Abstract:
An apparatus according to the present invention is a transfer plate used in conveying manufactured product or raw materials onto or off from a conveyor belt. Generally, the transfer plate includes a support member and a transfer extension depending from the support member to interface to a predetermined conveyor belt. The support member may be coupled to a support structure to allow multidirectional flotation, or acceptable operational movement, of the plate due to incidental movement of the conveyor belt. The support member is preferably manually couplable to the support structure, thereby preventing the need for tools during repair or replacement. The transfer interface may include fingers or a modular interface plate.

Description:
BACKGROUND 
       [0001]    The present invention relates generally to devices used in product manufacturing, and more particularly to a transfer plate for transferring products to or from a conveyor belt and a method of interfacing a transfer plate to a belt. 
         [0002]    Various designs of transfer plates are currently employed in manufacturing processes, such as beverage bottling and canning processes, for example. A given manufacturing process or process step may dictate the type of conveyor belt to be used in a transfer process. Generally, like the present invention, prior transfer plates included a support plate and a transfer extension depending from the support plate. However, the support plates of prior devices were attached to a support structure, thereby maintaining the plate in a desired position. Such attachment was most often provided by way of threaded fasteners securing the support plate to the support structure at a desired location. 
         [0003]    Mechanical fastening by way of threaded fasteners is undesirable for a variety of reasons. First, several plates may be placed side-by-side to span the entire width of a predetermined belt. Generally, use of threaded fasteners requires threaded receivers having nonvolatile positioning, thereby limiting the adjustability of the plates. Thus, if the width of the belt is not conducive to lining up a plurality of stationary plates, full utility of the belt may not be possible. In addition to limited adjustability, prior devices offered little, if any, flotation, or acceptable operational movement, of the plates. Indeed, depending upon belt style, belt speed and belt load conditions, multidirectional stresses may be exerted on a transfer plate. Regarding prior transfer plates incorporating fingers, there may be belt forces exerted primarily in two directions: a radial force may be caused by the belt acting on the bottom surface of the fingers, thereby exerting an upward force; and, a lateral force may be caused by loss of precise belt tracking. Prior devices relied on primarily the flexibility of the fingers of prior devices to withstand the applied forces, thereby leading to an increase in the breakage rate where the flexibility of the plate material cannot cope with the applied multidirectional forces. Finally, along with the limited adjustability and lack of multidirectional flotation, prior devices may result in significant machine downtime because of required tooling for replacement. That is, a qualified repair person may be required if the machine operator is not familiar with, or capable of, replacing worn or broken interface plates. If the machine must be shut down while waiting for the qualified repair person, significant productivity is lost. 
         [0004]    At least one improvement has been made over the standard threaded fastener connection between prior transfer plate devices and their support structures. The improvement included the use of a flanged U-shaped channel mounting structure, normally referred to as a DIN, or top-hat, rail mounting structure. While a DIN rail removes the tool requirement from the transfer plate replacement equation, such mounting structure does not offer desirable flotation of the transfer plate. That is, prior plates mounted to a DIN rail utilize an opposing clip structure that secures the plates to the DIN rail. Such attachment does not allow any flotation, or positional variance, of the finger plate with respect to the support structure. 
         [0005]    Therefore, the art of transferring materials to or from conveyor belts would be benefited by a transfer plate and cooperating support structure that eliminates the need for tools during plate replacement while simultaneously reducing the frequency of replacement situations caused by breakage and, in the event of breakage, reduces machine downtime. 
       SUMMARY 
       [0006]    An apparatus according to the present invention provides a transfer plate and cooperating support structure that eliminates the need for tools during plate replacement while simultaneously reducing the frequency of replacement situations caused by breakage and, in the event of breakage, reduces machine downtime. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1A  is a perspective view of a first embodiment of a transfer plate according to the present invention. 
           [0008]      FIG. 1B  is a perspective view of a second embodiment of a transfer plate according to the present invention. 
           [0009]      FIG. 2  is a bottom plan view of the embodiment of  FIG. 1 . 
           [0010]      FIG. 3  is a partial cutaway inverted right elevation view of the embodiment of  FIG. 1 . 
           [0011]      FIG. 4  is a partial front elevation cross-section view of a first embodiment of a support structure according to the present invention, taken along line  4 - 4  in  FIG. 5 . 
           [0012]      FIG. 5  is a perspective view of the plate of  FIG. 1  situated on the first embodiment of a support structure. 
           [0013]      FIG. 6  is a partial cutaway perspective view of a first conveyor belt. 
           [0014]      FIG. 7  is a perspective view of the plate of  FIG. 1  situated on the support structure of  FIG. 4 , interfaced with the belt of  FIG. 6 . 
           [0015]      FIG. 8  is a partial cutaway left elevation view of the arrangement of  FIG. 7 . 
           [0016]      FIG. 9  is an alternate perspective view of the arrangement of  FIG. 7 , further including product transferred by the belt. 
           [0017]      FIG. 10  is a partial cutaway perspective view of a second conveyor belt. 
           [0018]      FIG. 11  is an alternate partial cutaway perspective view of the belt of  FIG. 10 . 
           [0019]      FIG. 12  is a perspective view of a third embodiment of a transfer plate according to the present invention. 
           [0020]      FIG. 13  is a perspective view of the embodiment of  FIG. 12  interfaced to the second conveyor belt of  FIG. 10 , further including product transferred by the belt. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0021]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
         [0022]    Turning now to the Figures,  FIG. 1A  provides an embodiment  100  of a transfer plate according to the present invention. Generally, the plate  100  includes a support member  110  and a transfer extension  120  depending from the support member  110 . The transfer extension  120  may be formed integrally with the support member  110  or may be mechanically or adhesively coupled to the support member  110 . The transfer extension  120  in  FIG. 1A  has been formed integrally with the support member  110 . A preferred material for forming a transfer plate according to the present invention is a thermoplastic material, such as a polypropylene/polycarbonate blend. Such formation can be achieved by any process now known, such as injection molding, or later developed. In this embodiment  100 , the support member  110  comprises a generally planar plate  112  having a top surface  114  and a bottom surface  116  (see  FIG. 2 ). The top surface  114  is preferably formed, or otherwise provided such as by machining, with a plurality of grooves  118 . The bottom surface  116  may be provided with a reinforcement means  111  such as reinforcement ribs. The support member  110  generally includes two ends, a transfer end  113  and a support end  115 . The transfer extension  120  of this embodiment  100  includes a plurality of fingers  122  extending away from the transfer end  113 . Each finger  122  has a top surface  124 , a bottom surface  126  and a tip  128 . The top surface  124  of the fingers  122  is preferably coplanar with the top surface  114  of the support plate  112 . The tip  128  of the fingers  122  transitions into the top and bottom surfaces  124 , 126  through a tip angle  6  (see  FIG. 3 ), preferably an angle of between ten and twenty degrees, and more preferably an angle of thirteen degrees. The fingers  122  are preferably spaced by a finger spacing  123  (see  FIG. 2 ). Further attached to the support member  110  of the plate  100  is a support coupler  130 . While the coupler  130  may be provided separately and fastened to the support member  110 , a preferred coupler  130  is formed integrally with the support member  110  depending from the bottom surface  116  of the plate  112 . 
         [0023]      FIG. 1B  provides a second embodiment  160  of the present invention. This embodiment  160  includes a support coupler  130  that is in the form of a modular channel  162  provided separately from the support plate  112 , as opposed to being formed integrally therewith. The modular channel  162  may be mechanically or adhesively joined to the support member  110 . The support member  110  may comprise a portion of an existing interface plate not previously adapted to offer multidirectional flotation. Also shown in this Figure is a transfer extension  120  in the form of a modular finger insert  164  provided separately from the support plate  112 , as opposed to being formed integrally therewith. The modular finger insert  164  may be mechanically or adhesively joined or otherwise bonded to the support member  110 . While the separate support coupler  130  and separate transfer extension  120  are shown as being components of the same embodiment  160 , it is to be understood that a separate support coupler  130  could be provided and coupled to an interface plate having the transfer extension  120  integrally formed and vice versa. 
         [0024]    This embodiment  160 , like the first embodiment, has a support member  110  and a transfer extension  120 . However, each is slightly different than the corresponding structure of the first embodiment  100 . The support member  110  of the second embodiment  160  is preferably formed with a top surface  166  including a recessed portion  166 a, thereby exposing optional through-holes  121  (seen also in  FIG. 2 ) extending partially through the support plate  112  from the bottom surface  116 . The transfer extension  120  is also different than that provided in the first embodiment  100 . The transfer extension  120  of this embodiment  160  is comprised of the modular finger insert  164 , which is then mechanically or adhesively coupled to the support member  110 . The modular finger insert  164  is preferably mechanically coupled to the support member  110  by use of threaded fasteners  161  in cooperation with flanged collets  163 , through countersunk apertures  165 , provided through the modular finger insert  164 , and support member through-holes  121 . While many sufficiently rigid materials are available, the modular finger insert  164  is preferably formed from a high strength thermoplastic material. If the modular finger insert  164  is broken, or otherwise requires removal or replacement, the entire transfer plate  160  may be removed and replaced, and the modular finger insert  164  of the removed plate  160  can be replaced while the machine from which it was removed is running, thereby limiting machine downtime. 
         [0025]      FIGS. 2 and 3  provide views of a preferred support coupler  130  in greater detail. This embodiment of a coupler includes a longitudinal channel  132  formed to interface with a predetermined support structure  200  (shown in  FIG. 4 ). The channel  132  may be substantially partially circular in cross-section having a radius  138 , which may be of any desirable size adapted to interface to a predetermined support structure. The channel  132  depends from preferably the bottom surface  116  of the support plate  112  and is accessible through a first insertion angle α. Substantially coaxial with the channel  132 , which runs preferably substantially perpendicular to a transfer direction  135  of product onto or off from the plate  100 , the support coupler  130  may include at least one, but preferably two, retainer clips  134 . Each retainer clip  134  includes opposing retainer tabs  136 , which are generally biased towards each other, acting as a preferred bushing when the tabs  136  extend at least partially about a support structure. The biased tabs  136  provide access to the channel  132  through a second insertion angle β, which, for example, may be sixty degrees. Preferably, the first insertion angle α is larger than the second insertion angle β. The bias and width  137  of the tabs  136  may be changed to achieve desired frictional resistance. That is, the more severely the tabs  136  are biased towards each other and the wider the tabs  136 , the more frictional resistance to radial plate motion and plate sliding motion would be provided. The thickness  139  of the tabs  136  may be adjusted to achieve desired mounting force. A greater thickness  139  of the tabs  136  generally requires more effort to mount the clips  134  to a support structure, because the added material increases rigidity of the tabs  136 . For example, in one application, a certain radial frictional resistance may be wanted to allow radial plate flotation about a support structure, such as the support rod  202  of  FIG. 4 , and also to allow an axial flotation along the rod  202 , parallel to the rods central longitudinal axis. 
         [0026]      FIG. 4  depicts an embodiment  200  of a support structure according to the present invention. In the representative embodiment shown, the support structure  200  may be a substantially cylindrical rod  202  stationarily supported upon a support block  204 . Acting on the support rod  202  are a leveling means  210  and an attachment means  220 . The leveling means  210  preferably includes at least two threaded apertures  212  spaced along a length of the rod  202 . Cooperating with the threaded apertures  212  are threaded leveling screws  214 . The fastening means  220  includes at least two countersunk smooth bores  222  formed through the rod  202 . Aligned generally coaxially with the formed smooth bores  222  in the rod  202  are threaded apertures  224  formed in the support block  204 . Fastening screws  226  may be inserted through the smooth bores  222  in the rod  202  and threaded into the threaded apertures  224  in the support block  204  to maintain the rod  202  in a desired relative position. Several rod sections may be concatenated to form a continuous support rod  202  to accommodate a desired width and number of plates  100 . Such concatenation may be made possible by rod sections having mating ends, such as male/female dowelling or threads. 
         [0027]    To level the support rod  202  of the support structure  200 , the fastening screws  226  are first loosened. The leveling screws  214  cooperate with the threaded apertures  212  in the rod  202  and a leveling surface  206  of the support block  204 . The leveling screws  214  are then tightened or loosened to level the rod  202 . When a desired level has been reached, the fastening screws  226  are then tightened to maintain the desired position. While a number of different orientations of the leveling means  210  and the attachment means  220  are possible, if utilized as in the depicted embodiment, it is generally desirable to maintain the leveling means  210  in relatively close proximity to the attachment means  220  to minimize variations in the level due to flexing of the rod  202 .  FIG. 5  shows the embodiment  100  of  FIG. 1  coupled to the support structure  200  of  FIG. 4  by the support coupler  130  of  FIG. 3 . 
         [0028]    A transfer plate according to the present invention may be required in a system using a first conveyor belt  300 , as shown in  FIG. 6 . An example of this type of raised-rib belt is the Combinox belt offered by Twentebelt B. V., of the Netherlands. The view in  FIG. 6  is scaled down to illustrate the invention, since belts used in such manufacturing processes can be tens of feet wide and hundreds of feet long. The belt  300  includes a linked carriage  302 , generally formed from linked metal elements, and a plurality of upstanding raised ribs  304  extending outward from the carriage  302 . The ribs  304  extend along a length, generally parallel to the direction of belt travel. The ribs  304  each have a top surface  306 . The rib top surfaces  306 , collectively, form a transfer surface  308 . Adjacent rows of ribs  304  are spaced laterally across the belt  300  by a measurable rib spacing  303 , which is substantially similar to the finger spacing  123  of the plate  100 . Alternatively, the finger spacing  123  may be a multiple of the rib spacing  303 , if a finger  122  is not desired between each row of raised ribs  304 . The belt  300  is driven by a drive mechanism  310 , as is known in the art, which forms no part of the present invention. The drive mechanism  310  is pictured as rotating in a counter-clockwise direction  312 . 
         [0029]      FIG. 7  shows the embodiment  100  of  FIG. 1  supported by the support structure  200  of  FIG. 4  interfaced to the belt  300  of  FIG. 6 . The support structure  200  has been situated at a desired relative position to the belt  300 . The plate  100  has been placed on the support structure  200  and the fingers  122  have been inserted between the rows of raised ribs  304 . Since the finger spacing  123  of the plate  100  is substantially similar to the rib spacing  303  of the belt  300 , or multiples thereof, the fingers  122  can easily slide between the adjacent rows of ribs  304 . While shown as placed on the outfeed end of the belt  300 , it is understood that the plate  100  could instead be placed on the infeed end, as well. 
         [0030]      FIG. 8  is a side elevation view of the arrangement of  FIG. 7 . When the fingers  122  are inserted into the structure of the belt  300 , preferably between rows of ribs  304 , the top surface  124  of the fingers is preferably substantially coplanar with the transfer surface  308  formed by the top surfaces  306  of the ribs  304 . Furthermore, when inserted, the fingers  122  preferably extend into the belt  300 , beyond the breakpoint  314  of the linked carriage  302 . That is, as the linked carriage  302  travels around the drive mechanism  310 , each successive link will bend, thereby causing a break in the plane of the transfer surface  308 . The fingers  122  extend into the belt  300  structure such that there exists a relatively seamless transition between the belt transfer surface  308  and the top surface  124  of the fingers  122 . This type of transition is preferable as it minimizes plate oscillation and allows smooth product transfer. 
         [0031]      FIG. 9  is a perspective view of the arrangement of  FIG. 7 , further including a product  380  to be outfed from the belt  300 . 
         [0032]    A second type of conveyor belt  400  is shown in  FIG. 10 . An example of this type of belt is an Eyelink-to-Eyelink belt, also offered by Twentebelt B. V., of the Netherlands. This belt  400  includes a structure similar to the linked carriage  302  of the Combinox belt  300 . The belt  400  is comprised of a plurality of metal links  402  having a front loop  404 , a rear loop  406  and a top surface  408 . Generally, the front loop  404  of a given link  402  is rotatably coupled to the rear loop  406  of each adjacent link  404 , as can be more clearly seen in  FIG. 11 . The top surfaces  408 , collectively, of the links  402  create a generally planar transfer surface  408  while the belt  400  is traveling over a distance. However, unlike the Combinox belt  300 , which included rib spacing  303  between the ribs  304  and beneath the transfer surface  308 , this belt  400  provides a transfer surface  408  that is essentially uninterrupted, thereby preventing insertion of finger structures, similar to those  122  of the first embodiment  100 , under the transfer surface  408 . Although an eyelink belt  400  is described, it is to be understood that such generally uninterrupted transfer surface  408  may also be provided by other belt structures in which there is insufficient space beneath the transfer surface  408  to include fingers, such as an endless, flexible imperforate belt or a belt comprising a plurality of hinged plates. 
         [0033]    While a finger structure could be used if spaced from the belt  400 , it is desirable, instead, to use a relatively planar transfer extension  120  in such a case.  FIG. 12  provides a third embodiment  500  of a transfer plate according to the present invention. This embodiment  500 , like the first embodiment, has a support member  110  and a transfer extension  120 . However, each is slightly different than the corresponding structure of the first embodiment  100 . The support member  110  of the second embodiment  500  is preferably formed with a top surface  514  including a recessed portion  514 a, thereby exposing the optional through-holes  121  extending partially through the support plate  112  from the bottom surface  116 . The transfer extension  120  is also different than that provided in the first embodiment  100 . The transfer extension  120  of this embodiment  500  is comprised of a modular interface plate  522 , which is then mechanically or adhesively coupled to the support member  110 . The modular interface plate  522  has a top surface  524 , a bottom surface  526  and a leading edge  528 . The modular interface plate  522  is preferably mechanically coupled to the support member  110  by use of threaded fasteners  521  in cooperation with flanged collets  523 , through countersunk apertures  525  provided through the plate  522  and support member through-holes  121 . The bottom surface  526  cooperates with a portion of the support plate recessed portion  514   a , and the top surface  524  is preferably coplanar with the top surface  114  of the support member  110 . While many sufficiently rigid materials are available, the plate  522  is preferably formed from stainless steel, which may be embossed to reduce friction. If the plate  522  is deformed, or otherwise requires removal or replacement, the entire transfer plate  500  may be removed and replaced, and the modular interface plate  522  can be replaced while machine is running, thereby limiting machine downtime. 
         [0034]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.