Patent Publication Number: US-9834390-B2

Title: Bulk cargo blending hopper

Description:
FIELD 
     The field of the invention is a bulk cargo hopper that stores and dispenses bulk cargo. More specifically, the field of the invention is a bulk cargo hopper that employs vacuum pressure to draw bulk cargo to the hopper and into an interior volume of the hopper. The hopper then employs vacuum pressure to mix the bulk cargo in the interior volume of the hopper and blend together bulk cargo having different colors. 
     BACKGROUND 
     Bulk cargo hoppers that store and dispense bulk cargo are well known. The typical bulk cargo hopper employs vacuum pressure to draw bulk cargo to the hopper and into an interior volume of the hopper. The bulk cargo drawn to the hopper is temporarily stored in the hopper. When it is desired to dispense the stored bulk cargo from the hopper, the vacuum pressure supplied to the hopper is stopped and an outlet valve at the bottom of the hopper is opened. This allows a desired amount of the stored bulk cargo to fall from the interior volume of the hopper and into a container positioned below the outlet valve. When the container is filled with the dispensed bulk cargo to a desired amount, the outlet valve is closed. The container is then moved from beneath the hopper, allowing a further container to be positioned below the outlet valve of the hopper and filled with a desired amount of the bulk cargo from the hopper by opening the outlet valve. 
     Hoppers of the type described above are employed in the production of plastic material in the form of pellets, granules, powders, etc. that are later used in plastic extrusion manufacturing processes. The plastic material, for example small plastic pellets of a single color are drawn into the interior volume of the hopper by the vacuum pressure in the interior of the hopper supplied by a vacuum pressure source. 
     When it is desired to fill a container with the colored pellets, the vacuum pressure supplied to the hopper is stopped and the outlet valve of the hopper is opened. This allows a desired amount of colored pellets in the hopper to fall into the container. 
     A disadvantage of this product transferring method is that batches of the colored pellets produced and supplied to the hopper will often have slightly different colors. For example, a first batch of red pellets fed to the hopper may have a particular shade of red. A second batch of red pellets fed to the hopper and layered on top of the first batch of pellets may have a slightly different shade of red. 
     At some time during the unloading of the pellets from the hopper to a container, a portion of the first batch of pellets will be loaded into a container together with a portion of the second batch of pellets. The container, containing pellets of slightly different colors would then be sent to a manufacturer of plastic products. This would result in the manufacturer manufacturing plastic products having two different colors. For example, the manufacturer would manufacture a group of products having one shade of red and another group of products having a slightly different shade of red. This is an undesirable occurrence for the manufacturer that desires all of their products offered to consumers have the same color. 
     SUMMARY 
     The bulk cargo blending hopper of this disclosure overcomes the above described problem of sending a container of pellets to a manufacturer where the container contains a layer of pellets of one color and a second layer of pellets of a slightly different color. 
     The hopper has a housing that is constructed in a conventional manner. The housing has an interior volume that is continuous through the housing. 
     A source of vacuum pressure communicates with the interior volume of the housing. Again, the source of vacuum pressure and its communication with the interior of the housing are conventional. 
     A first conduit is connected to the housing. The first conduit has a length with opposite first and second ends. The first end of the first conduit is connected to the housing and communicates with the interior volume of the housing. The second end of the first conduit is configured to communicate with a source of bulk cargo. 
     A second conduit is also connected to the housing. The second conduit has a length with opposite first and second ends. The first end of the second conduit is connected to an upper portion of the housing and communicates with an upper portion of the interior volume of the housing. The second end of the second conduit is connected to a lower portion of the housing and communicates with a lower portion of the interior volume of the housing. The first end of the second conduit is positioned on the housing vertically above the second end of the conduit. 
     An outlet valve is provided on the housing at the bottom of the housing. The outlet valve is conventional and is operable when there is no vacuum pressure supplied to the housing to open and dispense bulk cargo in the hopper to a container below the hopper. The outlet valve is also operable to close, enabling vacuum pressure to fill the interior volume of the housing. 
     In operation of the hopper, the outlet valve is closed and vacuum pressure is supplied from a vacuum source to the interior volume of the hopper. The vacuum pressure in the interior volume of the hopper is communicated through the first conduit. Bulk cargo at the second end of the first conduit is drawn through the first conduit by the vacuum pressure in the interior volume of the hopper. A first batch of bulk cargo is drawn into the interior volume of the hopper and fills the bottom portion of the interior volume. 
     To further fill the interior volume of the housing, the second end of the first conduit is communicated with a second batch of bulk cargo which could have a slightly different color than the first batch of bulk cargo. The vacuum pressure in the interior volume of the housing draws the second batch of the bulk cargo through the first conduit and into the upper portion of the interior volume of the housing. The second batch of bulk cargo drawn into the interior volume of the housing forms a layer on top of the first batch of bulk cargo in the interior volume of the housing. 
     To overcome the problem of the first batch of bulk cargo in the interior volume of the housing and the second batch of bulk cargo in the interior volume of the housing having slightly different colors, the source of vacuum pressure communicated to the interior volume of the housing is switched to the second conduit. The vacuum pressure in the interior volume of the housing is communicated to the first end of the second conduit. The vacuum pressure at the first end of the second conduit is communicated through the second conduit to the second end of the second conduit that communicates with the lower portion of the interior volume of the housing. This results in the first batch of bulk cargo at the lower portion of the interior volume of the housing being drawn into the second conduit from the second end of the second conduit. The bulk cargo is drawn up through the second conduit to the first end of the second conduit where the first batch of bulk cargo is delivered into the upper portion of the interior volume of the housing on top of the second batch of bulk cargo. This process is continued until the first batch of bulk cargo is drawn from the lower portion of the interior volume of the housing and deposited into the upper portion of the interior volume on top of the second batch of bulk cargo. The second batch of bulk cargo then begins to be drawn through the second conduit up to the upper portion of the housing interior volume. This cycling of the bulk cargo through the second conduit is continued and results in mixing and blending of the bulk cargo of the first batch with the bulk cargo of the second batch. 
     On completion of the blending process, the vacuum pressure supplied to the interior volume of the housing is stopped. The outlet valve at the bottom of the housing is then opened and the blended bulk cargo is allowed to fall from the interior volume of the housing into a container below the housing of the hopper. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features of the bulk cargo blending hopper are set forth in the drawing figures and the detailed description. 
         FIG. 1  is a top, perspective view of the bulk cargo blending hopper. 
         FIG. 2  is a side elevation view of the bulk cargo blending hopper. 
         FIG. 3  is a top plan view of the bulk cargo blending hopper. 
     
    
    
     DESCRIPTION 
     The component parts of the bulk cargo blending hopper  10  are constructed of metal or other equivalent materials typically employed in the construction of such types of hoppers. 
     The hopper  10  is supported by a frame that includes four vertical columns  12 . As represented in the drawing figures, the four columns  12  are positioned at four corners of the frame. A rectangular lower platform  14  is supported by the four columns  12 . A lower railing  16  extends around three sides of the lower platform  14 . 
     An upper platform  18  is also supported by the four columns  12 . An upper railing  22  extends around three sides of the upper platform  18  and a portion of the fourth side of the upper platform  18 . 
     A set of stairs  24  are provided on the frame. The stairs  24  extend up to a landing  26 . The landing  26  is an extension of the lower platform  14 . Stair railings  28  extend along the opposite sides of the stairs  24  and around the landing  26 . 
     A ladder  32  extends from the stair landing  26  upward to the upper platform  18 . A protective cage  34  extends around the ladder  32 . 
     The hopper  10  has a housing  36  that surrounds a hollow interior volume of the hopper. 
     The housing  36  has an upper portion wall  38 . The upper portion wall  38  has a cylindrical configuration. However, other equivalent configurations could be employed. As represented in the drawing figures, the upper portion wall  38  of the housing is suspended downwardly from an underside of the upper platform  18 . The upper portion wall  38  of the housing  36  surrounds an upper portion  40  of the hollow interior volume of the housing  36 . The upper portion  40  of the hollow interior volume is identified in the drawing figures by an arrow that extends from the reference number  40  through a schematic representation of an opening through the upper portion wall  38  of the housing to the interior volume of the upper portion  40  of the hollow interior volume of the housing  36 . In actuality, there is no opening through the upper portion wall  38 . 
     The housing  36  also has a lower portion wall  42  that surrounds a lower portion  43  of the hollow interior volume of the housing  36 . The lower portion  43  of the hollow interior volume of the housing  36  is identified in the drawing figures by an arrow that extends from the reference number  43  through a schematic representation of an opening through the lower portion wall  42  of the housing  36  to the lower portion  43  of the hollow interior volume of the housing  36 . In actuality, there is no opening through the lower portion wall  42 . The lower portion wall  42  of the housing  36  is connected to the upper portion wall  38  of the housing and is suspended downwardly from the upper portion wall  38  of the housing. As represented in the drawing figures, the lower portion wall  42  of the housing  36  has a conical configuration. Other equivalent configurations could be employed in the construction of the lower portion wall  42  of the housing. The conical configuration of the lower portion wall  42  of the housing extends downwardly from the upper portion wall  38  of the housing to an outlet valve mechanism  44  at the bottom of the lower portion  42  of the housing. The outlet valve mechanism  44  is operable to selectively open and allow bulk cargo to be dispensed from the housing  36 , and close to stop dispensing of bulk cargo from the housing. 
     An outlet pipe  46  extends downwardly from the outlet valve mechanism  44 . The outlet pipe  46  directs bulk cargo dispensed from the housing  36  downwardly from the outlet valve mechanism  44  to a container  48  positioned below the outlet pipe  46 . The container represented in the drawing figures is a box. Other equivalent types of containers could be employed with the hopper  10 . 
     The housing  36  also has a vacuum portion  52  at the top of the housing. The vacuum portion  52  has a cylindrical side wall  54  that is connected to and supported on a top surface of the upper platform  18 . The vacuum portion  52  also has a circular top wall  56  supported on the top of the side wall  54 . The side wall  54  and top wall  56  of the vacuum portion  52  have an interior volume  58  that communicates through the upper platform  18  with the hollow interior volume of the housing  36 . The interior volume  58  of the vacuum portion  52  of the housing  36  is identified in the drawing figures by an arrow that extends from the reference number  58  through a schematic representation of an opening through the side wall  54  of the vacuum portion  52  to the interior volume  58  of the vacuum portion  52 . In actuality, there is no opening through the side wall  54  of the vacuum portion  52 . The interior volumes  58  of the vacuum portion  52 , the upper portion  38  of the housing  36  and the lower portion  42  of the housing  36  together form a continuous volume through the housing  36  with no interior obstructions in the housing  36 . 
     A first vacuum canister  62  is connected to the housing  36  of the hopper  10 . As represented in the drawing figures, the first vacuum canister  62  has a cylindrical side wall  64 , a conical bottom wall  66  and a domed shape top wall  68 . The side wall  64 , bottom wall  66  and top wall  68  surround an interior volume  70  of the first canister  62  that communicates with the hollow interior volume of the housing  36  through the top wall  56  of the housing vacuum portion  52 . The interior volume  70  of the first canister  62  is identified in the drawing figures by an arrow that extends from the reference number  70  through a schematic representation of an opening through the side wall  64  of the canister  62  to the interior volume  70  of the canister  62 . In actuality, there is no opening through the side wall  64  of the first vacuum canister  62 . 
     A second vacuum canister  72  is also connected to the housing  36  of the hopper  10 . The second vacuum canister  72  has substantially the same construction as the first vacuum canister  62 . The second vacuum canister  72  includes a cylindrical side wall  74 , a conical bottom wall  76  and a domed shape top wall  78 . The side wall  74 , bottom wall  76  and top wall  78  surround the interior volume  80  of the second vacuum canister  72  that communicates with the hollow interior volume of the housing  36  through the top wall  56  of the housing vacuum portion  52 . The interior volume  80  of the second vacuum canister  72  is identified in the drawing figures by an arrow that extends from the reference number  80  through a schematic representation of an opening through the side wall  74  of the second vacuum canister  72  to the interior volume  80  of the second vacuum canister  72 . In actuality, there is no opening through the side wall  74  of the second vacuum canister  72 . 
     A first valve  82  is provided on top of the top wall  68  of the first vacuum canister  62 . The first valve  82  is operable to provide communication with the interior volume  70  of the first vacuum canister  62  and to stop communication with the interior volume  70  of the first vacuum canister  62 . 
     A second valve  84  is provided on the top wall  78  of the second vacuum canister  72 . The second valve  84  is operable to establish communication with the interior volume  80  of the second vacuum canister  72  and to stop communication with the interior volume  80  of the second vacuum canister  72 . 
     A vacuum conduit  86  is connected in communication with the hollow interior volume of the housing  36  of the hopper  10 . The vacuum conduit  86  has a length with opposite first  88  and second  92  ends. The first end  88  of the vacuum conduit  86  is connected in communication with both the first valve assembly  82  and the second valve assembly  84 . As represented in the drawing figures, the first end  88  of the vacuum conduit  86  is connected in communication directly with the second valve assembly  84  and then with the first valve assembly  82  by a short extension  94  of the vacuum conduit  86 . The second end  92  of the vacuum conduit  86  is connected in communication with a source of vacuum pressure  96 . The source of vacuum pressure  96  is represented schematically in the drawing figures. 
     A second conduit  98  is connected in communication with the hollow interior volume of the housing  36  of the hopper  10 . The first conduit  98  has a length that extends between a first end  102  of the first conduit and a second end  104  of the first conduit. The length of the first conduit  98  is configured to convey bulk cargo to the interior volume of the housing  36 . As represented in the drawing figures, the first end  102  of the first conduit  98  is connected to the side wall  64  of the first vacuum canister  62  and communicates with the interior volume of the housing  36  through the interior volume  70  of the first vacuum canister  62  and through the interior volume  58  of the vacuum portion  52  of the housing  36 . The second end  104  of the first conduit  98  is configured for communication with a source of bulk cargo  106 , represented schematically in  FIG. 1 . The source of bulk cargo  106  is separated from the hopper  10 . 
     A second conduit  108  communicates with the hollow interior volume of the housing  36 . The second conduit  108  has a length that extends between a first end  112  of the second conduit and a second end  114  of the second conduit. The length of the second conduit  108  is configured for conveying bulk cargo. The first end  112  of the second conduit  108  is connected to the side wall  74  of the second vacuum canister  72  and the second end  114  of the second conduit  108  is connected to the lower portion  42  of the housing  36  below the first end  112  of the conduit. As represented in the drawing figures, the first end  112  of the second conduit  108  communicates with the hollow interior volume of the housing  36  through the side wall  74  of the second vacuum canister  72 , through the interior volume  80  of the second vacuum canister  72  and through the interior volume  58  of the vacuum portion  52  of the housing  36 . The second end  114  of the second conduit  108  communicates with the lower portion  43  of the hollow interior volume of the housing  36  through the lower portion  42  of the housing. 
     In operation of the hopper  10 , the outlet valve  44  is closed and vacuum pressure is supplied from the vacuum source  96 , through the vacuum conduit  86  to the interior volume of the housing  36 . The vacuum pressure in the interior volume of the housing  36  is communicated through the first valve  82  and the first conduit  98 . Bulk cargo at the second end  104  of the first conduit  98  is drawn through the first conduit by the vacuum pressure in the interior volume of the housing  36 . A first batch of bulk cargo is drawn into the interior volume of the housing  36  and fills the lower portion  43  of the interior volume. 
     To further fill the interior volume of the housing  36 , the second end  104  of the first conduit  98  is communicated with a second batch of bulk cargo which could have a slightly different color than the first batch of bulk cargo. The vacuum pressure in the interior volume of the housing  36  draws the second batch of the bulk cargo through the first conduit  98  and into the upper portion  40  of the interior volume of the housing  36 . The second batch of bulk cargo drawn into the interior volume of the housing  36  forms a layer on top of the first batch of bulk cargo in the interior volume of the housing  36 . 
     To overcome the problem of the first batch of bulk cargo in the interior volume of the housing  36  and the second batch of bulk cargo in the interior volume of the housing  36  having slightly different colors, the communication of the first valve  82  with the interior volume of the housing  36  is stopped and the second valve  84  is opened. The source of vacuum pressure communicated to the interior volume of the housing  36  is thereby switched to the second conduit  108 . The vacuum pressure in the interior volume of the housing  36  is communicated to the first end  112  of the second conduit  108 . The vacuum pressure at the first end  112  of the second conduit  108  is communicated through the second conduit  108  to the second end  114  of the second conduit  108  that communicates with the lower portion  43  of the interior volume of the housing  36 . This results in the first batch of bulk cargo at the lower portion  43  of the interior volume of the housing  36  being drawn into the second conduit  108  from the second end  114  of the second conduit  108 . The bulk cargo is drawn up through the second conduit  108  to the first end  112  of the second conduit  108  where the first batch of bulk cargo is delivered into the upper portion  40  of the interior volume of the housing  36  on top of the second batch of bulk cargo. This process is continued until the first batch of bulk cargo is drawn from the lower portion  43  of the interior volume of the housing and deposited into the upper portion  40  of the interior volume on top of the second batch of bulk cargo. The second batch of bulk cargo then begins to be drawn through the second conduit  108  up to the upper portion  40  of the housing interior volume. This cycling of the bulk cargo through the second conduit  108  is continued and results in mixing and blending of the bulk cargo of the first batch with the bulk cargo of the second batch. 
     On completion of the blending process, the vacuum pressure supplied to the interior volume of the housing  36  is stopped. The outlet valve  44  at the bottom of the housing  36  is then opened and the blended bulk cargo is allowed to fall from the interior volume of the housing  36  into a container  48  below the housing of the hopper. 
     As various modifications could be made in the construction of the apparatus and its method of operation herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present disclosure should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.