Abstract:
In the meat processing industry, maintaining a clean and efficient environment can be important. Over the years, modular conveyor belts have become a commonplace component of meat processing operations. To provide an efficient and long lasting conveyor system, sprocket driven modules are provided with improved configurations which result in improved belt tracking and reduce incidents of mechanical failure. Specifically, these improvements include a conveyor module having a central drive bar having alternating crest pairs and troughs along its top, connected by shoulders that enable improved driving and tracking while being structurally strong and easy to clean.

Description:
TECHNICAL FIELD OF INVENTION 
   The invention relates generally to a conveyor system, and, more particularly, to a meat transporting conveyor system. 
   BACKGROUND OF THE INVENTION 
   In the meat and meat packing industries, conveyor belts and conveyor systems are commonly utilized to transport meat in processing plants. 
   The most frequently employed conveyor systems comprise a number of interlocking conveyor modules linked together to form a continuous conveyor belt, which is driven by a sprocket. Some examples of these types of conveyor systems are U.S. Pat. Nos. 4,925,016, 6,423,279, 3,602,364, 4,072,062, 4,080,842, 4,213,527, and 4,556,142. Some systems both drive the belt and track the belt with the sprockets. Many of these devices, however, either lack adequate drive surfaces on the belt or provide inadequate tracking, allowing the belt to wander. 
   Therefore, there is a need for a conveyor system that addresses at least some of the problems associated with the conventional systems. In particular, a conveyor system is needed that is easy to drive, without fear of frequent failure, or disengagement between the sprocket and conveyor belt. 
   SUMMARY OF THE INVENTION 
   Advantages of the various embodiments of the present invention are that it is simple, safe, and durable. Another advantage of the present invention is that it is inexpensive to manufacture. Another advantage of the present invention is that it provides for a simplified, easily deployable, and easily removable system. Other advantages of the various embodiments of the present invention is that it is easy to clean and provides improved tracking. 
   In accordance with a preferred embodiment of the present invention, a conveyor belt cleaning system is provided. A plurality of conveyor modules are pivotally secured to one another. Each conveyor module includes a planar member having a first edge, an opposing second edge, a top surface, and a bottom surface. 
   Also in accordance with the above-mentioned preferred embodiments are several features extending from the planar member. A plurality of first links are located along the first edge, and a plurality of second links are located along the second edge. The first and second links form eyelets. The second links are adapted to engage and coaxially align with the first links so as to form a pivot joint between each conveyor module. 
   Also in accordance with the above-mentioned preferred embodiments are additional features extending from the planar member. A drive bar is also included which extends perpendicular from the bottom surface and is substantially parallel to the first and second edges. The drive bar includes a drive face and a plurality of crest pairs with a trough therebetween connected by a pair of shoulders. In the preferred embodiment, the shoulders are nonplaner. 
   In the preferred embodiment the shoulders in a trough extend towards each other. In another preferred embodiment, opposing shoulders converge at the trough such that distance between the shoulders at the crest pairs is greater than the distance between the shoulders at the trough. A driving force from a sprocket may be applied across at least a portion of the drive face. Each pair of shoulders is adapted to engage a tracking tooth of a sprocket. 
   In another preferred embodiment of the present invention, each shoulder further comprises a pair of intersecting planar members. In an alternative embodiment of the present invention, each shoulder further comprises a curvilinear surface. 
   In another preferred embodiment of the present invention, the curvilinear surface is a spheroid section. In another preferred embodiment of the present invention, the curvilinear surface is a prolate spheroid section. 
   In another preferred embodiment of the present invention, a conveyor system is provided. Within the conveyor system is a sprocket and a conveyor belt formed of a plurality of interlocked conveyor modules pivotally secured to one another. The sprocket includes a plurality of generally semicircular recesses and a tracking tooth located between each recess member. Each recess member includes a driving member at each end. 
   Within the conveyor belt, a plurality of conveyor modules are pivotally secured to one another. Each conveyor module includes a planar member having a first edge, an opposing second edge, a top surface, and a bottom surface. A plurality of first links are located along the first edge, and a plurality of second links are located along the second edge. The second links are adapted to engage and coaxially align with the first links so as to form a pivot joint between each conveyor module. 
   Also in accordance with the above-mentioned preferred embodiments are additional features extending from the planar member. A drive bar is also included which extends perpendicular from the bottom surface and is substantially parallel to the first and second edges. The drive bar includes a drive face and a plurality of crest pairs with a trough therebetween connected by a pair of shoulders. In the preferred embodiment, the shoulders are nonplaner. 
   In another preferred embodiment, the shoulders in a trough extend towards each other. In another preferred embodiment, opposing shoulders converge at the trough such that distance between the shoulders at the crest pairs is greater than the distance between the shoulders at the trough. A driving force from a sprocket may be applied across at least a portion of the drive face. Each pair of shoulders is adapted to engage a tracking tooth of a sprocket. In an alternate embodiment of the present invention, each tracking tooth is adapted to form a complementary fit with the shoulders. 
   The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements. 
     The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention. 
       FIG. 1  is a plan view of a conveyor module in accordance with a preferred embodiment of the present invention. 
       FIG. 2  is an isometric view of the conveyor module of  FIG. 1 . 
       FIG. 3  is a plan view of a sprocket for use with the conveyor module of  FIG. 1 . 
       FIG. 4  is an elevation view of the conveyor system of  FIGS. 1–3 . 
       FIG. 5  is a plan view of a conveyor module in accordance with another preferred embodiment of the present invention. 
       FIG. 6  is an isometric view of the conveyor module of  FIG. 5 . 
       FIG. 7  is a plan view of a sprocket for use with the conveyor module of  FIG. 5 . 
       FIG. 8  is an elevation view of the conveyor system of  FIGS. 5–7 . 
       FIG. 9  is a plan view of a conveyor module in accordance with another preferred embodiment of the present invention. 
       FIG. 10  is an isometric view of the conveyor module of  FIG. 9 . 
       FIG. 11  is a plan view of a sprocket for use with the conveyor module of  FIG. 9 . 
       FIG. 12  is an elevation view of the conveyor system of  FIGS. 9–11 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   In the following discussion, numerous specific details are set forth to provide a thorough understanding of the present invention. However, those skilled in the art will appreciate that the present invention may be practiced without such specific details. In other instances, well-known elements have been illustrated in schematic or block diagram form in order not to obscure the present invention in unnecessary detail. 
   The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. 
   Referring to  FIGS. 1 ,  2 ,  5 ,  6 ,  9 , and  10  of the drawings, the reference numeral  100  generally designates a conveyor module. Conveyor module  100  comprises a planar member  102 , which has a first edge  104 , and a second edge  106 , a top surface  108  (shown in  FIGS. 4 ,  8 , and  12 ) and a bottom surface  110 . Along first edge  104  are first links  112 , and along second edge  106  are second links  114 , which are offset from first links  112 . First links  112  and second links  114  form eyelets that are designed to engage and coaxially align with each other to form a continuous conveyor belt  300 , as shown in  FIGS. 4 ,  8 , and  12 . 
   Also shown in  FIGS. 1 ,  2 ,  5 ,  6 ,  9 , and  10  is drive bar  116 . The bottom of drive bar  116  extends generally perpendicular from bottom surface  110  of planer member  102  and is substantially parallel to first edge  104  and second edge  106 , and substantially centralized therebetween. Along each vertical side of drive bar  116  is a drive face  118 . In a preferred embodiment, drive face  118  is at an angle inclined relative to planar member  102 . Included within drive bar  116  are crest pairs  120  with troughs  122  therebetween, forming the top of drive bar  116 . Connecting troughs  122  to crest pairs  120  are nonplanar shoulders  124 . 
   In the preferred embodiment, shoulders  124  in trough  122  extend towards each other. In another preferred embodiment, opposing shoulders  124  converge at trough  122  such that distance between shoulders  124  at crest pairs  120  is greater than the distance between shoulders  124  at trough  122 . 
   In the preferred embodiment illustrated in  FIGS. 1 and 2 , nonplanar shoulders  124  are comprised of intersecting planes. In the preferred embodiment illustrated in  FIGS. 5 and 6 , nonplanar shoulders  124  are comprised of sections of a spheroid. In the preferred embodiment illustrated in  FIGS. 9 and 10 , nonplanar shoulders  124  are comprised of sections of a prolate spheroid. 
   Referring to  FIGS. 3 ,  4 ,  7 ,  8 ,  11 , and  12  of the drawings, the reference numeral  200  generally designates a sprocket. Sprocket  200  comprises generally semicircular recesses  202  located along the periphery. Specifically, the local minimums of semicircular recesses  202  or the point where the first derivative of the curves defining semicircular recesses  202  is zero are at a first radius r 1 . At the ends of semicircular recesses  202  are driving members  204 . Between driving members  204  of adjacent semicircular recesses  202  are tracking teeth  206 , which are at a second radius r 2 . 
   As can be seen in  FIGS. 3 ,  4 ,  7 ,  8 ,  11 , and  12 , tracking teeth  206  can have different configurations. In  FIGS. 3 and 4 , tracking teeth  206  are shaped to form a complementary fit with nonplanar shoulders  124  of  FIGS. 1 and 2 . In  FIGS. 7 and 8 , tracking teeth  206  are shaped to form a complementary fit with nonplanar shoulders  124  of  FIGS. 5 and 6 . In  FIGS. 11 and 12 , tracking teeth  206  are shaped to form a complementary fit with nonplanar shoulders  124  of  FIGS. 9 and 10 . 
   Advantages of the present invention are that it is simple, safe, and durable. Another advantage of the present invention is that it is inexpensive to manufacture. Another advantage of the present invention is that it provides for a simplified, easily deployable, and easily removable system. Another advantage of the present invention is that it is easy to clean and provides improved tracking. 
   OPERATION OF THE PREFERRED EMBODIMENTS 
   In forming a conveyor system, several integral components are employed, namely sprocket  200  and conveyor belt  300 . As can be seen in  FIGS. 4 ,  8 , and  12 , sprocket  200  drives conveyor belt  300 , while tracking conveyor belt  300  at the same time. Each of sprocket  200  and conveyor belt  300  can be formed of a variety of materials including, but not limited to, metal, plastic, and porcelain. In a preferred embodiment of the present invention, the sprocket  200  and conveyor belt  300  are formed of an injection molded polyvinyl chloride (PVC). 
   Conveyor belt  300  is comprised of multiple interlocking conveyor modules  100 . Referring to  FIGS. 1 ,  2 ,  5 ,  6 ,  9 , and  10  of the drawings, conveyor module  100  is shown. There are a number of ways to configure conveyor module  100 ; however, there are some common features to each configuration. In particular, conveyor module  100  comprises a planar member  102 , which has a first edge  104 , a second edge  106 , a top surface  108 , and a bottom surface  110 . Planar member  102  forms the central component from which the remainder of conveyor module  100  is built. Additionally, planar member  102  is responsible for carrying meat products when conveyor belt  300  is in operation. 
   Along first edge  104  of planar member  102  are first links  112 , and along second edge  106  of planar member  102  are second links  114 . First links  112  and second links  114  are designed to engage and coaxially align with each other to form conveyor belt  300 . Specifically, first links  112  and second links  114  are cylindrical tubes, or eyelets that engage and coaxially align with one another to form a pivotal hinge over a pivot bar (not shown). 
   In  FIGS. 1 ,  2 ,  5 ,  6 ,  9 , and  10 , drive bar  116  is illustrated. The function of drive bar  116  is two-fold: driving and tracking. Specifically, drive bar  116  extends perpendicular from bottom surface  110  of planer member  102  and is substantially parallel to first edge  104  and second edge  106 . Along each vertical side of drive bar  116  is a drive face  118 . At the juncture of drive face  118  between drive bar  116  and planar member  102  is a stress riser. Because drive bar  116  can extend along the entire length of planar member  102 , stress can be more distributed to material along the length of the juncture, thus, reducing the incidence of fracture or mechanical breakdown. 
   In an alternative embodiment, drive face  118  can be inclined at an obtuse angle relative to bottom surface  110 . Having this inclination allows for easier engagement of conveyor modules  100  with sprocket  200  and adds to the strength of drive bar  116 . In a preferred embodiment, the angle of inclination between drive face  118  and bottom surface is between 100 and 120 degrees. 
   Also included within drive bar  116  are crest pairs  120  with troughs  122  therebetween. The combination of crest pairs  120  and troughs  122  provides tracking of conveyor belt  300 . Specifically, tracking teeth  206  on sprocket  200  are cradled between the crest pairs  120  in troughs  122 . However, troughs  122  and crest pairs  120  do not typically provide sufficient tracking. Oftentimes, there is considerable lateral play that can cause a conveyor belt to lose tracking and bind the conveyor system. However, use of narrow troughs  122  can result in system binding and failure. In the preferred embodiment of the present invention, nonplanar shoulders  124  are employed which connect troughs  122  to crest pairs  120 . 
   In the preferred embodiment, shoulders  124  in trough  122  extend towards each other. This provides a converging configuration that guides tracking teeth  206  on sprocket  200  to the center of troughs  122 . In another preferred embodiment, opposing shoulders  124  converge at trough  122  such that the distance between shoulders  124  at crest pairs  120  is greater than the distance between shoulders  124  at trough  122 . This configuration ensures smooth operation of conveyor system  300  when tracking teeth  206  engage shoulders  124 . 
   The alternative embodiments disclose differing geometries of nonplanar shoulders  124 . In one preferred embodiment of the present invention, as shown in  FIGS. 1 and 2 , nonplanar shoulders  124  are comprised of two intersecting planes. In essence, a wedge or V-shape is formed. Typically, the line of intersection of the planes is at an incline to bottom surface  110  so that tracking teeth  206  can be more easily engaged. Thus, the intersecting planes of shoulder  124  provide smooth transitional alignment of conveyor modules  100  relative to sprocket  200  and prevent lateral misalignment. 
   In another preferred embodiment of the present invention, illustrated in  FIGS. 5 and 6 , nonplanar shoulders  124  are comprised of sections of a spheroid. In another preferred embodiment of the present invention, illustrated in  FIGS. 9 and 10 , nonplanar shoulders  124  are comprised of sections of a prolate spheroid. This geometry is commonly referred to as football-shaped. 
   Referring to  FIGS. 3 ,  4 ,  7 ,  8 ,  11 , and  12  of the drawings, sprocket  200  is shown. There are a number of ways to configure sprocket  200 ; however, there are some common features to each configuration. Sprocket  200  comprises generally semicircular recesses  202  located along the periphery. Specifically, the local minimums of generally semicircular recesses  202  or the point where the first derivative of the curves defining semicircular recesses  202  is zero are at a first radius r 1 . Typically, first radius r 1  is from about 2.5 inches to about 4.75 inches. 
   At the ends of each of recesses  202  are driving members  204 . Driving members  204  apply force to drive face  118  of drive bar  116  and contact bottom surface  110  of planar member  102 . In the preferred embodiment, the height of driving members  204  is sufficient to prevent linking members  112  and  114  from contacting semicircular recesses  202 , and to prevent tracking teeth  206  from contacting troughs  122 . The pivot joint formed between first linking member  112  and second linking member  114  of adjacent conveyor modules  100  is notoriously difficult to clean and is an ideal location for bacterial colonies to grow. Preventing contact with recesses  202 , and with troughs  122  prevents meat from being compressed between first links  112  and second links  114  and prevents meat from being compressed inside of either the first links  112  or second links  114 . Thus, conveyor belt  300  is easier to clean. 
   Differences in the alternate embodiments can be seen with the differing geometries of tracking teeth  206 , which correspond to the different geometries of nonplanar shoulders  124  discussed above. Between semicircular recesses  202  are tracking teeth  206 , which are at a second radius r 2 . Typically, second radius r 2  is from about 2.75 inches to about 5.0 inches. In one embodiment of the present invention, as shown in  FIGS. 3 and 4 , tracking teeth  206  are shaped to form a complementary fit with nonplanar shoulders  124  of  FIGS. 1 and 2 . In another embodiment of the present invention, as shown in  FIGS. 7 and 8 , tracking teeth  206  are shaped to form a complementary fit with nonplanar shoulders  124  of  FIGS. 5 and 6 . In yet another preferred embodiment of the present invention, as shown in  FIGS. 11 and 12 , tracking teeth  206  are shaped to form a complementary fit with nonplanar shoulders  124  of  FIGS. 9 and 10 . 
   Advantages of various embodiments of the present invention are that it is simple, safe, and durable. Another advantage of various embodiments of the present invention is that it is inexpensive to manufacture. Another advantage of various embodiments of the present invention is that it provides for a simplified, easily deployable, and easily removable system. Other advantages of various embodiments of the present invention are that it is easy to clean and provides improved tracking. 
   It will be readily apparent to those skilled in the art that the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. 
   Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.