Abstract:
A paper interleaver that is separate from the food patty molding machine for inserting a sheet of paper underneath a meat patty.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a paper interleaver that is separate from the food patty molding machine for inserting a sheet of paper underneath a meat patty. 
       BACKGROUND OF THE INVENTION 
       [0002]    U.S. Pat. No. 7,159,372 relates to a sheet interleave system for reciprocating mold plate patty forming apparatus used during the processing and packaging of patty molded food products. The apparatus inserts thin, flexible material, such as sheets of paper, plastic film, or other like material, between adjacent, individual finished patty molded products immediately upon the molded patties being knocked out of the cavities in the mold plate of the patty forming apparatus. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention relates to a paper interleaver that is separate from the food patty molding machine for inserting a sheet of paper, or other like material, underneath a food patty. 
         [0004]    The present invention relates to a system for making food patties with a sheet of paper underneath the patty comprising: a food patty molding machine; a separate cuber machine, and a separate interleaver which inserts a sheet of paper underneath a food patty. 
         [0005]    The present invention relates to a system for making food patties with a sheet of paper underneath the patty comprising: a food patty molding machine, and a separate interleaver which inserts a sheet of paper underneath a food patty. 
         [0006]    In the paper interleaver, paper is loaded into a hopper (box). The bottom of the box is open. A device beneath the hopper releases paper one sheet at a time. It is an object of the present invention for a paper pusher to hold the paper down in the hopper. It is an object of the present invention to use a tear pin design to release one sheet of paper at a time. A shuttle plate reciprocates under the hopper. The shuttle plate contains one or more holes (ports) which draw air into the ports creating a suction or vacuum to hold the paper in place. The paper is then transported to a location. The location can be determined by a mechanical stop, positions by a hydraulic cylinder, a pneumatic cylinder, an electric motor with limit switch or proximity sensor, or a servo motor. 
         [0007]    It is an object of the present invention to have multiple hoppers attached to a baseplate, each hopper having an opening at the bottom where the paper comes out of the hopper. It is an object of the present invention for there to be a guide plate under the hopper that is a guide for the fingers and holds the hopper in place. 
         [0008]    It is an object of the present invention for each of the hoppers to have fingers that are either in an extended or retracted position, having vacuum coming through openings in the fingers to hold the paper once it is released from the hopper. It is an object of the present invention for the fingers to be part of a finger mounting bracket. It is an object of the present invention for the finger mounting bracket and the fingers to move out and back from below the hopper. 
         [0009]    It is an object of the present invention for the finger mounting bracket to comprise lightning holes that lessen the weight of the finger mounting bracket so that the servo drive motor moves the finger mounting bracket faster due to less weight. 
         [0010]    It is an object of the present invention for all of the fingers to move together at the same time. 
         [0011]    It is an object of the present invention for the shuttle to be in a forward position or a retracted position, the shuttle attached to the finger mounting bar having fingers mounted on it, the shuttle bracket connected to guide shafts. 
         [0012]    It is an object of the present invention for the fingers to not be connected to a finger mounting bracket so that the fingers move separately. 
         [0013]    A patty is delivered via a conveyor to the paper interleaver. The patty is detected by a switch or sensor. The switch or sensor sends a signal to stop the vacuum which is holding the paper to the shuttle. The patty reaches the end of the conveyor and falls on the shuttle with the paper in place. As the shuttle withdraws, the patty with the paper fall onto an exit device (conveyor or packaging machine). The shuttle then retracts and moves forward picking up the next piece of paper as described above. 
         [0014]    It is an object of the present invention for the bottom of the hopper to contain a sharp blade that allows only one sheet of paper to be released at a time from the hopper of the interleaver. 
         [0015]    It is an object of the present invention for the food patty molding machine to comprise a mold plate that delivers the food patties to an inbound conveyor of the cuber machine and then to the cuber machine, then followed by an outbound conveyor of the cuber machine which moves the food patties to an inbound conveyor of the interleaver which then moves the patties to the interleaver. It is an object of the present invention for the system to comprise an outbound interleaver conveyor at the end of the paper interleaver. 
         [0016]    It is an object of the present invention for the food patty molding machine to comprise a mold plate that delivers the food patties to an inbound conveyor of the interleaver which then moves the patties to the interleaver, then to an outbound interleaver conveyor at the end of the paper interleaver. 
         [0017]    It is an object of the present invention for the inbound interleaver conveyor to be comprised of a conveyor belt and a laser head assembly. It is an object of the present invention for the laser head assembly to determine when the paper interleaver release paper by sending signals to a computer/PLC. It is an object of the present invention for the laser head assembly to send a laser beam from one side of the inbound interleaver conveyor to the other side. It is an object of the present invention for the laser beam to be a continuous beam, that when broken, signals the computer/PLC that a patty has passed through the laser beam. 
         [0018]    It is an object of the present invention for the system to further comprise a servo drive cabinet having controls for the inbound and outbound conveyors and belts of the interleavers that control speed, feeds and dwells of the fingers of the paper interleaver. 
         [0019]    It is an object of the present invention for the cuber machine to comprise a cuber, having a cuber head assembly, a conveyor belt for moving the patties, an upper knife to score the top half of the patty and a lower knife to score the bottom half of the patty. It is an object of the present invention for the cuber to further comprise stripper belts. 
         [0020]    The present invention relates to a method for placing a sheet of paper under a meat patty comprising: forming a patty by a patty forming machine. The patty is dropped (via knock out cups pushing the patty out of the mold plate) on to a conveyor moving the patty away from the machine. The patty is conveyed to move between a series of blades (top and bottom) for cubing or perforation. After perforation, the patties are conveyed to the interleaver infeed belt. The velocity of this belt is the same as or greater than the cuber belt. On the interleaver infeed belt, the patties activate a switch which starts the paper assembly process. The paper assembly process includes the use of vacuum to hold the paper to bars having ports with a vacuum force in the ports with an elastomer seal to maintain a seal between the paper and the bars. The paper is moved from the bottom of a magazine by a shuttle to position the paper for assembly to the patty. With the paper in position, the patty is conveyed to the paper and the vacuum is withdrawn, the bars move, and the patty drops to an exit conveyor. The patty is then conveyed to the next operation, i.e., freezing, packing, etc. 
         [0021]    It is an object of the present invention for the device to apply paper to the food patty after top and bottom perforations are completed. This is not possible if the interleaver is mounted directly to the food patty molding machine. It is an object of the present invention for the device to roll out a homestyle patty and then center it on the paper. This is not possible if the interleaver is mounted directly to the food patty molding machine. 
         [0022]    The top and bottom perforations provide quicker freezing and cooking times. Interleavers mounted to formers can only perforate the top of the food patty. 
         [0023]    It is an object of the present invention for the device to have higher production speeds that enables the device to apply paper to double row forming technology. Interleavers mounted to formers can only apply paper to single row mold plates. 
         [0024]    It is an object of the present invention for the paper interleaver to be used with a forming machine that comprises a rotary former. 
         [0025]    The design of the present invention improves efficiency during production, less production interruptions/down time repairing machines mounted to the interleaver. 
         [0026]    It is an object of the present invention for the device to eliminate many wearing of parts, therefore extending the life time of current parts, reducing the cost versus the machine mounted interleaver. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]      FIG. 1  shows a side view of an embodiment of a meat patty molding machine, cuber and paper interleaver of the present invention. 
           [0028]      FIG. 2  shows a side view of an embodiment of a meat patty molding machine, cuber, and paper interleaver of the present invention. 
           [0029]      FIG. 3  shows a side view of an embodiment of a cuber and paper interleaver of the present invention. 
           [0030]      FIG. 4  shows an internal view of an embodiment of a servodrive cabinet of the present invention. 
           [0031]      FIG. 5  shows an internal view of an embodiment of a servodrive cabinet of the present invention. 
           [0032]      FIG. 6  shows a side view of an embodiment of the cuber of the present invention. 
           [0033]      FIG. 7  shows a side view of an embodiment of the cuber and inbound paper interleaver conveyor belt of the present invention. 
           [0034]      FIG. 8  shows a front view of an embodiment of the paper interleaver of the present invention. 
           [0035]      FIG. 9  shows front view of an embodiment of the paper interleaver of the present invention. 
           [0036]      FIG. 10  shows a top view of an embodiment of the paper interleaver of the present invention. 
           [0037]      FIG. 11  shows a top view of an embodiment of finger assembly of the paper interleaver of the present invention. 
           [0038]      FIG. 12  shows a top view of an embodiment of the paper interleaver of the present invention. 
           [0039]      FIG. 13  shows a rear view of an embodiment of the paper interleaver of the present invention. 
           [0040]      FIG. 14  shows a front view of an embodiment of the paper interleaver of the present invention. 
           [0041]      FIG. 15  shows a front view of an embodiment of the paper interleaver of the present invention. 
           [0042]      FIG. 16  shows a rear view of an embodiment of the paper interleaver of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0043]      FIG. 1  shows a food patty molding machine  10  having a mold plate  12  that delivers patties to an inbound conveyor of the cuber  14  to the cuber  16 . After the patties are cubed, they are provided to an outbound cuber conveyor  18 , and then to an interleaver inbound converyor  20 , having an interleaver inbound conveyor motor  22 . After the interleaver inbound conveyer is the paper interleaver  24  which has a paper hopper  26 . 
         [0044]      FIG. 2  shows the food patty molding machine  10  having a mold plate  12  that delivers patties to an inbound conveyor of the cuber  14  to the cuber  16 . After the patties are cubed, they a provided to an outbound cuber conveyor  18  and then to an interleaver inbound conveyor  20 , having an interleaver inbound conveyor motor  22 . After the interleaver inbound conveyor is the paper interleaver  24  which has a paper hopper  26 . At the end of the paper interleaver is the outbound interleaver conveyor  28 . To the side of the paper interleaver  24  is guard  30 . 
         [0045]      FIG. 3  shows the inbound conveyor of the cuber  14 , the cuber  16 , the outbound cuber conveyor  18  and the interleaver inbound conveyor  20 . The figure further shows the paper interleaver  24  having a paper hopper  26  and the outbound interleaver conveyor  28 .  FIG. 3  further shows the servo drive cabinet  32  that has controls for the inbound and outbound conveyor and belts of the interleaver and also controls the speeds, feeds and dwells of the fingers of the paper interleaver  24 . 
         [0046]      FIG. 4  shows the servo drive cabinet  32  having shuttle bracket  34  in the forward position. The shuttle bracket  34  is attached to the bar with fingers mounted on it. The shuttle bracket  34  is connected to guide shafts  36 . Also in the servo drive cabinet  32  is an idler pulley  38 , a drive sprocket  40 , a servomotor  42 , and a timing belt  44 . The servo drive cabinet further comprises a motor  46  for the outbound paper interleaver conveyor. Also shown is the vacuum control valve  48  and  50  where the vacuum comes in from the vacuum control valve  48 . 
         [0047]      FIG. 5  shows the servo drive cabinet  32  of  FIG. 4 , except the only difference is the shuttle bracket  34  is in the retracted position. 
         [0048]      FIG. 6  shows an internal view of the cuber  16 , having a cubing head assembly  60 , and a conveyor belt  62  for moving the patties. The cuber  16  has an upper knife  64  which is used for scoring the top half of the patty and a lower knife  66  which is used for scoring the bottom half of the patty. The cubing head assembly  60  further comprises stripper belts  68  and  70 . The patties move in the direction of arrow  72 . After the patties are cubed they follow outbound cuber conveyor  18 . 
         [0049]      FIG. 7  shows the cuber head assembly  60  followed by the outbound cuber conveyor  18  which is then followed by the inbound interleaver conveyor  20 . The inbound interleaver conveyor  20  is comprised of conveyor belt  80  and a laser head assembly  82 . The laser head assembly  82  determines when the paper interleaver releases the paper by sending signals to a computer/PLC. The laser head assembly  82  sends a laser beam from one side of the inbound interleaver conveyor  20  to the other side. It is a continuous beam, that when broken, signals the computer that a patty has passed through the laser beam. 
         [0050]      FIG. 8  shows the paper interleaver  24  comprised of paper hoppers  26 . The hopper  26  is attached to the baseplate  90  by a mounting bracket  92 . Underneath the hopper is a guide plate  94  that is a guide for the fingers and holds the hopper  26  in place. In an embodiment, in front of the hopper is a spring clamp  96  that holds a spring  98  to a block  100 . A bumper  102  is placed in front of the hopper  26  that protects components of the hopper. Also shown is a paper pusher  104  that holds the paper down in the hopper  26 . 
         [0051]      FIG. 9  shows an embodiment where the hopper  26  has a block  110  that holds a spring  98  to the hopper  26 . The figure further shows slot  112  which is the opening where the paper comes out of the hopper. 
         [0052]      FIG. 10  shows the hoppers  26  on top of the base plate  90 . A mounting bracket  92  is on each end of the hoppers  26 . A paper pusher  104  is placed on top of the paper  120 . The paper pusher  104  adds weight to the paper  120 . Also shown at the rear of the paper interleaver  24  are finger openings  122 . Also shown in an embodiment is the guide plate  94 , a spring  98  that releases the paper, and a spring clamp  96  that keeps pressure on the spring to keep it tight. 
         [0053]      FIG. 11  shows a finger mounting bracket  130  having fingers  132 . The fingers  132  are mounted to the finger mounting bracket  130  by tongues  134  that are inserted through O-rings  136  and into the finger mounting bracket  130 . The fingers  132  have openings  138  in which O-rings  140  are placed. Vacuum is created in the openings  138 . An O-ring gasket  142  seals vacuum drawn from openings in fingers  132 . Vacuum is created by the vacuum pump that sends vacuum to shuttle bracket block  34  which is where the finger mounting bracket  130  is mounted. From the finger mounting bracket  130 , the vacuum goes to the fingers  132 . 
         [0054]      FIG. 12  shows the paper interleaver  24  having hoppers  26  mounted between mounting brackets  92  at each end of the hoppers  26 . The figure shows the finger mounting bracket  130  having lightning holes  150 . The fingers  132  are shown in the retracted position. 
         [0055]      FIG. 13  shows the paper interleaver  24  having hoppers  26  having mounting brackets  92  at each end of the hoppers  26 . The figure shows the finger mounting bracket  130  having lightning holes  150 . The fingers  132  are shown in the retracted position. The lightning holes  150  lessen the weight of the finger mounting bracket  130  so that the servo drive motor can move the finger mounting bracket  130  faster due to less weight. In the design shown in  FIG. 13 , all the fingers move together at the same time. In an alternate design, the fingers are not connected to a finger mounting bracket and can be separately moved, with potentially separate motors. 
         [0056]      FIG. 14  shows the paper interleaver  24  having hoppers  26  within mounting brackets  92  at each end of the hoppers  26 . The figure also shows the fingers  132  in the extended position. In an embodiment, each hopper  26  has two fingers  132  with it. The hopper  26  has bumper  102  in located in the front. The paper interleaver  24  has finger mounting bracket  130 . The finger mounting bracket  130  and the fingers  132  move out and back from below the hopper  26 . In an embodiment of the invention the fingers are made of aluminum. 
         [0057]      FIG. 15  shows the paper interleaver  24  having hoppers  26  mounted within mounting brackets  92  located at each end of the hoppers  26 . The figure also shows the fingers  132  in the extended position. Each hopper has two fingers  132  with it having the paper  200  which has been released by the hopper  26 , and held on the fingers by vacuum coming from the openings  138 . 
         [0058]      FIG. 16  shows an embodiment of a paper hopper assembly  250  having hoppers  252  connected by fastening devices  254  to a support plate  256 . At the ends of the hopper assembly  252  is mounting brackets  258 . At the bottom of each hopper  250  is a guide plate  260 . The guide plate  260  rests on wear guides  262 . In front of the guide plate  260  and hopper  252  is located a patty bumper  264  and cap screw  266 . Pin  268  holds the paper in the hopper  252  until a single piece of paper is released.