Abstract:
A conveyor assembly is configured to convey and maintain compression of multiple compressible batts. Adjacent pairs of conveyor systems within the conveyor assembly define a space between the pair of conveyor systems for receiving and conveying compressible batts. Each pair of adjacent conveyor systems has at least two upper belts in a coplanar relationship. One of the two upper belts travels in an advancing direction and other upper belt travels in a returning direction. Each pair of adjacent conveyor systems also has at least two lower belts in a coplanar relationship. One of the lower belts travels in the advancing direction and the other lower belt travels in the returning direction.

Description:
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION 
     The present invention relates to an apparatus and method for compressing and packaging compressible batts, and is useful, in particular, for the compression packaging of batts of insulating material. The batts, once at least partially compressed, remain under compression without being allowed to expand during the compressing and packaging. 
     BACKGROUND OF THE INVENTION 
     Fibrous insulation material is typically manufactured in common lengths and widths, called insulation batts, to accommodate typical building frame structure dimensions. Fibrous insulation batts are commonly made of mineral fibers, such as glass fibers, and usually have a density within the range of from about 0.2 to about 1.0 pounds per cubic foot (3.2 to 16 kg/m 3 ). Typical batt sizes are 16 or 24 inches (40.6 cm or 61.0 cm) wide by 8 to 10 feet (2.44 m) long. These batts can be packaged in various ways. The batts can be staggered and rolled together along their lengths so that a roll would contain about 10 batts. 
     Alternatively, in order to reduce storage and transportation costs, it is common practice to package insulation batts by compressing them and then providing them with a covering, for example, a bag, which maintains the batts in their compressed state. When the bag is subsequently removed at the point of utilization of the batts, the batts expand to their normal size. 
     In the past, the compression of the insulation batts has been achieved by stacking the batts in a compression chamber which has a fork for compressing the batts and a piston for discharging the compressed batts from the compression chamber into a bagging apparatus. The compressed batts are typically forced into the bag. 
     The insulation batts are delivered to the compression machine by an endless conveyor from a production line. To avoid interruption of the operation of the production line or an accumulation of uncompressed insulation batts, it is necessary to ensure that the insulation batts are promptly handled by the compression machine. 
     Normally, the insulation batts are manually collected from the conveyor belt into batches. Each batch comprises a stack of the batts, which are then manually loaded into the compression chamber. This collection process requires a considerable amount of manual handling of the insulation batts, which is uneconomical. At times, the batts expand during this packaging process, which causes further delays and sometimes damage to the batts. 
     Also, the compression machine itself sometimes causes damage to the batts. For example, top and bottom batts are damaged due to the shear motion between the adjacent batts and/or the batts&#39; contact with the doors and snouts on the compression machine. 
     In other instances, the batts can be subjected to facing flange damage due to mechanical finger movements of the compression machine. 
     Another concern with currently available compression machines is that there is a loss of efficiency in the packaging process since the compression machines often must use a mechanical retracting motion which takes critical time in the overall packaging process. 
     It is, accordingly, an object of the present invention to provide a novel and improved apparatus for compressing and packaging compressible batts which, while entirely eliminating manual handling of the compressible batts, enables a larger number of the compressible batts to be included in one package. 
     The invention will be more readily understood from the following description of a preferred embodiment thereof given, by way of example, with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic, side elevational, illustration of one embodiment of an apparatus for compressing and packaging compressible batts, showing a first position of the apparatus for compressing and packaging compressible batts. 
         FIG. 2  is a schematic, side elevational, illustration showing a second position of the apparatus of  FIG. 1 . 
         FIG. 3  is a schematic, side elevational, illustration showing a third position of the apparatus of  FIG. 1 . 
         FIG. 4  is a schematic, side elevational, illustration showing a fourth position of the apparatus of  FIG. 1 . 
         FIG. 5  is a schematic, side elevational, illustration showing a fifth position of the apparatus of  FIG. 1 . 
         FIG. 6  is a schematic, side elevational, illustration showing a sixth position of the apparatus of  FIG. 1 . 
         FIG. 7  is a schematic, side elevational, illustration showing a seventh position of the apparatus of  FIG. 1 . 
         FIG. 8  is a schematic, side elevational, illustration showing an eighth position of the apparatus of  FIG. 1 . 
         FIG. 9A  is a schematic, side elevational, illustration of another embodiment of an apparatus for compressing and packaging compressible batts, showing a first position of the apparatus for compressing and packaging compressible batts. 
         FIG. 9B  is a schematic, side elevational, illustration showing a second position of the apparatus of  FIG. 9A . 
         FIG. 10  is a schematic, side elevational, illustration showing a third position of the apparatus of  FIG. 9A . 
         FIGS. 11-30  are diagrammatic illustrations of another embodiment of an apparatus for compressing and packaging compressible batts, where the apparatus is shown in various positions, or stages, of a compressing/packaging cycle that the apparatus passes through while performing a method for compressing and packaging compressible batts. 
     
    
    
     SUMMARY OF INVENTION 
     According to the present invention, there is provided an apparatus and a method for compressing and packaging compressible batts. The batts, once at least partially compressed, remain under compression without being allowed to expand during the compressing and packaging. 
     In one aspect the conveyor assembly includes a vertical stack of at least two conveyor systems. Adjacent pairs of conveyor systems within the conveyor assembly define a space between the pair of conveyor systems for receiving and conveying compressible batts. A pair of adjacent conveyor systems has: i) at least two upper belts in a coplanar relationship and positioned above and facing the space between the pair of conveyor systems, with one of the two upper belts positioned above the space mounted for traveling in an advancing direction relative to the conveyor assembly and the other of the two upper belts positioned above the space mounted for traveling in a returning direction; and, ii) and at least two lower belts in a coplanar relationship and positioned below and facing the space between the pair of conveyor systems, with one of the two lower belts positioned below the space mounted for traveling in the advancing direction relative to the conveyor assembly and the other of the two lower belts positioned below the space mounted for traveling in the returning direction. 
     In certain embodiments, the assembly has shields associated with each of the belts traveling the returning direction. The shields are positioned to prevent contact between the belts and a compressible batt contained between the conveyor systems. 
     In certain embodiments, the upper advancing belt and the lower returning belt are in a vertically aligned relationship, and the lower advancing belt and the upper returning belt are in a vertically aligned relationship. 
     In yet another aspect, the present invention relates to a method for conveying compressible batts and for maintaining compression of multiple compressible batts by conveying multiple compressible batts using a conveyor assembly having a pair of adjacent conveyor systems. 
     In certain embodiments, the method includes sequentially receiving individual batts in each space between the pair of conveyor systems; holding each individual batt in each space until a determined number of batts are held in the conveyor assembly; and, transferring the held batts as a stack of batts from the conveyor assembly. 
     Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiments, when read in light of the accompanying drawings. 
     DESCRIPTION OF THE INVENTION 
     The present invention provides an apparatus and a method for compressing and packaging compressible batts. The apparatus maintains the batts, once at least partially compressed, substantially under compression without being allowed to expand during the stacking, compressing and packaging. 
     In certain embodiments, the individual batts are kept separated while being compressed. This separation while the batts are being compressed makes it easier to maintain compression on each batt. 
     Also, in certain embodiments, the individual batts are gathered into stacks, and these stacks are kept separated while being further compressed. This separation while the stacks of batts are being further compressed also makes it easier to maintain compression on each batt. 
     Referring now to the Figures,  FIGS. 1-8  are schematic, side elevational, illustrations of one embodiment of an apparatus  10  for compressing and packaging compressible batts, such as batts of fiberglass materials. The batts, once at least partially compressed, remain under compression substantially without being allowed to expand during the compressing and packaging. 
     In certain embodiments, the apparatus  10  for compressing and packaging compressible batts can include a folding device (not shown) that generally folds the compressible batts. Such folding devices are well-known in the industry. The apparatus  10  generally includes a delivery assembly  12  for delivering a supply of successive compressible batts a 1 , a 2 , etc. to a stacking assembly  14 . The stacking assembly  14  sequentially compiles multiple compressible batts into a stack s 1  and simultaneously delivers the stack of compressible batts to a pre-compressing assembly  16 . The pre-compressing assembly  16  receives multiple stacks of compressible batts and “pre-compresses” the multiple stacks to a first stage of compression. The pre-compressing means  16  delivers the pre-compressed multiple stacks to a compressing assembly  18 . The compressing assembly  18  compresses the multiple, pre-compressed stacks into a batch b 1  and delivers the compressed batch b 1  to a packaging assembly  20  for packaging the compressed batches. In certain embodiments, the packaging assembly  20 , for example, applies a suitable covering to the compressed batches. 
     In the embodiment shown in  FIGS. 1-8 , the delivery assembly  12  receives a plurality of compressible batts and delivers the compressible batts to a pivoting assembly  13 . The pivoting assembly  13  pivotably moves a continuous distributive conveyor  22  into a position adjacent individual stacking conveyors of the stacking assembly  14 , as described below. 
     The stacking assembly  14  includes a set  30  of stacking conveyors. In the embodiment shown, the set  30  of stacking conveyors includes eight stacking conveyors; it should be understood, however, that in certain embodiments, the stacking assembly  14  can contain fewer or more stacking conveyors. The stacking assembly  14  is incrementally movable with respect to the article delivery assembly  12  such that the stacking assembly  14  is adaptable for delivering multiple and separate compressible batts to individual conveyors of the pre-compressing assembly  16 . 
     The pre-compressing assembly  16  includes a set  40  of pre-compressing conveyors. It is to be understood that in other embodiments, there can be a different number of pre-compressing conveyors, and that such embodiments are within the contemplated scope of the present invention. The pre-compressing assembly  16  is incrementally movable with respect to the stacking assembly  14  such that the pre-compressing assembly  16  is adaptable for delivering multiple and separate stacks of compressible batts to the compressing assembly  18 . 
     The compressing assembly  18  includes a set  50  of compressing conveyors. In the embodiment shown, the compressing assembly  18  includes a top compressing conveyor  51  and a bottom compressing conveyor  52 . The top compressing conveyor  51  and the bottom compressing conveyor  52  are positioned at an angle with respect to each other such that both the top compressing conveyor  51  and the bottom compressing conveyor  52  have leading edges  53  and  54 , respectively, that are adjacent the pre-compressing assembly  16  and, further, have trailing edges  55  and  56 , respectively, that are adjacent the packaging assembly  20 . The leading edges  53  and  54  are spaced a first distance d 1  from each other that is greater than a second distance d 2  between the trailing edges  55  and  56 . When stacks of compressible batts leave the pre-compressing assembly  16  and are delivered into the leading edges  53  and  54 , the compressible batts are further compressed as the compressible batts are moved, or conveyed, toward the closer positioned trailing edges  55  and  56 . 
     Referring now to  FIGS. 1-8  in sequence, the numerals “ 5 ” and “ 6 ” generally depict the number of compressible batts present at the particular stage within pre-compressing assembly  16  as the compressible batts are being formed into stacks. The larger numerals “ 5  and/or  6 ” shown in  FIGS. 1-3  and  5 - 7  depict such compressible batts at a stage in the process prior to being “pre-compressed”. The smaller numerals “ 5  and/or  6 ” shown in  FIGS. 2-4  and  6 - 8  depict such compressible batts at a stage in the process where such compressible batts are “pre-compressed. The even smaller numerals “ 16 ” shown in  FIGS. 4 and 8  depict the number of compressible batts at a stage in the process where the compressible batts are “compressed” into a batch. 
     Referring now to  FIGS. 9A ,  9 B and  10  in sequence, the numeral “ 4 ” generally depicts the number of compressible batts present at the particular stage within pre-compressing assembly  16  as the compressible batts are being formed into stacks. The larger numeral “ 4 ” shown in  FIGS. 9A and 9B  depicts such compressible batts at a stage in the process prior to being “pre-compressed”. The smaller numeral “ 4 ” shown in  FIG. 9B  depicts such compressible batts at a stage in the process where such compressible batts are “pre-compressed. The small numeral “ 8 ” shown in  FIG. 10  depicts the number of compressible batts at a stage in the process where the compressible batts are “compressed” into a batch. 
     Referring now to  FIGS. 11 through 30  (along with the  FIGS. 1-8  and  FIGS. 9A ,  9 B and  10 ), depicted therein are diagrammatic illustrations of the multi-functional apparatus  10  for stacking, compressing and packaging compressible batts. In the embodiments shown in  FIGS. 1-8  and in  FIGS. 9-10 , it is to be understood that the delivery assembly  12  includes the pivoting assembly  13  which delivers the compressible batts to the stacking assembly  14  where the stacking assembly  14  is stationery and does not move in a vertical direction. In the embodiment shown in  FIGS. 11-30 , the delivery assembly  12  delivers compressible batts to the stacking assembly  14  which is capable of movement in a vertical direction. Likewise, in the embodiments shown in  FIGS. 1-8  and  FIGS. 9-10 , it is to be understood that the compressing assembly  18  includes the set  50  of top compressing conveyor  51  and bottom compressing conveyor  52  that are positioned at an angle with respect to each other, while in  FIGS. 11-30 , the set  50  of top and bottom compressing conveyors  51  and  52 , respectively, are in a parallel relationship. 
     It is to be understood that all embodiments shown in  FIGS. 1-30  are within the contemplated scope of the present invention, and that the following description of compressible batts moving through the apparatus  10  is equally applicable to all embodiments described herein. For ease of illustration, the numerals, as used in the Figures, are kept the same for all embodiments. 
     In the embodiment shown in the diagrammatic figures, the delivery assembly  12  includes the continuous distributive conveyor  22  for delivering a plurality of compressible batts, numbered as a 1 , a 2 , a 3 , etc. herein, to the stacking assembly  14 . 
     In the embodiment shown, the stacking assembly  14  includes the set  30  multiple stacking conveyors. It is to be understood that in other embodiments, there can be a different number of stacking conveyors, and that such embodiments are within the contemplated scope of the present invention. In the embodiments shown in  FIGS. 11-30 , the set  30  of conveyors includes a top engaging stacking conveyor  30   t , and a plurality of stacking conveyors, numbered herein as a first stacking conveyor  31  through a seventh stacking conveyor  37 . 
     The first stacking conveyor  31  receives the first article a 1  from the distributive conveyor  22 , as shown in  FIGS. 11-12 . After the first stacking conveyor  31  receives the first article a 1 , the reciprocating stacking assembly  14  moves in an upward direction, as indicated by arrow A, such that the second stacking conveyor  32  is positioned adjacent the delivery conveyor  20  for receiving the second article a 2 . Similarly, after the second stacking conveyor  32  receives the second article a 2 , the reciprocating stacking assembly  14  moves in the upward direction such that the third stacking conveyor  33  is positioned adjacent the delivery conveyor  20  for receiving the third article a 3 , as shown in  FIG. 13 . The reciprocating stacking assembly  14  continues to move in the upward direction until the sixth stacking conveyor  36  receives the sixth article a 6 , as shown in  FIG. 14 . 
     The first through sixth stacking conveyors  31 - 36  are operatively engaged, or activated, by the stacking assembly  14  such that the first through sixth compressible batts a 1 -a 6  are conveyed to the pre-compressing assembly  16 , as shown in  FIG. 15 . 
     The invention also contemplates that a bottom article, shown as seventh article a 7 , can be included in the stack s 1  so that the set  30  of stacking conveyors is operated most efficiently. Further, the adjacent article of a subsequent stack can be delivered to the bottom conveyor  36  as the article already on the conveyor is being conveyed to the pre-compressing assembly  16 . 
     The pre-compressing assembly  16  includes a set  40  of pre-compressing conveyors. It is to be understood that in other embodiments, there can be a different number of pre-compressing conveyors, and that such embodiments are within the contemplated scope of the present invention. In the embodiments shown in  FIGS. 11-30  the set  40  of pre-compressing conveyors include a top engaging pre-compressing conveyor  40   t , and a plurality of stacking conveyors, numbered herein as a first pre-compressing conveyor  41  through a third pre-compressing conveyor  43 . It is to be understood that in other embodiments, there can be a different number of pre-compressing conveyors, and that such embodiments are within the contemplated scope of the present invention. 
     At this stage of the process, as shown in  FIG. 15 , the second pre-compressing conveyor  42  is in a planar relationship with the sixth stacking conveyor  36  and receives the compressible batts a 1 -a 6 , thereby forming a first stack s 1 . 
     Simultaneously, the delivery assembly  12  delivers a seventh article a 7  to the seventh stacking conveyor  37 , as shown in  FIGS. 14 and 15 . As the compressible batts a 1 -a 6  are being delivered to second pre-compressing conveyor  42  and forming the stack s 1 , the stacking assembly  14  is receiving additional compressible batts. The stacking assembly  14  begins to move in a downward direction, as indicated by arrow B, such that the delivery assembly  12  delivers an eighth article a 8  to the sixth stacking conveyor  36 , a ninth article a 9  to the fifth stacking conveyor  35 , a tenth article a 10  to the fourth stacking conveyor  34 , and an eleventh article a 11  to the third stacking conveyor  33 . 
     The third stacking conveyor  33  through seventh stacking conveyor  37  are operatively engaged, or activated, by stacking assembly  14  such that the seventh through eleventh compressible batts a 7 -a 11  are conveyed to third pre-compressing conveyor  43  of the pre-compressing assembly  16 , as shown in  FIG. 17 . The seventh through eleventh compressible batts a 7 -a 11  form a second stack s 2 . 
     While the seventh through eleventh compressible batts a 7 -a 11  are being formed into the second stack s 2 , the continuous distributive conveyor  22  is delivering additional compressible batts to the stacking assembly  14 , as shown in  FIG. 17 . As the stacking assembly  14  continues to move in the upward direction, the continuous distributive conveyor  22  delivers a twelfth article a 12  to the second stacking conveyor  32 , a thirteenth article a 13  to the third stacking conveyor  33 , a fourteenth article a 14  to the fourth stacking conveyor  34 , a fifteenth article a 15  to the fifth stacking conveyor  35 , and a sixteenth article a 16  to the sixth stacking conveyor  36 , as shown in  FIG. 18 . 
     The compressible batts a 12  through a 16  are being delivered to the stacking assembly  14  to form a third stack s 3 , as shown in  FIG. 19 . At the same time, the first pre-compressing conveyor  41  and the second pre-compressing conveyor  42  are operatively moved by the pre-compressing assembly  16  in a downward direction, as shown in  FIGS. 18 and 19  by an arrow C. The first pre-compressing conveyor  41  and the second pre-compressing conveyor  42  are moved in a downward direction toward the third pre-compressing conveyor  43  such that the stacks s 1  and s 2  are compressed, as shown in  FIG. 19  by the arrows D and E, respectively. 
     While the stack s 3  is being conveyed to the first pre-compressing conveyor  41 , the continuous distributive conveyor  22  is delivering additional compressible batts to the stacking assembly  14 . The continuous distributive conveyor  22  delivers a seventeenth article a 17  to the seventh stacking conveyor  37 , an eighteenth article a 18  to the sixth stacking conveyor  36 , and so on as the stacking assembly  14  again moves in the downward direction. 
     As the continuous distributive conveyor  22  continues to deliver compressible batts to the stacking assembly  14 , the pre-compressing assembly  16  reverses direction and moves in an upward direction, as indicated by arrow F, toward the first pre-compressing conveyor  41 , thereby compressing the third stack s 3 , as shown in  FIG. 20 . The first pre-compressing conveyor  41 , the second pre-compressing conveyor  42  and the third pre-compressing conveyor  43  are operatively engaged, or activated by, the pre-compressing assembly  16  to convey the compressed stacks s 1 -s 3  to the compressing assembly  18 , as shown in  FIGS. 20 and 21 . 
     The compressing assembly  18  includes a top compressing conveyor  51  and a bottom compressing conveyor  52 . The top compressing conveyor  51  and the bottom compressing conveyor  52  are in an opposed and parallel relationship with respect to each other. The bottom compressing conveyor  52  is in a coplanar relationship with third pre-compressing conveyor  43  such that the stacks s 1 , s 2  and s 3  are delivered to the bottom compressing conveyor  52 . After the stacks s 1 -s 3  are conveyed to the bottom compressing conveyor  52 , the top compressing conveyor  51  and the bottom compressing conveyor  52  are moved in a direction toward each other, as shown in  FIG. 22 . The top compressing conveyor  51  and the bottom compressing conveyor  52  compress the stacks s 1 -s 3  to form a first batch b 1 . 
     The top compressing conveyor  51  and bottom compressing conveyor  52  are operatively engaged, or activated by, the compressing assembly  18  to convey the batch b 1  to the packaging assembly  20 , as shown in  FIG. 23 . The packaging assembly  20  includes a top packaging conveyor  61  and a bottom packaging conveyor  62 . The top packaging conveyor  61  and the bottom packaging conveyor  62  are in an opposed and parallel relationship. 
     Referring again to  FIGS. 19 to 23 , the continuous distributive conveyor  22  is delivering the compressible batts a 17  through a 22  to the stacking assembly  14  to form a fourth stack s 4 . As shown in the figures, the stacking assembly  14  is movable in a downward direction to receive the compressible batts a 17 -a 22 . As shown in  FIG. 24 , the stack s 4  is delivered to the second pre-compressing conveyor  42  of the stacking assembly  14 . The continuous distributive conveyor  22  continues to deliver yet additional compressible batts, such as shown in  FIG. 24  where an article a 23  is delivered to the first stacking conveyor  31 , and so on. In this second half of the multi-reciprocating cycle, the stacking assembly  14  is again moved in the upward direction, as shown by arrow A.  FIG. 25  shows compressible batts a 23  through a 27  being conveyed to the first pre-compressing conveyor  41  of the stacking assembly  14 , thereby forming a fifth stack s 5 . 
     The stacking assembly  14  continues to move in the upward direction while the sixth stacking conveyor  36  receives an article a 28 , as shown by arrow A in  FIG. 25 . The stacking assembly  14  is engaged such that the stack s 5  is moved to first pre-compressing conveyor  41 , as shown in  FIG. 26 . 
     The stacking assembly  14  is moved in the downward direction, as shown by arrow B, and the stacking assembly  14  continues to receive compressible batts a 28  through a 32 , as shown in  FIGS. 26 and 27 . 
     The second stacking conveyor  32  through the sixth stacking conveyor  36  are operatively engaged by the stacking assembly  14  are moved by stacking assembly  14  to the pre-compressing assembly pre-compressing assembly  16  to form a sixth stack s 6 . The first pre-compressing conveyor  41  and the second pre-compressing conveyor  42  are moved in the upward direction toward the top engaging pre-compressing conveyor  40   t  while the pre-compressing assembly  16  is delivering the sixth stack s 6  to the third pre-compressing conveyor third pre-compressing conveyor  43 , and the first pre-compressing conveyor  41  and second pre-compressing conveyor  42  are moved in a vertical direction toward the third pre-compressing conveyor  43 . 
     The pre-compressing assembly  16  activates the top pre-compressing conveyor  40   t , the first pre-compressing conveyor  41 , the second pre-compressing conveyor  42 , and the third pre-compressing conveyor  43  to convey the stacks s 4 -s 6  to the compressing assembly  18 , as shown in  FIGS. 28 and 29 . 
     The top compressing conveyor  51  and the bottom compressing conveyor  52  are moved in a direction toward each other such that a second batch b 2  is formed. The batch b 2  contains the compressed stacks s 4 -s 6 , as shown in  FIGS. 29 and 30 . 
     The top compressing conveyor  51  and the bottom compressing conveyor  52  of the compressing assembly  18  are moved in a direction toward each other and compress the multiple, pre-compressed stacks s 4 , s 5  and s 6  into a batch b 2 . The compressing assembly  18  delivers the compressed batch b 2  to the packaging assembly  20  for packaging and/or covering the compressed batches b 2 . 
     The principles and the modes of operation of this invention have been described in its preferred embodiments. However, it should be noted that this invention may be practiced otherwise than as specifically illustrated and described without departing from the scope of the invention.