Patent Description:
Conveyors, such as endless conveyor belts trained around reversing elements at each end, or roller conveyors comprising a series of rotatable rollers for moving objects, are often arranged end-to-end with a gap between the downstream end of an upstream conveyor and the upstream end of a downstream conveyor. Bridging the gap can be problematic for certain articles. Various transfer mechanisms, such as transfer belts, transfer plates and transfer platforms have been used to provide a smoother product transfer between the confronting ends of the two conveyors.

Transfers often cause jostling of conveyed products, such as trays holding meat, which requires manual intervention (called 'styling'). Other products require gentle transfer because of top-heavy packaging (e.g. tall bottles) that are prone to toppling during transfer.

<CIT> discloses a holding belt for a hydraulic automatic pearl oyster cleaner. In terms of claim <NUM>, such a document also shows:
A transfer conveyor (see <FIG>) suitable for transferring product (<NUM>), comprising: a frame (<NUM>) configured to overlay a transfer gap between a first product conveyor (<NUM>) and a second product conveyor (<NUM>), the frame comprising a first outer side wall having a first section that extends along a first side of the first product conveyor, and a third section that bridges the transfer gap,
a second outer side wall having a first section that extends along a second side of the first product conveyor, and a third section that bridges the transfer gap, and a transfer plate (<NUM>) extending between the third sections of the first and second outer side walls, the transfer plate bridging the transfer gap.

A conveyor system includes a transfer conveyor for gently transferring products between two product conveyors. The transfer conveyor comprises a frame and two transfer conveyor belts nestled around the product conveyors for lifting and transferring product over a transfer gap between the product conveyors. Each transfer conveyor belt comprises a series of modules arranged in an endless loop and containing a plurality of movable lifting flaps for carrying the product in the transfer region.

According to the invention, a transfer conveyor for transferring product comprises a frame configured to overlay a transfer gap between a first product conveyor and a second product conveyor. The frame comprises a first outer side wall having a first section that extends along a first side of the first product conveyor, a second section that curves laterally inwards and a third section that bridges the transfer gap a second outer side wall having a first section extends along a second side of the first product conveyor, a second section that curves laterally inwards and a third section that bridges the transfer gap, and a transfer plate extending between the third sections of the first and second outer side walls, the transfer plate bridging the transfer gap. The transfer conveyor further comprises a first transfer conveyor belt comprising a plurality of hingedly connected modules capable of shifting laterally relative to each other and forming an endless loop, the first transfer conveyor belt extending between the first product conveyor and the second product conveyor adjacent to the first outer side wall. The transfer conveyor further comprises a second transfer conveyor belt comprising a plurality of hingedly connected modules capable of shifting laterally relative to each other and forming an endless loop, the second transfer conveyor belt extending between the first product conveyor and the second product conveyor adjacent to the second outer side wall, wherein the frame further includes a first inner side wall opposing the first section of the first outer side wall to form a channel for guiding the first transfer conveyor belt.

According to another aspect, a conveying system, comprises a first product conveyor for conveying product from an infeed to an outfeed, a second product conveyor for receiving product conveyed by first product conveyor and conveying the product away from the first product conveyor, the second product conveyor having an infeed separated from the first product conveyor outfeed by a transfer gap and a transfer conveyor extending between the first product conveyor and the second product conveyor for lifting and carrying the product over the transfer gap.

According to still another non claimed aspect a module for a transfer conveyor comprises a main body, a first hinge element extending from a first end of the main body, a pair of hinge elements extending from a second end of the main body and forming a space for receiving the first hinge element of an adjacent module in a transfer conveyor belt formed by hingedly connecting a plurality of modules together and a lifting flap pivotally connected to a first side of the module body to form a surface for supporting a conveyed product.

A conveying system includes a transfer conveyor for gently transferring product from a first product conveyor to a second product conveyor using chain conveyors nested around confronting ends of the product conveyors. The invention will be described relative to certain illustrative embodiments, though those skilled in the art will recognize that the invention is not limited to the illustrative embodiments.

One version of a conveying system <NUM> including a transfer conveyor embodying features of the invention is shown in <FIG>. A conveying system <NUM> includes a first product conveyor <NUM>, shown as a conveyor belt trained around reversing elements <NUM>, <NUM> to form a carryway for conveying product <NUM> in a conveying direction <NUM>, and a returnway below the carryway. Product <NUM> is transferred via a transfer conveyor <NUM> to a second product conveyor <NUM>. The transfer conveyor <NUM> surrounds and lifts the product <NUM> up and across the transfer gap <NUM> between the two product conveyors <NUM>, <NUM> to provide a smooth transition between the two product conveyors <NUM>, <NUM>. The illustrative second product conveyor <NUM> comprises a conveyor belt trained around reversing elements <NUM>, <NUM> to form a carryway for continuing to convey product received from the transfer conveyor <NUM> in the conveying direction <NUM>, and a returnway below the carryway, though the invention is not so limited. The first and second product conveyors <NUM>, <NUM> can comprise any suitable type of conveyor for conveying product and are not limited to conveyor belts. In addition, the first and second product conveyors are not limited to an in-line, parallel arrangement. In another embodiment, the second product conveyor <NUM> is angled relative to the first product conveyor <NUM>, and the transfer conveyor <NUM> can curve between the two product conveyors to bridge the gap between the two product conveyors.

The illustrative transfer conveyor <NUM> comprises a pair of chain radius belts extending along the sides of the two product conveyors <NUM>, <NUM> and guided by a frame <NUM>. The chain radius belts comprise a first transfer conveyor belt <NUM> extending from a first longitudinal location alongside a first side of the first product conveyor <NUM> to a second longitudinal location alongside a first side of the second product conveyor <NUM> and a second transfer conveyor belt <NUM> extending from the first longitudinal location alongside a second side of the first product conveyor <NUM> to the second longitudinal location alongside a second side of the second product conveyor <NUM>. The transfer conveyor belts <NUM>, <NUM> travel in the conveying direction alongside the product conveyors <NUM>, <NUM> and return in a returnway adjacent the returnways of the product conveyors <NUM>, <NUM>. The transfer conveyor belts <NUM>, <NUM> are trained around reversing elements <NUM>, <NUM> located at the first and second longitudinal locations. The reversing elements <NUM>, <NUM> are disposed between the carryway and returnway of the product conveyors <NUM>, <NUM> along the side edges of the product conveyors <NUM>, <NUM>.

The frame <NUM> guides the first and second radius conveyor belts <NUM>, <NUM> through and over the transfer gap <NUM> between the first product conveyor <NUM> and the second product conveyor <NUM>. In a central region upstream of the transfer gap <NUM>, the frame <NUM> pushes the transfer conveyor belts <NUM>, <NUM> laterally inwards to surround and engage the conveyed product <NUM>. The transfer conveyor belts then convey the product over the transfer gap <NUM>. Downstream of the transfer gap <NUM>, the frame <NUM> separates the transfer conveyor belts <NUM>, <NUM>, pushing the transfer conveyor belts <NUM>, <NUM> laterally outwards to release the product to the second product conveyor <NUM>. The second product conveyor <NUM> then continues to convey the product <NUM> away from the first product conveyor <NUM>.

The illustrative transfer conveyor belts <NUM>, <NUM> are modular conveyor belts comprising a series of hingedly connected modules capable of shifting laterally relative to each other and arranged in an endless loop. One or more of the modules includes a movable flap or other element for lifting and carrying product over the transfer gap <NUM>. For example, as shown in <FIG>, at the first longitudinal location <NUM>, i.e., the beginning of the carryway for the first and second transfer conveyor belts <NUM>, <NUM>, the belts are spaced out on each side of the first product conveyor belt carryway. As the transfer conveyor belts <NUM>, <NUM> advance down the carryway towards the end of the first product conveyor <NUM>, the frame <NUM> pushes the transfer conveyor belts <NUM>, <NUM> laterally inwards towards the conveyed product <NUM>. The transfer conveyor belts <NUM>, <NUM> include lifting flaps <NUM>, <NUM>, as described in detail below, that can be deployed to receive the conveyed product <NUM> from the first product conveyor belt <NUM> and convey the product over the transfer gap <NUM>. The illustrative lifting flaps <NUM>, <NUM> converge to support the product <NUM> from below on each side of the product <NUM>, with minimal impact on the product. After the transfer conveyor belts <NUM>, <NUM> pass over the transfer gap <NUM>, the transfer conveyor pulls the lifting flaps <NUM>, <NUM> from the product to release the product <NUM> to the second product conveyor <NUM>. Alternatively, other means for conveying the product over the transfer gap <NUM> may be used.

The product conveyors <NUM>, <NUM> and the transfer conveyor <NUM> may operate at different speeds to facilitate transfers. For example, the first product conveyor <NUM> may move faster than the transfer conveyor belts <NUM>, <NUM> to push product into product receiving region between the transfer conveyor belts, but the invention is not so limited.

<FIG> show an embodiment of a module <NUM> suitable for forming a transfer conveyor belt <NUM> or <NUM> according to an embodiment. The illustrative module <NUM> is a radius chain module having a main body <NUM>, a first hinge element <NUM>, shown as a knuckle, extending from a first end of the main body and a pair of hinge elements <NUM> extending from the second end of the main body and forming a space for receiving the first hinge element of an adjacent module in the transfer conveyor belt. A hinge pin <NUM> may be inserted through aligned openings of the hinge elements <NUM>, <NUM> to connect successive modules to each other. The modules <NUM> are capable of shifting laterally relative to each other to navigate curves.

The illustrative module <NUM> further includes a lifting flap <NUM> that is pivotally connected to a first side <NUM> of the module body <NUM> to form a surface for supporting the conveyed product <NUM>. The illustrative lifting flap <NUM> is connected to the laterally inner side <NUM> of the module <NUM>. The lifting flap <NUM> may have any suitable size, shape and -or configuration suitable for supporting a conveyed product <NUM>. In a deployed position, shown in <FIG>, the lifting flap <NUM> is horizontal, parallel to the conveying surfaces of the product conveyors <NUM>, <NUM>. As shown in <FIG>, the lifting flap <NUM> can pivot about pivot locations <NUM> to a retracted position, shown in <FIG>. In the retracted position, the lifting flap <NUM> is flipped to a vertical or substantially vertical position, making the module <NUM> more compact to fit in the returnway.

In the illustrative embodiment, both transfer conveyor belts <NUM>, <NUM> are formed of identical modules, with the modules oriented opposite each other (i.e., belt <NUM> has the knuckle portion leading, while belt <NUM> has the hinge elements <NUM> leading) in order to keep the flaps <NUM>, <NUM> on the laterally inner side of the transfer conveyor.

Alternatively, the transfer conveyor belt <NUM> comprises similar modules that are mirror images of the modules of the transfer conveyor belt <NUM>, so that the lifting flap <NUM> is formed on the opposite side of the transfer conveyor belt.

<FIG> show an embodiment of a frame <NUM> suitable for guiding the transfer conveyor belts <NUM>, <NUM>, as well as moving the lifting flaps <NUM>, <NUM> between the deployed and retracted position. The illustrative frame <NUM> comprises props <NUM>, <NUM> extending alone each side of the carryway. The props <NUM>, <NUM> may be attached to the product conveyor frames (not shown). The illustrative props have a main body formed of sheet metal and including openings to reduce weight, but the invention is not so limited. A straight outer edge of the main body overlies the side edges of the product conveyors and spans the transfer gap between the product conveyors <NUM>, <NUM>.

At a first end, shown in detail in <FIG>, each prop <NUM>, <NUM> forms a channel <NUM> for guiding a transfer conveyor belt <NUM> or <NUM>. The channel comprises an inner side wall <NUM>, an outer side wall <NUM> and a bottom wall <NUM>. The inner side wall <NUM> holds the flaps <NUM>, <NUM> in the retracted position and only extends along the first end sections of the props <NUM>, <NUM>. Downstream of the inner side wall <NUM>, the channel <NUM> includes a twisting flap dropping guide <NUM> for dropping the lifting flaps to the deployed position as the modules pass through the channel <NUM>.

The outer side walls <NUM> extend from a straight first section adjacent the side edges of the first product conveyor at the first longitudinal location <NUM> to a curved second section. In the curved second section, the outer side walls curve laterally inward, pushing the conveyor belt modules <NUM> towards the center of the carryway. With the flaps in the deployed position, the transfer conveyor belts <NUM>, <NUM> converge, placing the deployed flaps <NUM>, <NUM> under the conveyed product with minimal impact on the product.

At a central portion, the outer side walls <NUM> form a narrowed carryway that is just wide enough to fit the product, so that the lifting flaps <NUM>, <NUM> effect the conveying of the product. In the central portion, the frame <NUM> includes a transfer plate <NUM> that bridges the product conveyors. The illustrative transfer plate is curved and arcs over the transfer gap <NUM> between conveyor ends. The outer side walls <NUM> also bridge the transfer gap <NUM>. The illustrative outer side walls are also arc-shaped and continue adjacent to the sides of the curved transfer plate <NUM> to confine and guide the transfer conveyor belts <NUM>, <NUM>. In the central portion, the transfer conveyor belts <NUM>, <NUM> lift and carry the conveyed product over the transfer gap <NUM>. In another embodiment, the transfer section of the transfer conveyor <NUM> is flat and the invention is not limited to arched components.

After the central portion, as shown in <FIG>, the outer side walls <NUM> form another curved section, causing the outer side walls <NUM> to widen out again to the side edges of the second product conveyor <NUM>, pulling the flaps from under the product and transferring the product <NUM> to the second product conveyor <NUM>. A twisting flap-lifting guide <NUM> pushes the flap <NUM> or <NUM> back to a vertical, retracted position for travel in the returnway <NUM>. Inner side walls each <NUM> form another belt-guiding channel with the last, straight section of the outer side walls <NUM> to guide the transfer conveyor belts to the reversing element <NUM>. The belt-guiding channel pushes the belt modules back to the side edges of the product conveyor <NUM> and holds the flaps in the retracted position. The flaps remain in the retracted position in the returnway <NUM>.

The illustrative transfer conveyor provides gentle handling of products, reducing manual intervention during transfer.

While the illustrative flap actuators comprise twisting guides, alternative means for flipping the flaps between the deployed and retracted position may be used. For example, a mechanical, electrical or magnetic means may be used to move the flaps between the deployed and retracted positions.

Claim 1:
A transfer conveyor (<NUM>) for transferring product (<NUM>), comprising:
a frame (<NUM>) configured to overlay a transfer gap (<NUM>) between a first product conveyor (<NUM>) and a second product conveyor (<NUM>), the frame (<NUM>) comprising
a first outer side wall (<NUM>) having a first section that extends along a first side of the first product conveyor, a second section that curves laterally inwards and a third section that bridges the transfer gap (<NUM>),
a second outer side wall (<NUM>) having a first section that extends along a second
side of the first product conveyor, a second section that curves laterally inwards and
a third section that bridges the transfer gap (<NUM>), and
a transfer plate (<NUM>) extending between the third sections of the first and second outer side walls (<NUM>), the transfer plate (<NUM>) bridging the transfer gap (<NUM>);
a first transfer conveyor belt (<NUM>) comprising a plurality of hingedly connected modules (<NUM>) capable of shifting laterally relative to each other and forming an endless loop, the first transfer conveyor belt (<NUM>) extending between the first product conveyor (<NUM>) and the second product conveyor (<NUM>) adjacent to the first outer side wall (<NUM>); and
a second transfer conveyor belt (<NUM>) comprising a plurality of hingedly connected modules (<NUM>) capable of shifting laterally relative to each other and forming an endless loop, the second transfer conveyor belt (<NUM>) extending between the first product conveyor (<NUM>) and the second product conveyor (<NUM>) adjacent to the second outer side wall (<NUM>);
wherein the frame (<NUM>) further includes a first inner side wall (<NUM>) opposing the first section of the first outer side wall (<NUM>) to form a channel (<NUM>) for guiding the first transfer conveyor belt (<NUM>).