION 
     The objects set forth above as well as further and other objects and advantages of the present invention are achieved by the embodiments of the invention described hereinbelow. 
     The present material disposal system is ideally suited for use in container filling operations and includes a cover member and a hopper having a lower door operable relative to the hopper by pneumatic or other actuating means for opening and closing the passage disposed above a drum or other container to be filled. The cover member and hopper are fixedly attached to each other. The cover member forms a seal around the inside of the container opening such that air and other gases escaping from the container by the filling or other material handling operation are directed through filter means which separate airborne particulates therefrom. The present device is adaptable for covering and sealing a wide variety of containers. The present filter means is adaptable for filtering a wide variety of materials and particulate sizes for removal of toxic gases, vapors and other airborne effluents. 
     In a typical container filling operation, a drum or other container to be filled is located beneath the drum cover. The invention operates to cover the open top of a drum or other container during solids handling operations and which acts to seal the opening of the container and filter particulate matter from the air which is displaced and escapes from the container and associated material handling devices during the handling operation. The present material disposal system is well suited for use in industrial plants, warehouses and packaging facilities wherein it is desired to control nuisance and greater levels of odors without the requirement of complex air movement means such as ducts and blowers and the like. The present material disposal system is especially well suited for use in solids loading. The present material disposal system may be operated using pneumatic power or other means and may be automatically controlled by a plurality of valves. The present material disposal system includes odor purging means for use as required with toxic substances and also an inlet port usable for purging the system with inert gas and for other purposes. 
     The present device may be controlled using a variety of different systems. The preferred embodiment has two systems: a hopper door control system and a hopper purge control system. The hopper door control system is controlled by a five-position/two-way valve that control the introduction of compressed air to a plurality of other valves, which actuate, for example, pneumatic cylinders pivotally connected to the hopper bottom door. When the two-way valve is placed in the down or doors open position, air is immediately and simultaneously supplied to the top side of each air cylinder. When the material in the hopper has been dumped into the drum, the two-way valve is reversed to the up or close door position raising of the bottom door. 
     The second function of the pneumatic control system is to upply air to the vacuum pump to evacuate the hopper. A three-position/two-way valve, conventionally attached to the base on the hopper, is activated when the hopper doors return to their closed position. The three-position/two-way valve opens the air flow path from the air supply to the vacuum pump. After a desired period of delay as determined by the air flow through delay/timer valve, a second valve opens to flow air through the vacuum pump. The air in the hopper is drawn out and through the filter, for example a 3 microns charcoal filter element, for purification before being released into the environment. After a predetermined time period, delay/timer valve closes and the process is ready to begin again. The pneumatic system is driven by at least a 50 PSI air supply, thereby eliminating the need for electricity. 
     The invention is designed to fit securely on top of a waste disposal drum, for example a 55-gallon steel drum or other equivalent containers. The preferred invention is a pneumatically operated hopper system that allows for the disposal of noxious waste into the drum without re-introducing odors to the work environment. 
     Alternative embodiments can be electrically or hydraulically actuated hopper systems. 
     Alternative embodiments may serve as a secure device for disposal with lock out capabilities. 
    
    
     For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description and its scope will be pointed out in the appended claims. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a pictorial view of the preferred embodiment of the present invention; 
     FIG. 1 a  is a top view of the present of the FIG. 1 embodiment of the present invention; 
     FIG. 2 a  is a side view of the FIG. 1 embodiment; 
     FIG. 2 b  is a section view of cut IIb—IIb of the FIG. 1 a  embodiment of the present invention; 
     FIG. 3 is a schematic of the pneumatic system of the FIG. 1 embodiment. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the preferred embodiment of the above invention illustrated in the accompanying drawings, there is illustrated in FIG. 1 a pictorial view of the material disposal system constructed in accordance with the invention, same being generally indicated by numerical designation  10 , adapted to be removably attached to a container  32 , such as a disposal drum, by a conventional retaining ring (not shown). The disposal drum  32  is shown as a conventionally shaped drum having an opening (not shown) at the top thereof. 
     As illustrated in FIGS. 1,  2   a  and  2   b , the structure of the device  10  includes a case  12 , a hopper  44 , a lid  14 , bottom doors  40 , and a drum cover  78 . The case  12  includes sidewalls  12   a  that form a cavity  12   c  with a top opening  12   d  and a bottom opening  12   e . The hopper  44  includes sidewalls  44   a  that form a chamber  44   b  with a top feed hole  44   c  and a bottom drop hole  44   d . The hopper  44  is disposed within the cavity  12   c  of the case  12  forming a gap  13  between the inner surface  12   b  of the case  12  and the outer surface  44   c  of the hopper  44 . The pneumatic cylinders (to be discussed later) are disposed in the gap  13  to be protected from the waste material and the contaminated environment of the hopper  44 . The lid  14  is attached by conventional means, for example hinges  80 , to the upper edge  12   f  of the case  12 . The lid  14  forms a sufficient seal with the sidewalls  12   a  of the case  12  and/or the sidewalls  44   a  of the hopper  44  such that when in the closed position during operation there is little or no outside air leakage into the hopper  44 . The bottom doors  40  are attached by conventional means, for example hinges  80 , to the lower surface  78   a  of the drum cover  78  and form a sufficient seal when in the closed position during operation such that there is little or no outside air leakage from the disposal drum  32  into the hopper  44 . Though the bottom doors are shown as two doors, it is within the scope of the invention that the functionality of the doors can be achieved with as few as one door or more than two. With the cavity  12   c  of the case  12  and/or the chamber  44   b  of the hopper  44  adequately sealed, a sufficient vacuum can be created in the hopper  44  to purge the contaminated air from the hopper  14 . 
     The case  12  may be permanently or detachably mounted on the drum cover  78  using conventional means so as to be supported thereby. The case  12  is made preferably of polypropylene, but any material suitable, such as Teflon or metals including stainless steel, for the operating conditions and environment is acceptable. The lid  14  and lower doors  40  are also made of lightweight and high strength materials. 
     The lower doors  40  are controlled by a plurality of pneumatic cylinders  52 ,  54 ,  56 ,  58  pivotally attached to the inner wall  12   b  of the case  12  and the top surface  40   a  of the lower doors  40 , and is axially operable upwardly and downwardly relative thereto. FIG. 2 b , a section view of cut IIb—IIb of the FIG. 1 a  embodiment of the present invention, illustrates the pneumatic cylinders  52 ,  54 ,  56 ,  58  fully retracted and fully extended, respectively. The hopper  44  forms a protective barrier insolating the pneumatic cylinders  52 ,  54 ,  56 ,  58  from the waste material in the hopper  44 . When in the retracted position, the pneumatic cylinders  52 ,  54 ,  56 ,  58  apply sufficient resistive force on the lower doors  40  such that the lower doors  40  will remain in the closed position and maintain an adequate seal with the lower surface  78   a  of the drum cover  78  when waste material is in the hopper  44 . This will assure the lower doors  40  do not open prematurely under the weight of the waste material. 
     Drum cover  78 , as best shown in FIGS. 1 and 2 b , is a conventional cylindrical shaped structure having a central passage  78   b  therethrough which forms a conduit for the flow of material into disposal drum  32  which may be fabricated from sheet metal or other suitable material. The circumferential rim  78   c  of the drum cover  78  is configured to form a sufficient seal with the rim (not shown) of the disposal drum  32  to minimize odor escaping from the disposal drum  32  into environment either during operation or when idle. 
     Material disposal system  10  is preferably operated by a pneumatic control system that can perform multiple functions as illustrated in the schematic diagram shown in FIG.  3 . The first function of the pneumatic control system is the opening and closing of the lower doors  40  to release waste material deposited in the hopper  44  into the disposal drum  32 . Supply air  90  provides compressed air, at least 50 PSI, to a five-way/two-position valve  50  that controls the opening and closing of the lower door  40 . When toggle switch  46  is positioned to lower the lower doors  40  to the open position, as shown in FIG. 2 b , valve  50  is opened and compressed air is supplied directly to a three-way/two position valve  36  and to the restricted flow sides of flow controls  60 ,  64 ,  68 , which restricts the air flow to a pneumatic cylinders  52 ,  54 ,  56 ,  58 . Valve  50  provides simultaneous and equal air pressure to upper air lines  52   a ,  54   a ,  56   a ,  58   a  which supply air to the top of each air cylinder  52 ,  54 ,  56 ,  58 . When toggle switch  46  is positioned to raise the lower doors  40  to the closed position, compressed air is supplied directly to a three-way, two position valve  38  and to the restricted flow sides of flow controls  62 ,  66 ,  60 , which restricts the air flow to a pneumatic cylinders  52 ,  54 ,  56 ,  58 . Valve  50  provides simultaneous and equal air pressure to lower air lines  52   b ,  54   b ,  56   b ,  58   b  which supply air to the bottom of each air cylinder  52 ,  54 ,  56 ,  58  to exhaust the air from the bottoms of cylinders. 
     The second function of the pneumatic control system is to supply air to the venturi vacuum pump  76  to evacuate the hopper  44 . Exhaust tubing  88  links the hopper  44 , the venturi vacuum pump  76 , and the filter  30 . After the lower doors  40  are in the closed position, as shown in FIG. 2 a , a plunger valve  7 , shown in FIG. 2 b  attached to the lower surface  78   a  of the drum cover  78  and activated by the closing of the lower doors  40 , will redirect the supply air  90  to a programmable delay/timer  28 . The delay/timer  28  is battery operated and controls the compressed air that flows from the supply air  90  through the venturi vacuum pump  76 . After a desired period of delay as determined by a delay/timer  28 , a valve  82  opens to flow air through the venturi vacuum pump  76 . The air in the hopper  44  is drawn out and through the filter  30 , for example a 3 microns charcoal filter element or other suitable porous material, for purification before being released into the environment. After a predetermined time period (preferably 20 seconds), delay/timer  28  closes the valve  82  and the process is ready to begin again. 
     To assure clean and dry air is supplied, supply air  90  flows through, for example, a 0.3-micron particulate filter  16  upon entering at the compressor supply air hook up  22 . A regulator  18  and a 100-PSI gauge  20  control the supply air intake. Supply air  90  can be supplied to the system  10  by attaching tubing  24 , having commercially available couplers specified by the customer, to the compressor air facility hook up  22  at one end and the supply air hook up (not shown) at the other end. An example of the tubing  24  is 25 ft of ¼″ polyurethane 95 durometer with quick couplings  25  for easy connect to/disconnect from the facility compressed air. 
     Although the invention has been described as utilizing pneumatic cylinders as an actuating means, any other suitable means may be used, such as hydraulic systems, electric servos and solenoids, a manual controlled lever or other means utilizing mechanical advantages. 
     MODE OF OPERATION 
     As stated above, the lower doors  40  are pneumatically driven having a series of 3-way valves  36 , 38 , 50 , flow control valves  60 ,  62 ,  64 ,  68 ,  70 ,  72 ,  74 , and double acting cylinders  52 ,  54 ,  56 ,  58 , coupled by tubes  24  to open and close the lower doors  40 . The double acting cylinders  52 ,  54 ,  56 ,  58 , are pivotally connected to the lower doors  40  and the casing  12 . When the lid  14  is open, two normally closed 3-way manual valves  36 ,  38 , are deactivated blocking the flow of supply air  90  to prevent the lower doors  40  from opening to the disposal drum  32  and exposing the fumes and odors to the outside environment. Once the lid  14  is closed, the two valves  36 ,  38 , in the lid  14  are actuated simultaneously allowing supply air  90  to flow to the pneumatic cylinders  52 , 54 ,  56 ,  58 . Once the waste material is place in the hopper  44  and the lid  14  is closed, the operator advances the toggle lever  46  that opens the 3-way valve  50 . The supply air  90  advances through flow control valves  60 ,  64 ,  68 ,  72  to the double acting cylinders  52 ,  54 ,  56 ,  58 , which extend and open the lower doors  40  allowing the waste material to drop into the disposal drum  32 . Next the operator releases the toggle lever  46  causing the supply air  90  to reverse through the flow control valves  62 ,  66 ,  70 ,  74 , thereby retracting the double acting cylinders  52 ,  54 ,  56 ,  58 , and closing the lower doors  40 . 
     Additional, upon the release of the toggle lever  46  and actuation of the plunger valve  7 , the venturi vacuum pump  76  generates a suction and contaminated air in the hopper  44  evacuates through the venturi vacuum pump  76  to the charcoal absorbent exhaust filter  30 , preferably a 0.3 micro particle filter. As stated above, a delay/timer  28  and a valve  82  control the start and duration of the airflow from the supply air  90  to the filter  30 . 
     It will now be apparent to those skilled in the art that other embodiments, improvements, details, and uses can be made consistent with the letter and spirit of the foregoing disclosure and within the scope of this patent, which is limited only by the following claims, construed in accordance with the patent law, including the doctrine of equivalents.