Abstract:
In ovo injection apparatus include an egg carrier configured to hold a plurality of eggs and to provide external access to the eggs, a plurality of injection devices positioned above the carrier, and an egg support assembly positioned beneath the carrier that is configured to support each egg in the carrier during contact therewith by a respective injection device. The egg support assembly includes a frame, a plate having an array of openings attached to the frame, and a plurality of pedestals removably secured within a respective one of the openings. The egg support assembly is operatively associated with the plurality of injection devices such that each pedestal moves upwardly through a respective opening in the carrier to support an egg as a respective injection device makes contact with the egg.

Description:
RELATED APPLICATION  
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/442,863 filed Jan. 27, 2003, the disclosure of which is incorporated herein by reference in its entirety as if set forth fully herein. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The present invention relates generally to eggs and, more particularly, to methods and apparatus for processing eggs in ovo.  
         BACKGROUND OF THE INVENTION  
         [0003]    Injections of various substances into avian eggs have been employed to decrease post-hatch mortality rates, increase the potential growth rates or eventual size of the resulting bird, and even to influence the gender determination of the embryo. Similarly, injections of antigens into live eggs have been employed to incubate various substances used in vaccines which have human or animal medicinal or diagnostic applications. Examples of substances that have been used for, or proposed for, in ovo injection include vaccines, antibiotics and vitamins. In addition, removal of material from avian eggs has been employed for various purposes, such as testing and vaccine harvesting. Examples of in ovo treatment substances and methods of in ovo injection are described in U.S. Pat. No. 4,458,630 to Sharma et al., U.S. Pat. No. 5,028,421 to Fredericksen et al., and U.S. Pat. Nos. 6,032,612 and 6,286,455 to Williams, the contents of which are incorporated by reference herein in their entireties.  
           [0004]    An egg injection apparatus conventionally is designed to operate in conjunction with commercial egg carrier devices or flats. The injection apparatus may comprise a plurality of injection needles which operate simultaneously or sequentially to inject a plurality of eggs, or a single injection needle used to inject a plurality of eggs. The injection apparatus may comprise an “injection head” which comprises the injection needle or needles, and wherein each injection needle is in fluid communication with a source containing a treatment substance to be injected. A single fluid source may supply all of the injection needles in an injection device, or multiple fluid sources may be utilized.  
           [0005]    An exemplary in ovo injection apparatus  10  is illustrated in FIG. 1. The illustrated apparatus  10  includes an egg carrier (e.g., an egg flat)  15  that supports eggs  20  for transport, a frame  16 , and a plurality of injection delivery devices, or heads,  25  with fluid delivery means such as needles positioned therein in accordance with known techniques. The illustrated flat  15  holds a plurality of eggs  20  in a substantially upright position and is configured to provide external access to predetermined areas of the eggs  20 . Specifically, each egg  20  can be contacted from above the flat  15  and from beneath the flat  15 . Each egg  20  is held by the illustrated flat  15  so that a respective end thereof is in proper alignment relative to a corresponding one of the injection heads  25 .  
           [0006]    In ovo injection of substances (as well as in ovo extraction of materials) typically occurs by piercing an egg shell to form an opening (e.g., via a punch), extending an injection needle through the hole and into the interior of the egg (and in some cases into the avian embryo contained therein), and injecting treatment substance(s) through the needle and/or removing material therefrom. For example, each injection head  25  of the apparatus of FIG. 1 includes a punch  26  and an injection needle  27  with the punch surrounding the needle  27  in coaxial relationship therewith as illustrated in FIG. 2A- 2 B. The punch  26  is configured to pierce the shell of an egg  20  so as to form an opening therein and the needle  27  is configured to deliver a substance into the egg  20  (FIG. 2B) via the opening.  
           [0007]    Egg flats utilized in conjunction with in ovo injection apparatus typically contain an array of pockets that are configured to support a respective plurality of eggs in a generally upright orientation. An exemplary egg flat  15  is illustrated in FIG. 3A- 3 B. The illustrated egg flat  15  includes a plurality of rows of pockets  32 . Each pocket  32  is configured to receive one end  20   a  of a respective egg  20  so as to support the respective egg  20  in a substantially vertical position. Each pocket  32  of the illustrated egg flat  15  contains a plurality of tabs  34  that are configured to support a respective egg as illustrated in FIG. 4.  
           [0008]    Although effective in supporting eggs during transport, these support tabs  34  can damage eggs during in ovo processing. The force applied to an egg by an in ovo processing punch or needle can push an egg downwardly against the support tabs  34  with sufficient force to cause the egg to crack. In addition to reducing hatch rates, cracked eggs can lead to contamination of other eggs within an egg flat, as well as contamination of processing equipment.  
           [0009]    In addition, support tabs in conventional egg flats are typically somewhat flexible and may deflect when an egg supported thereby is punched. In addition, conventional egg flats themselves may be somewhat flexible. As such, during punching of a plurality of eggs, an egg flat structure may warp and/or twist. This warping and/or twisting of an egg flat may add to the deflection of the support tabs such that when the force of punching is removed the egg flat and tabs can grip an egg, thereby making removal of the egg from the egg flat difficult. Accordingly, it would be desirable to be able to punch through the shell of an egg supported within an egg flat without causing the egg to crack and without causing the egg to become stuck within the egg flat.  
         SUMMARY OF THE INVENTION  
         [0010]    In view of the above discussion, an in ovo injection apparatus, according to embodiments of the present invention, includes an egg carrier configured to hold a plurality of eggs and to provide external access to the eggs, a plurality of injection devices positioned above the carrier, and an egg support assembly positioned beneath the carrier that is configured to support each egg in the carrier during contact therewith by a respective injection device. According to embodiments of the present invention, the egg support assembly includes a frame that is movable between an operative position and a retracted position, a plate having an array of openings attached to the frame, and a plurality of pedestals. Each pedestal is removably secured within a respective one of the openings and includes a free end portion configured to engage an egg within the carrier when the frame is in the operative position. The egg support assembly is operatively associated with the plurality of injection devices such that each pedestal moves upwardly through a respective opening in the carrier to support an egg as a respective injection device makes contact with the egg.  
           [0011]    According to embodiments of the present invention, the egg support assembly is configured to lift each egg slightly from the carrier during contact with each egg by a respective injection device. Moreover, the height of the free end portion of each pedestal relative to the plate may be adjustable.  
           [0012]    According to embodiments of the present invention, a method of injecting eggs in ovo includes positioning an egg carrier containing a plurality of eggs beneath a plurality of injection devices, and supporting the plurality of eggs from beneath the egg carrier while simultaneously delivering a predetermined dosage of a treatment substance into each egg and/or removing material from each egg. The eggs may be lifted slightly from the carrier according to embodiments of the present invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]    The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain principles of the invention.  
         [0014]    [0014]FIG. 1 is a side elevation view of an exemplary in ovo processing apparatus that is configured to form an opening in an egg shell and inject material into an egg and/or remove material from an egg.  
         [0015]    [0015]FIG. 2A- 2 B are cross-sectional views of a lower portion of an injector head of the apparatus of FIG. 1 wherein a punch is about to pierce the shell of an egg (FIG. 2A), and wherein a needle is injecting material into an egg after an opening has been formed in the shell thereof by the punch (FIG. 2B).  
         [0016]    [0016]FIG. 3A is a perspective view of a conventional egg flat.  
         [0017]    [0017]FIG. 3B is a top plan view of the egg flat of FIG. 3A.  
         [0018]    [0018]FIG. 4 is a cross-sectional view of the egg flat of FIG. 3B taken along lines  4 - 4  and illustrating an egg supported within a pocket thereof.  
         [0019]    [0019]FIG. 5 is a perspective view of an in ovo injection apparatus that includes an egg support assembly according to embodiments of the present invention.  
         [0020]    [0020]FIG. 6 is a plan view of the injection apparatus of FIG. 5 taken along lines  6 - 6  and illustrating the conveyor system.  
         [0021]    [0021]FIG. 7 is a perspective view of the egg support assembly illustrating its location beneath the rails of the conveyor system.  
         [0022]    [0022]FIG. 8 is an exploded perspective view of the plate and pedestals of the egg support assembly of FIG. 7.  
         [0023]    [0023]FIG. 9 is a perspective view of a pedestal according to embodiments of the present invention.  
         [0024]    [0024]FIG. 10 is a side, cross-sectional view of a pedestal according to embodiments of the present invention.  
         [0025]    [0025]FIG. 11 illustrates a lifting device according to embodiments of the present invention that is configured to raise and lower the egg support assembly of FIG. 7.  
         [0026]    [0026]FIG. 12 is a perspective view of the frame portion of the lifting device of FIG. 11.  
         [0027]    [0027]FIG. 13 is a perspective view of the egg support assembly of the present invention with the pedestals moved to an engaged position so as to support eggs within an egg flat.  
         [0028]    [0028]FIG. 14 is an enlarged perspective view of a portion of the egg support assembly and egg flat of FIG. 13.  
         [0029]    [0029]FIG. 15A- 15 E illustrate sequential operations for supporting an egg via the egg support assembly according to embodiments of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]    The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.  
         [0031]    As used in the description of the invention and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.  
         [0032]    All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.  
         [0033]    In the drawings, the thickness of lines, layers and regions may be exaggerated for clarity. It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. It will be understood that when an element is referred to as being “connected” or “attached” to another element, it can be directly connected or attached to the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly connected” or “directly attached” to another element, there are no intervening elements present. Terms such as “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only.  
         [0034]    Methods and apparatus according to embodiments of the present invention may be practiced with any type of avian egg, including, but not limited to, chicken eggs, turkey eggs, duck eggs, geese eggs, quail eggs, ostrich eggs, emu eggs, squab eggs, game hen eggs, pheasant eggs, exotic bird eggs, etc. Moreover, methods and apparatus according to embodiments of the present invention may be utilized to punch the shell of an egg at any time during the embryonic development period (also referred to as the incubation period) thereof. Embodiments of the present invention are not limited to a particular day during the embryonic development period.  
         [0035]    An exemplary egg injection device, with which methods and apparatus for punching eggs according to embodiments of the present invention may be utilized, is the INOVOJECT® brand automated injection device (Embrex, Inc., Research Triangle Park, North Carolina). However, embodiments of the present invention may be utilized with any type of in ovo processing device, without limitation.  
         [0036]    Methods and apparatus according to embodiments of the present invention may be utilized to inject eggs in various orientations. Embodiments of the present invention are not limited only to in ovo injection devices that inject eggs in the illustrated orientation.  
         [0037]    Referring now to FIG. 5, an in ovo injection apparatus  100  incorporating an egg support assembly, according to embodiments of the present invention, is illustrated. The illustrated in ovo injection apparatus  100  includes a frame  110  that supports a conveyor system  112  and a plurality of egg injection devices  25 .  
         [0038]    [0038]FIG. 6 is a plan view of the injection apparatus  100  of FIG. 5, taken along lines  6 - 6 , and illustrating the conveyor system  112 . The illustrated conveyor system  112  includes a pair of substantially parallel rails  114  and a plurality of guides  116  therebetween. The guides  116  are configured to slidably receive egg flats placed thereon for movement along the direction indicated by arrow A 1 . In operation, each egg flat is moved along direction A 1  to a position directly beneath the egg injection devices so that the plurality of eggs within the flat can be injected.  
         [0039]    Positioned between illustrated rails  114  is an egg support assembly  130  according to embodiments of the present invention. The egg support assembly  130  is positioned between the rails such that egg flats pass thereover. FIG. 7 is a perspective view of the egg support assembly  130  illustrating its location beneath rails  114 ,  116 . As will be described below, the egg support assembly  130  is configured to support each egg in an egg flat during contact by an egg injection device  25 .  
         [0040]    The illustrated egg support assembly  130  includes a plate  132  having a plurality of pedestals  134  extending from an upper surface  132   a  of the plate  132 . Each pedestal  134  is configured to support a respective egg in an egg flat positioned thereover, as will be described below. The plate  130  and each pedestal  134  may be formed from any type of material that is easily cleanable, and that, for example, is easy to machine. An exemplary material includes Hydrex 4101, available from the Hyde Corporation. However, embodiments of the present invention are not limited to this material. Various materials and combinations of materials may be utilized including, metals, polymers, etc.  
         [0041]    [0041]FIG. 8 is an exploded perspective view of the egg support assembly  130  of FIG. 7 that illustrates the plate  132  and pedestals  134 . In the illustrated embodiment, the plate  132  includes an array of openings  133  formed therein in a pattern matching the array of pockets in an egg flat. Each pedestal  134  is removably secured within a respective one of the plate openings  133 .  
         [0042]    Each pedestal  134  includes a proximal end  134   a  and a distal free end  134   b . An O-ring  135  is secured to each pedestal adjacent the proximal end  134   a  and provides a snug, friction fit when the proximal end  134   a  is disposed within a respective opening  133 . One or more shims  136  may be utilized to adjust the height of the distal end  134   b  of each pedestal  134  above the plate surface  132   a , as illustrated. It may be necessary to adjust pedestal height for specific types of eggs and/or for specific types of egg flats. The pedestals  134  are configured to be easily removed from the plate  132  such that shims can be added and removed as necessary.  
         [0043]    Referring to FIG. 9- 10 , the distal end portion  134   b  of each pedestal  134  has a concave configuration defined by wall  140  that is configured to engage an egg. Wall  140  is inclined relative to a centerline C of pedestal  134  between about twenty five degrees and about fifty five degrees (25°-55°), although other inclination angles may be utilized. The illustrated wall  140  has a generally flat, conical configuration. However, according to embodiments of the present invention, wall  140  can have a curved conical (e.g. parabolic, etc.) configuration as well. A groove  138  is formed within the illustrated pedestal  134  adjacent the proximal end  134   a  thereof, and is configured to receive an O-ring  135  therein.  
         [0044]    Referring now to FIG. 11- 12 , the plate  132  (FIG. 7) is movably secured between rails  114  via lifting device  150 . Lifting device  150  includes a frame  152  having two members  154  extending between opposite rails  114  in generally parallel, spaced-apart relationship, and a pair of spaced-apart support members  156  extending between members  154 . Each frame member  154  includes opposite end portions  154   a ,  154   b . Each frame member  154  also includes a pair of support blocks  158  extending from opposite sides thereof, as illustrated. A dowel  160  extends upwardly from each support block  158 . The dowels  160  are configured to removably engage respective receptacles in the plate  132  and to thereby support the plate  132 . The illustrated dowels  160  have a free end  160   a  with a tapered configuration. However, embodiments of the present invention are not limited to the illustrated configuration of the dowels  160  or to the illustrated frame  152 . The tapered configuration of each dowel  160  facilitates easy removal of plate  132  for cleaning and maintenance.  
         [0045]    The frame  152  is movable between an engaged position and a disengaged position via actuators  170 . The illustrated actuators are pneumatically controlled and receive pressurized air via nozzles  172 . Other types of actuators may be utilized including, but not limited to, hydraulic actuators, electromagnetic actuators, electronic actuators, etc. and/or combinations thereof. Embodiments of the present invention are not limited to pneumatic actuators.  
         [0046]    When the frame  152  is moved to the engaged position, an egg support assembly  130  supported thereon is moved upwardly so that each pedestal  134  attached thereto extends into the pocket of an egg flat and supports a respective egg during in ovo injection. According to embodiments of the present invention, each pedestal  134  may raise each egg slightly from the egg flat, although this is not required.  
         [0047]    [0047]FIG. 13- 14  illustrate the frame  152  and pedestal plate  132  of the egg support assembly  130  moved to an engaged position. A row of eggs  20  in an egg flat  15  are supported by respective pedestals  134  which extend upwardly into the egg flat pockets. Each pedestal  134  provides solid support for a respective egg  20  and reduces damage to an egg resulting from contact from an injection device. Moreover, each pedestal  134  prevents an egg from being pushed downwardly against flexible portions of the egg flat pocket.  
         [0048]    In operation, an egg flat  15  containing a plurality of eggs  20  is moved over the egg support assembly  130  prior to injection by a plurality of injection heads. The frame  152  of the egg support assembly  130  is moved upwardly such that the plate  132  containing a plurality of pedestals  134  is moved upwardly until each pedestal  134  engages a respective egg  20 . The injection heads  25  contact the eggs, which are supported by the pedestals  134 , form an opening in the shell thereof and deliver a predetermined dosage of a treatment substance into (and/or remove a substance from) the egg via the opening.  
         [0049]    Referring now to FIG. 15A- 15 E, sequential operations for supporting an egg  20  via a pedestal  134  according to embodiments of the present invention, will now be described. Referring initially to FIG. 15A- 15 B, an egg flat  15  is moved into position such that an egg injection head  25  is positioned above an egg  20 , and such that a pedestal  134  of an egg support assembly  130  is positioned beneath the egg  20 . In FIG. 15C, the pedestal  134  is moved upwardly, as described above, such that the pedestal distal free end  134   b  contacts the egg  20  as the egg injection head  25  moves downwardly into contact with the egg  20 . In FIG. 15D, the pedestal  134  has actually lifted the egg  20  slightly upwardly from the egg flat  15 . After in ovo injection (or in ovo material removal), the injection head  25  is moved upwardly and the pedestal  134  is moved downwardly from the egg  20 , as illustrated in FIG. 15E.  
         [0050]    The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. Therefore, it is to be understood that the foregoing is illustrative of the present invention and is not to be construed as limited to the specific embodiments disclosed, and that modifications to the disclosed embodiments, as well as other embodiments, are intended to be included within the scope of the appended claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.