Patent Description:
Food patties of various kinds, including hamburgers, molded steaks, fish cakes, chicken patties, pork patties, potato patties, and others, are frequently formed in high-volume automated molding machines. <CIT> discloses an example of a rotary molding system for molding food products. According to its abstract <CIT> relates to an installation for moulding of three dimensional products from a mass of pumpable foodstuff material, for example from ground meat, wherein the installation comprises: -a pump having at least one pump chamber, an inlet, and an outlet for the foodstuff mass, -a pump drive, -a moulding device comprising a mould member having multiple mould cavities, and a mould member drive for moving the mould member along a path, said path including a fill position of a mould cavity where mass is filled into a mould cavity and a product release position of a mould cavity where a moulded product is released from the mould cavity, -a mass feed member having a chamber with an inlet and a discharge mouth facing the mould member at the fill position along the path of the mould member, the mass feed member being adapted to transfer the foodstuff mass into a mould cavity of the mould member in a corresponding mould cavity filling event that is defined by the moment of first flow of foodstuff mass into the mould cavity and the moment wherein the mould cavity has been fully filled and flow of foodstuff mass therein is terminated.

According to the invention, the rotary molding system includes a stripper plate in communication with a feed source, the stripper plate having a plurality of holes therethrough through which food product is configured to pass; a wear plate having a planar input and output surfaces, the stripper plate being capable of moving in a reciprocating manner relative to the wear plate, the wear plate having a plurality of holes therethrough through which food product is configured to pass; a fill plate having a plurality of holes therethrough through which food product is configured to pass, the wear plate being releasably attached to the fill plate; and a cylindrical drum having mold cavities into which food product is configured to be deposited, the drum being proximate to the output surface of the fill plate.

The wear plate of the rotary mould system according to the invention is releasably attached to the stripper plate by a plurality of retainer bars, wherein each retainer bar defines a recess into which the stripper plate seats, the stripper plate being capable of being removed relative to the retainer bars.

The recesses of the retainer bars allow relative movement of the stripper plate. Such movement enables the stripper plates to be easily removed from the retainer bars, which is advantageous during routine maintenance as it reduces downtime.

In accordance with some example embodiments, the rotary molding system includes a fill plate having a plurality of holes therethrough through which food product is configured to pass; a cylindrical drum having mold cavities into which food product is configured to be deposited, the drum being proximate to the fill plate; and a platen mounted within the drum, the platen including a body having a plurality of passageways therethrough which are in communication with the mold cavities, the drum being configured to rotate relative to the platen.

In accordance with some example embodiments, the rotary molding system includes a fill plate having a plurality of holes therethrough through which food product is configured to pass; a cylindrical drum having mold cavities into which food product is configured to be deposited, the drum being proximate to the fill plate; and a platen mounted within the drum, the platen including a body having drum roller supports provided thereon, and a roller mounted within each drum roller support, the rollers extending partially outwardly from the outer surface of the platen and being in contact with the inner surface of the drum, the drum being configured to rotate relative to the platen and the rollers.

In accordance with some example embodiments, the fill plate includes a plurality of holes through which food product is configured to pass, the holes being aligned in rows and columns such that a central row of holes is defined, each hole in the central row being formed by a straight wall extending from the inlet surface of the fill plate and a tapered wall extending from an outlet end of the straight wall to the outlet surface of the fill plate and a central axis of the straight wall and a central axis of the tapered wall are aligned with each other; and each hole in rows other than the central row being formed by a straight wall extending from the inlet surface of the fill plate and a tapered wall extending from an outlet end of the straight wall to the outlet surface of the fill plate and a central axis of the straight wall and a central axis of the tapered wall are angled relative to each other at an angle.

This Summary is provided merely for purposes of summarizing some example embodiments so as to provide a basic understanding of some aspects of the disclosure.

The organization and manner of the structure and operation of the disclosed embodiments, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying drawings, which are not necessarily drawn to scale, wherein like reference numerals identify like elements in which:.

<FIG> and <FIG> illustrate the primary components of an embodiment of a rotary molding system <NUM> configured for use in a patty forming machine <NUM>.

In general, the patty forming machine <NUM> includes a feeder portion <NUM> which supplies food product to the rotary molding system <NUM>. In an embodiment, the feeder portion <NUM> is formed from a hopper <NUM> connected to a pump box <NUM> by an auger system connected to a pump intake passage, a motor driven rotary pump, and a pump output passage (not shown). Such a feeder portion is disclosed in <CIT>,.

As shown in <FIG> and <FIG>, the pump box <NUM> may include a housing <NUM> and an insert <NUM> inserted within a chamber <NUM> in the housing <NUM>. When the housing <NUM> and insert <NUM> are connected together, a cavity is formed therebetween. The position of the insert <NUM> may be adjusted relative to the housing <NUM> in order to vary the size of the cavity therebetween. The housing <NUM> has at least one feed opening <NUM> and the insert <NUM> has at least one feed opening <NUM> to channel food product from the hopper <NUM> through the pump box <NUM>. The feed openings <NUM>, <NUM> may be aligned. In an embodiment, the pump box <NUM> is formed of a single component.

The rotary molding system <NUM> includes a stationary support structure <NUM> which is attached to a cabinet <NUM> of the patty forming machine <NUM>, a rotary hollow mold or drum <NUM> rotatably mounted on the support structure <NUM> by an inner platen <NUM>, and a food channel assembly <NUM> which directs food product from the pump box <NUM> to the drum <NUM>.

In an embodiment, the support structure <NUM> has an outer surface 38a and is cantilevered from the cabinet <NUM>. The support structure <NUM> may be formed of steel. Alternatively, the support structure <NUM> can be supported on both ends. In an embodiment, the support structure <NUM> is a mandrel.

The drum <NUM>, see <FIG>, is formed of a cylindrical wall <NUM> having an outer surface 48b and an inner surface 48a, and a toothed gear ring <NUM> extending about the circumference of the outer surface 48b of the wall <NUM> at each end thereof. A plurality of spaced apart mold cavities <NUM> are provided through the wall <NUM> and are disposed around the circumference of the wall <NUM>. The wall <NUM> has a thickness which corresponds to the depth of the mold cavities <NUM>. The number of mold cavities <NUM> around the circumference of the wall <NUM> can vary. In addition, the shape of the mold cavities <NUM> can vary. Structure <NUM> for rotating the drum <NUM> around the support structure <NUM>, such as driven toothed endless belts, are provided. Such a structure <NUM> for rotating the drum <NUM> is disclosed in <CIT>. The drum <NUM> rotates about a central axis <NUM>.

The inner platen <NUM>, see <FIG>, is formed from a body <NUM> having a drum facing surface 58a and support structure engaging surface 58b defined by parallel side edges 58c, 58d and parallel end edges 58e, 58f. A length of the inner platen <NUM> is defined between the side edges 58c, 58d. The drum facing surface 58a is curved in accordance with the radius of curvature of the cylindrical drum <NUM>. The support structure engaging surface 58b may be curved. The inner platen <NUM> may be formed of plastic.

The body <NUM> has a central perforated portion <NUM> with a non-perforated portion <NUM> extending around the perimeter of the central perforated portion <NUM> and between the central perforated portion <NUM> and the edges 58c, 58d, 58e, 58f. The central perforated portion <NUM> provides an air management system for allowing air to escape the mold cavities <NUM> as food product fills the mold cavities <NUM> and displaces the air in the mold cavities <NUM>.

The central perforated portion <NUM> includes an array of a plurality of distinct holes <NUM> which form rows and columns, a plurality of fins <NUM> separating columns of the holes <NUM> from each other and forming recesses <NUM> therebetween which are in communication with the holes <NUM>, and an elongated opening <NUM> proximate to the fins <NUM>. In an embodiment, the fins <NUM> extend perpendicular to the axis of rotation of the drum <NUM> and partially between the end edges 58e, 58f. In an embodiment, the fins <NUM> are curved in accordance with the radius of curvature of the drum <NUM>. Each recess <NUM> may be formed of a first recess part 68a which extends between adjacent fins <NUM> and extends from the surface of the central perforated portion <NUM> and a plurality of second recess parts 68b which extend from the first recess part 68a. The second recess parts 68b are recessed further from the support structure engaging surface 58b than the respective first recess part 68a. The column of holes <NUM> may be in communication with the second recess part 68b. The columns of holes <NUM> may be transverse to the length of the body <NUM>. In an embodiment, the holes <NUM> in alternating columns are aligned with each other. In an embodiment, the holes <NUM> have a diameter of <NUM> to <NUM> (<NUM> to <NUM> inches). The holes <NUM> may be formed of a first smaller diameter portion 64a which extends from the drum facing surface 58a and a second larger diameter portion 64b which extends from the first portion to the second recess part 68b.

The elongated opening <NUM> extends along a portion of the length of the body <NUM> and is proximate to the recesses <NUM> and is in communication with the recesses <NUM>.

A continuous recess <NUM> extends around the perimeter of the central perforated portion <NUM> into which an O-ring <NUM> is seated.

The inner platen <NUM> is affixed to the support structure <NUM> by suitable means such as fasteners which extend through apertures <NUM> provided through the non-perforated portion <NUM>.

A plurality of roller mounting apertures <NUM> are provided in the non-perforated portion <NUM>. As best shown in <FIG>, each roller mounting aperture <NUM> has a first section 76a which extends from the drum facing surface 58a of the inner platen <NUM>, and a second section 76b which extends from the first section 76a to the support structure engaging surface 58b of the inner platen <NUM>. The first section 76a has a dimension which is smaller than the second section 76b. In an embodiment, the first and second sections 76a, 76b are rectangular.

A drum roller support <NUM>, see <FIG>, is mounted within each roller mounting aperture <NUM> and supports an elongated cylindrical roller <NUM>, see <FIG>. The drum roller support <NUM> is formed of a base wall <NUM> and a side wall <NUM> depending therefrom. The base wall <NUM> and the side wall <NUM> define an open-ended cavity <NUM>. A pair of spaced apertures <NUM> are provided through the base wall <NUM> and are in communication with the cavity <NUM>. The portion of the base wall <NUM> between the apertures <NUM> forms a curved race 82a. The base wall <NUM> extends outwardly of the side wall <NUM> and forms a flange 82b. In an embodiment, the surface 82c opposite to the race 82a is planar. In an embodiment, the surface 82c is curved. While the drum roller support <NUM> is described as a separate component, the drum roller support <NUM> may be integrally formed as part of the body <NUM> of the inner platen <NUM>.

The flange 82b of the drum roller support <NUM> seats within the second section 76b of the mounting aperture <NUM> and the side wall <NUM> seats within the first section 76a of the mounting aperture <NUM>. The flange 82b corresponds in shape to the second section 76b and the side wall <NUM> corresponds in shape to the first section 76a so as to provide a secure fit between the drum roller support <NUM> and the inner platen <NUM>.

In an embodiment, each roller <NUM> has a central cylindrical body section 80a and a reduced cylindrical end section 80b at both ends of the body section 80a. In an embodiment, the body section 80a of each roller <NUM> is crowned to provide a self-aligning feature when the rollers <NUM> contact the inner surface of the drum <NUM> as described herein. The rollers <NUM> may be formed of plastic or metal. In an embodiment, each roller <NUM> is about <NUM> (<NUM> inches) long.

The body section 80a of the roller <NUM> seats against the race 82a of the drum roller support <NUM>. The body section 80a is wider than the cavity <NUM> such that the body section 80a partially protrudes outwardly from the side wall <NUM> of the drum roller support <NUM>.

When the inner platen <NUM> is mounted on the support structure <NUM>, the outer ends of the fins <NUM> are proximate to the outer surface 38a of the support structure <NUM> and the <NUM>-ring <NUM> engages against the outer surface 38a of the support structure <NUM>. The surface 82c of each drum roller support <NUM> engages against the outer surface 38a of the support structure <NUM>. The drum <NUM> is mounted on the inner platen <NUM> such that the drum facing surface 58a of the inner platen <NUM> is proximate to the inner surface 48a of the drum <NUM> and the rollers <NUM> engage the inner surface 48a of the drum <NUM>. The drum <NUM> rotates around the inner platen <NUM> and the support structure <NUM>.

The food channel assembly <NUM> includes a fill plate <NUM> which is proximate to the drum <NUM>, a wear plate <NUM> fixedly attached to the fill plate <NUM>, and a stripper plate <NUM> attached to the wear plate <NUM> and capable of movement relative to the wear plate <NUM>, see <FIG> and <FIG>. The food channel assembly <NUM> is attached to the housing <NUM> of the pump box <NUM>. In an embodiment, the fill plate <NUM> is formed of two parts, with an inner perforated body <NUM> which seats within an outer platen <NUM>. The body <NUM> is formed of metal. The outer platen <NUM>, if provided, is formed of plastic.

The inner perforated body <NUM> has an inlet surface 96a and an outlet surface 96b defined by parallel side edges 96c, 96d and parallel end edges 96e, 96f. The body <NUM> has a centerline <NUM> which extends between the side edges 96c, 96d. The body <NUM> has a central perforated portion <NUM> with non-perforated portions <NUM> extending between the central perforated portion <NUM> and the end edges 96e, 96f. The inlet surface 96a is planar. The outlet surface 96b formed by the central perforated portion <NUM> is curved in accordance with the radius of curvature of the drum <NUM>. The outlet surface 96b formed by the non-perforated portions <NUM> may be planar as shown, or may be curved in accordance with the radius of curvature of the drum <NUM>. A length of the fill plate <NUM> is defined between the side edges 96c, 96d.

An array of a plurality of distinct holes <NUM> are provided through the body <NUM> in the central perforated portion <NUM>. In an embodiment and as shown, the holes <NUM> in the fill plate <NUM> are aligned in rows and columns; the rows extending between the side edges 96c, 96d and the columns extending between end edges 96e, 96f. A central row <NUM> of holes <NUM> is formed along the centerline <NUM> of the body <NUM>. In an embodiment, the holes <NUM> in the fill plate <NUM> are randomly placed. In an embodiment, the holes <NUM> in the fill plate <NUM> have a diameter of <NUM> to <NUM> (<NUM> to <NUM> inches). In an embodiment, the fill plate <NUM> has an elongated feeder inlet passage (not shown) through which the food product passes to enter the mold cavities <NUM>. An example of a curved fill plate <NUM> is shown in <CIT>. Because of the shape of the fill plate <NUM>, the fill plate <NUM> is an expensive component to make and can be an expensive component to properly maintain.

In a first embodiment as shown in <FIG>, the wall <NUM> forming each hole <NUM> is straight from the inlet surface 96a to the outlet surface 96b, that is each hole <NUM> has a uniform diameter along its length from the inlet surface 96a to the outlet surface 96b. The central axis <NUM> of each hole <NUM> is parallel to each other and is transverse to the centerline <NUM> of the body <NUM>.

In a second embodiment as shown in <FIG>, each of the holes <NUM> in the array or predetermined ones of the holes <NUM> in the array have a straight wall <NUM> extending from the inlet surface 96a and a tapered or frustoconical wall <NUM> extending from the outlet end of the straight wall <NUM> to the outlet surface 96b. Each straight wall <NUM> has a uniform diameter along its length from the inlet surface 96a to the tapered or frustoconical wall <NUM>. Each tapered or frustoconical wall <NUM> has its smallest diameter (which corresponds to the diameter of the straight wall <NUM>) at its inlet end where tapered or frustoconical wall <NUM> joins with the straight wall <NUM> and has its largest diameter at its outlet end which is at the outlet surface 96b. The tapered or frustoconical wall <NUM> has a continuously increasing diameter as it extends along its length from its inlet end to its outlet end. The tapered or frustoconical wall <NUM> may extend along a small section of the length of the hole <NUM>, along half or the length of the hole <NUM>, or along almost the entire length of the hole <NUM>. In each hole <NUM>, a central axis <NUM> of the straight wall <NUM> and a central axis <NUM> of the tapered or frustoconical wall <NUM> are aligned with each other. The central axis <NUM>/<NUM> of each hole <NUM> is parallel to each other and is transverse to the centerline <NUM> of the body <NUM>. In an embodiment, the length of the straight wall <NUM> increases as the rows move outwardly from the central row <NUM> of holes <NUM>.

In a third embodiment as shown in <FIG>, all holes <NUM> in the central row <NUM> have a straight wall <NUM> extending from the inlet surface 96a and a tapered or frustoconical wall <NUM> extending from the outlet end of the straight wall <NUM> to the outlet surface 96b. Each straight wall <NUM> has a uniform diameter along its length from the inlet surface 96a to the tapered or frustoconical wall <NUM>. Each tapered or frustoconical wall <NUM> has its smallest diameter (which corresponds to the diameter of the straight wall <NUM>) at its inlet end where tapered or frustoconical wall <NUM> joins with the straight wall <NUM> and has its largest diameter at its outlet end which is at the outlet surface 96b. The tapered or frustoconical wall <NUM> has a continuously increasing diameter as it extends along its length from its inlet end to its outlet end. The tapered or frustoconical wall <NUM> may extend along a small section of the length of the hole <NUM>, along half or the length of the hole <NUM>, or along almost the entire length of the hole <NUM>. In each hole <NUM>, the central axis <NUM> of the straight wall <NUM> and the central axis <NUM> of the tapered or frustoconical wall <NUM> are aligned with each other. The central axis <NUM>/<NUM> of each hole <NUM> in the central row <NUM> is aligned with each other and is transverse to the centerline <NUM> of the body <NUM>. The central axis <NUM> of the straight wall <NUM> and the central axis <NUM> of the tapered or frustoconical wall <NUM> of each hole <NUM> in the array which is offset from the central row <NUM> of holes <NUM> are at an angle to each other, and the tapered or frustoconical wall of each hole <NUM> is angled relative to the plane formed by the centerline <NUM> of the body <NUM>. The holes <NUM> in the rows adjacent to the central row <NUM> are defined as the second rows; the holes <NUM> in the rows adjacent to the second rows are defined as the third rows; the holes <NUM> in the rows adjacent to the third rows are defined as the fourth rows; and so forth. As the rows progress outwardly from the central row <NUM>, the angle increases. As an example, the holes <NUM> in the second row are angled at an angle α of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the third row are angled at an angle β of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the fourth row are angled at an angle γ of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the fifth row are angled at an angle Δ of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the sixth row are angled at an angle ε of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the seventh row are angled at an angle η of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the eight row are angled at an angle θ of <NUM> degrees relative to the centerline <NUM>; the holes <NUM> in the ninth row are angled at an angle κ of <NUM> degrees relative to the centerline <NUM>. More than or fewer than nine rows of holes <NUM> can be provided. The central axis <NUM> of the straight wall <NUM> of each hole <NUM> in the rows adjacent to the central row <NUM> is parallel to each other and is transverse to the centerline <NUM>. By angling the holes <NUM> which are not in the center row in this manner, the food product is directed to the middles of the mold cavities <NUM>. As an alternative in this embodiment, the holes <NUM> in the central row <NUM> may be straight, that is, the holes <NUM> have a uniform diameter along its length.

The holes <NUM> in the fill plate <NUM> may be a combination any of the types of holes <NUM> shown.

The outlet surface 96b of the body <NUM> is in in close proximity to, but spaced from, the outer surface of the drum <NUM>. The body <NUM> extends for a length which corresponds approximately to, or just slightly greater than, the distance spanned by the row of mold cavities <NUM> in the drum <NUM>. A sealing mechanism or layer (not shown) may be disposed on outlet surface of the body <NUM> to ensure adequate close contact with the drum <NUM> and to prevent food product from leaking from the mold cavities <NUM> once the mold cavities <NUM> are filled.

When the body <NUM>, the drum <NUM> and the inner platen <NUM> are assembled together, the holes <NUM> in the inner platen <NUM> are offset from the holes <NUM> in the body <NUM>. In addition, the body <NUM> has substantially more holes <NUM> than the number of holes <NUM> in the inner platen <NUM>.

In an embodiment, the body <NUM> is mounted in outer platen <NUM> which forms a frame for the body <NUM>. The outer platen <NUM> is formed from a body <NUM> having an inlet surface 120a which is planar and an outlet surface 120b which is curved in accordance with the radius of curvature of the drum <NUM>. A passageway <NUM> is provided through the body <NUM> and extends from the inlet surface 120a to the outlet surface 120b. The body <NUM> seats within the passageway <NUM>. In an embodiment, the outer platen <NUM> is sandwiched between the pump box <NUM> and the drum <NUM>, and is free floating relative to the pump box <NUM> and drum <NUM>. In an embodiment, the outer platen <NUM> is affixed to the housing <NUM> of the pump box <NUM> by suitable means such as bolts, and is spaced from the drum <NUM>.

As shown in <FIG>, the wear plate <NUM> is formed from a body <NUM> having a first surface 124a and a second surface 124b defined by parallel side edges 124c, 124d and parallel end edges 124e, 124f. The wear plate <NUM> is formed of metal. The first and second surfaces 124a, 124b are planar. A length of the wear plate <NUM> is defined between the side edges 124c, 124d. The body <NUM> has a central perforated portion <NUM> with a non-perforated portion <NUM> extending around the perimeter of the central perforated portion <NUM> and between the central perforated portion <NUM> and the edges 124c, 124d, 124e, 124f. An array of a plurality of distinct holes <NUM> are provided through the central perforated portion <NUM> of the body <NUM>. The walls <NUM> forming the holes <NUM> are straight from the first surface 124a to the second surface 124b, that is each hole <NUM> has a uniform diameter along its length from the first surface 124a to the second surface 124b. The central axis of each hole <NUM> is parallel to each other. In an embodiment, the holes <NUM> in the wear plate <NUM> have the same diameter as the holes <NUM> in the body <NUM>. In an embodiment, the holes <NUM> in the wear plate <NUM> have a diameter of <NUM> to <NUM> (<NUM> to <NUM> inches). The wear plate <NUM> has two pairs of recesses <NUM> in each surface 124a, 124b in the non-perforated portion <NUM> proximate to, but spaced from, the side edges 124c, 124d. When the wear plate <NUM> is assembled with the body <NUM>, the holes <NUM> in the wear plate <NUM> are aligned with the holes <NUM> in the body <NUM>. The wear plate <NUM> has a plurality of apertures <NUM> through the non-perforated portion <NUM> proximate to, but spaced from, the end edges 124e, 124f.

The wear plate <NUM> can be assembled with the body <NUM> with either the first surface 124a abutting against the body <NUM> or with the second surface 124b abutting against the body <NUM> as the wear plate <NUM> is identically formed on both surfaces 124a, 124b.

The stripper plate <NUM> is disposed between the wear plate <NUM> and the pump box <NUM> and is capable of reciprocal movement relative to the wear plate <NUM> and the pump box <NUM>. The stripper plate <NUM> is formed of metal. As shown in <FIG>, the stripper plate <NUM> is formed from a body <NUM> having an inlet surface 136a and an outlet surface 136b defined by parallel side edges 136c, 136d and parallel end edges 136e, 136f. The inlet and outlet surfaces 136a, 136b are planar. A length of the stripper plate <NUM> is defined between the side edges 136c, 136d. The body <NUM> has a central perforated portion <NUM> with a non-perforated portion <NUM> extending around the perimeter of the central perforated portion <NUM> and between the central perforated portion <NUM> and the edges 136c, 136d, 136e, 136f. An array of a plurality of distinct holes <NUM> are provided through the central perforated portion <NUM> of the body. Each hole <NUM> in the array may be straight as it extends from the inlet surface 136a to the outlet surface 136b such that it has a uniform diameter along its length. Each of the holes <NUM> in the array or predetermined ones of the holes <NUM> in the array may have a tapered or frustoconical wall <NUM> extending from the inlet surface 136a and a straight wall <NUM> extending from the outlet end of the tapered or frustoconical wall <NUM> to the outlet surface 136b. The tapered or frustoconical wall <NUM> has its greatest diameter at its inlet end which is at the inlet surface 136a of the stripper plate <NUM> and has its smallest diameter at its outlet end which is at the junction of the tapered or frustoconical wall <NUM> and the straight wall <NUM>. The tapered or frustoconical wall <NUM> has a continuously reducing diameter as it extends along its length from its inlet end to the outlet end. The straight wall <NUM> has a uniform diameter along its length. The holes <NUM> may be a combination of both types. In an embodiment, the holes <NUM> in the stripper plate <NUM> are aligned in rows and columns. In an embodiment, the holes <NUM> in the stripper plate <NUM> have the same diameter as the holes <NUM> in the body <NUM>. In an embodiment, the holes <NUM> in the stripper plate <NUM> have a diameter of <NUM> to <NUM> (<NUM> to <NUM> inches).

In a first embodiment as shown in <FIG> and <FIG>, the holes <NUM> in the stripper plate <NUM> are aligned in rows and columns and when assembled with the wear plate <NUM> and in the fill plate <NUM>, the holes <NUM> in the stripper plate <NUM> are aligned with the holes <NUM> in the wear plate <NUM> and the holes <NUM> in the body <NUM> when in a first position, and when the stripper plate <NUM> is shifted, the holes <NUM> in the stripper plate <NUM> are offset from the holes <NUM> in the wear plate <NUM> and in the holes <NUM> in the body <NUM> when in a second position. This forms a seal off version of the stripper plate <NUM>.

In a second embodiment as shown in <FIG>, the number of holes <NUM> in the stripper plate <NUM> are doubled from the first embodiment to form a non-seal off version of the stripper plate <NUM>. A first column of holes <NUM> is defined at the first end of the stripper plate <NUM> and a second column of holes <NUM> is defined next to the first column of holes <NUM>. The first and second columns of holes <NUM> alternate along the length of the stripper plate <NUM>. When the stripper plate <NUM> is assembled with the wear plate <NUM> and in the fill plate <NUM>, the first columns of holes <NUM> in the stripper plate <NUM> are aligned with the holes <NUM> in the wear plate <NUM> and in the holes <NUM> in the body <NUM> when in a first position, and when the stripper plate <NUM> is shifted, the second columns of holes <NUM> are aligned with the holes <NUM> in the wear plate <NUM> and in the holes <NUM> in the body <NUM> when in a second position.

The stripper plate <NUM> is connected to the wear plate <NUM> by retainer bars <NUM> attached to the wear plate <NUM> see <FIG> and <FIG>. In the prior art, as disclosed in United States Publication No. <CIT>, the stripper plate was slidably attached to the fill plate by a plurality of spacers which had a thickness that is slightly greater than the thickness of the stripper plate and a plurality of bracket bars; the spacers and the bars being mounted by a plurality of fasteners. In the present disclosure, each retainer bar <NUM> combines the two prior art components into a single retainer bar <NUM>. As best shown in <FIG>, the retainer bar <NUM> has an elongated body <NUM> having first and second surfaces 152a, 152b defined by parallel side edges 152c, 152d and parallel end edges 152e, 152f. A length is defined along the body <NUM> between the side edges 152c, 152d. A recess <NUM> is machined into the elongated body <NUM> along its length and has a first part 154a and a second part 154b. The first part 154a of the recess <NUM> is formed from a first planar wall <NUM> which extends from the end edge 152f and is offset from the second surface 152b and a second planar wall <NUM> which extends from the second surface 152b and is perpendicular to the first wall <NUM>. The second part 154b is formed at the junction between the first and second walls <NUM>, <NUM> and is form a curved wall <NUM>. The curved wall <NUM> is offset from the second surface 152b at a greater distance than the first wall <NUM>. The elongated body <NUM> has a plurality of spaced apart apertures <NUM> therethrough which will accept fasteners <NUM>. The apertures <NUM> are offset from the recess <NUM>.

Each retainer bar <NUM> is attached to the wear plate <NUM> by a plurality of the fasteners <NUM> that extend through the apertures <NUM> and through the associated apertures <NUM> in the wear plate <NUM>. The second surface 152b of each retainer bar <NUM> abuts against one of the surfaces 124a, 124b of the wear plate <NUM> (depending upon which way the wear plate <NUM> is used).

The stripper plate <NUM> seats within the recesses <NUM> such that the edges 136e, 136f abut against the second wall <NUM>, the inlet surface 136a abuts against the first wall <NUM> of the retainer bar <NUM>, and the outlet surface 136b abuts against the first or second surface 124a, 124b of the wear plate <NUM> (depending upon which way the wear plate <NUM> is used).

The stripper plate <NUM> and the wear plate <NUM> seat within the pump box <NUM>. The stripper plate <NUM> is proximate to the feed openings <NUM>, <NUM> in the pump box <NUM>. The planar inlet surface 96a of the body <NUM> which forms the fill plate <NUM> seats against the first or second surface 124a, 124b of the wear plate <NUM> (depending upon which way the wear plate <NUM> is used). Thereafter, fasteners, such as bolts, are passed through the pump box <NUM>, through the wear plate <NUM> and through the fill plate <NUM> to connect the pump box <NUM>, the stripper plate <NUM>, the wear plate <NUM> and the fill plate <NUM> together.

As disclosed in <CIT>, in an embodiment, two rods 146a, 146b, see <FIG>, have disk shaped heads <NUM> that are in contact with the side edges 136c, 136d of the stripper plate <NUM>. The rods 146a, 146b extend through the side walls of the pump box housing <NUM> and are connected to respective first and second drive mechanisms 147a, 147b, such as hydraulic cylinders. To move the stripper plate <NUM> relative to the wear plate <NUM>, the first drive mechanism 147a is activated to extend the rods 146a and move the stripper plate <NUM> in a first direction thereby causing the rods 146b to retract within the second drive mechanism 147b, and thereafter the second drive mechanism 147b is activated to extend the rods 146b and move the stripper plate <NUM> in a second, opposite direction thereby causing the rods 146a to retract within the first drive mechanism 147a. This is repeated to cause the stripper plate <NUM> to slide back and forth across the wear plate <NUM> in a reciprocating manner. The heads <NUM> of the rods <NUM> seat within the recesses <NUM> of the wear plate <NUM> to abut against the side edges 136c, 136d of the stripper plate <NUM> to sever any residual food product fibers which may be caught in the holes <NUM> of the wear plate <NUM> after each time the food product is passed through the holes <NUM> of the wear plate <NUM>. The recesses <NUM> provide a running clearance to allow the stripper plate <NUM> to shift relative to the wear plate <NUM>. The operation of the stripper plate <NUM> is discussed in further detail in <CIT>, published as <CIT>.

As shown in <FIG>, the stripper plate <NUM> has been modified to include a pair of recess or apertures <NUM> into which the heads <NUM> of the rods <NUM> are seated. A pair of spaced apart apertures <NUM> are provided on surface 136a and on the same side of the stripper plate <NUM>, for example, proximate to edge 136c. Alternatively, recesses may be provided on each surface of the stripper plate <NUM>. Rods <NUM> extend through the same side wall of the pump box housing <NUM> and are connected to a single drive mechanism <NUM>, such as an electric actuator or a hydraulic cylinder, by a coupler <NUM>. The drive mechanism <NUM> is mounted on a stationary frame <NUM> connected to the pump box housing <NUM>. The drive mechanism <NUM> includes a piston <NUM> which can be extended from a cylinder <NUM> or can be retracted into the cylinder <NUM>. The piston <NUM> is coupled to the rods <NUM> by the coupler <NUM>. In this embodiment, the piston <NUM> of the drive mechanism <NUM> is linearly aligned with the rods <NUM>. To move the stripper plate <NUM> relative to the wear plate <NUM>, the drive mechanism <NUM> is activated to extend the piston <NUM> from the cylinder <NUM>, thereby moving the rods <NUM> and the stripper plate <NUM> in a first direction relative to the wear plate <NUM>, and thereafter the drive mechanism <NUM> is activated to retract the piston <NUM> into the cylinder <NUM>, thereby moving the rods <NUM> and the stripper plate <NUM> in a second, opposite direction relative to the wear plate <NUM>. This is repeated to cause the stripper plate <NUM> to slide back and forth across the wear plate <NUM> in a reciprocating manner to sever any residual food product fibers which may be caught in the holes <NUM> of the wear plate <NUM> after each time the food product is passed through the holes <NUM> of the wear plate <NUM>. The recesses <NUM> in the wear plate <NUM> may be eliminated as recesses <NUM> are not used in this embodiment.

As shown in <FIG>, the modified stripper plate <NUM> and the drive mechanism <NUM> of <FIG> are used and the specifics are not repeated. The rods <NUM> extend through a side wall of the pump box housing <NUM> and are connected to the single drive mechanism <NUM> by a coupling arrangement <NUM>. In this embodiment, the piston <NUM> of the drive mechanism <NUM> is not linearly aligned with the rods <NUM>, and instead is perpendicular to the rods <NUM> as a result of the coupling arrangement <NUM>. In this embodiment, the coupling arrangement <NUM> includes a first link <NUM> having a first end 184a pivotally attached to the end 178a of the piston <NUM> and second end 184b pivotally attached to a stationary frame <NUM> connected to the pump box housing <NUM>, a second link <NUM> having a first end 186a pivotally attached to the end 178a of the piston <NUM> and second end 186b pivotally attached to a first end 188a of a rod <NUM>, the rod <NUM> extending through the stationary frame <NUM>. The rod <NUM> and the second end 184b of the first link <NUM> may be linearly aligned. A second end 188b of the rod <NUM> is coupled to the rods <NUM> by the coupler <NUM>. To move the stripper plate <NUM> relative to the wear plate <NUM>, the drive mechanism <NUM> is activated to move the rods <NUM> and the stripper plate <NUM> in a first direction relative to the wear plate <NUM>, and thereafter the drive mechanism <NUM> is activated to move the rods <NUM> and the stripper plate <NUM> in a second, opposite direction relative to the wear plate <NUM>. When the piston <NUM> is extended from the cylinder <NUM>, the first ends 184a, 186a of the first and second links <NUM> move away from the cylinder <NUM> which causes the rod <NUM> to translate in a direction perpendicular to the piston <NUM> and toward the wear plate <NUM>. This movement of the rod <NUM> causes movement of the rods <NUM> and then movement of the stripper plate <NUM> in the first direction. When the piston <NUM> is retracted into the cylinder <NUM>, the first ends 184a, 186a of the first and second links <NUM> move toward the cylinder <NUM> which causes the rod <NUM> to translate in a direction perpendicular to the piston <NUM> and away from the wear plate <NUM>. This movement of the rod <NUM> causes movement of the rods <NUM> and then movement of the stripper plate <NUM> in the second, opposite direction. This is repeated to cause the stripper plate <NUM> to slide back and forth across the wear plate <NUM> in a reciprocating manner to sever any residual food product fibers which may be caught in the holes <NUM> of the wear plate <NUM> after each time the food product is passed through the holes <NUM> of the wear plate <NUM>. The recesses <NUM> in the wear plate <NUM> may be eliminated as recesses <NUM> are not used in this embodiment.

The rotary molding system <NUM> may include a knock-out mechanism <NUM> which is known in the art. Such a knock-out mechanism is disclosed in <CIT>,.

In operation, as the drum <NUM> rotates, the mold cavities <NUM> rotate past the holes <NUM> in the fill plate <NUM>. Food product is pumped from the hopper <NUM> to the rotary molding system <NUM> by the feeder portion <NUM>. Food product passes through feed openings <NUM>, <NUM> in the pump box <NUM>, through the holes <NUM> in the stripper plate <NUM>, through the holes <NUM> in the wear plate <NUM>, and through the holes <NUM> in the body <NUM> to fill the mold cavities <NUM>. As the food product is injected into the mold cavities <NUM>, any air within the mold cavities <NUM> is discharged via the air release passageway formed by the holes <NUM>, the recesses <NUM> and the elongated opening <NUM> of the central perforated portion <NUM> of the inner platen <NUM>. The mold cavities <NUM> are rotated from a fill position to an eject position where the knock-out mechanism <NUM> is activated.

During operation, the stripper plate <NUM> shifts relative to the wear plate <NUM> from the first position to the second position, then back to the first position and then to the second position and so on. Because the stripper plate <NUM> shifts, the wear plate <NUM> may become worn. When the wear plate <NUM> becomes worn on one surface, for example surface 124a, the wear plate <NUM> is flipped over so that the surface 124b is in contact with the shifting stripper plate <NUM> (the retainer bars <NUM> are detached from the one surface and reattached to the other surface during this flipping). When both surfaces 124a, 124b become worn, the wear plate <NUM> is replaced. Since the wear plate <NUM> is a planar plate with straight holes <NUM>, this is a relatively inexpensive component to replace. The wear plate <NUM> is much less expensive to replace than replacing the curved body <NUM> which forms the fill plate <NUM>.

During rotation of the drum <NUM>, the drum facing surface 58a of the inner platen <NUM> is disposed in proximity to a portion of the inner surface 48b of the drum <NUM> with the rollers <NUM> engaging the inner surface 48b of the drum <NUM>. Therefore, the drum <NUM> does not rub against the entire surface of the inner platen <NUM> and instead the drum <NUM> is only in contact with the rollers <NUM>. This decreases the motor amperage required to rotate the drum <NUM>. As the drum <NUM> rotates into the fill position, the mold cavities <NUM> in the drum <NUM> become disposed between the fill plate body <NUM> and the inner platen <NUM>, with the drum facing surface 58a of the inner platen <NUM> serving as the bottom surface of the mold cavities <NUM> as the mold cavities <NUM> rotate through the region where it is in contact with the fill plate body <NUM> and the inner platen <NUM>. The rollers <NUM> allow for the free rotation of the drum <NUM> relative to the inner platen <NUM>. The inner platen <NUM> remains stationary as the drum <NUM> rotates past the inner platen <NUM>. The support structure <NUM> behind the inner platen <NUM> provides support for the inner platen <NUM> as pressure from filling the mold cavities <NUM> is exerted into the mold cavities <NUM> during the filling process.

In the seal off embodiment of the stripper plate <NUM> shown in <FIG> and <FIG>, when the stripper plate <NUM> is in the first position, food product can flow therethrough to fill the mold cavities <NUM>, but when the stripper plate <NUM> is moved to be in the second position to sever the food product, food product cannot flow therethrough. When the stripper plate <NUM> is in the second position, the drum <NUM> is indexed to rotate the next set of mold cavities <NUM> into position. The stripper plate <NUM> moves continuously between the first and second positions.

In the non-seal off embodiment of the stripper plate <NUM> shown in <FIG>, when the stripper plate <NUM> is in the first position, food product can flow therethrough to fill the mold cavities <NUM>, and when the stripper plate <NUM> is in the second position, food product can flow therethrough to fill the mold cavities <NUM>. To accommodate this, the drum <NUM> is constantly rotating. Each time the stripper plate <NUM> shifts, the food product is severed.

The rotary molding system <NUM> can be pivoted relative to the cabinet <NUM> as is known in the art, <CIT>. A sensor <NUM>, such as a proximity sensor or an ultrasonic sensor, may be provided on the cabinet <NUM> to monitor the position of the rods <NUM> to ensure that the rods <NUM> are retracted before pivoting. The sensor <NUM> is in communication with a control system (not shown) which is used to alert an operator if the rods <NUM> are not properly retracted. This aids in deterring damage to the rotary molding system <NUM>.

Claim 1:
A rotary molding system configured to mold food products comprising:
a stripper plate (<NUM>) having an inlet surface (136a) and an outlet surface (136b), the inlet surface (136a) being in communication with a feed source, the stripper plate (<NUM>) having a plurality of holes (<NUM>) therethrough through which food product is configured to pass;
a wear plate (<NUM>) having a planar first surface (124a) and a planar second surface (124b), the first surface (124a) of the wear plate (<NUM>) abutting against the outlet surface (136b) of the stripper plate (<NUM>), the stripper plate (<NUM>) being capable of moving in a reciprocating manner relative to the wear plate (<NUM>), the wear plate (<NUM>) having a plurality of holes (<NUM>) therethrough through which food product is configured to pass;
a fill plate (<NUM>) having an inlet surface (96a) and an outlet surface (96b), the inlet surface (96a) of the fill plate (<NUM>) abutting against the second surface (124b) of the wear plate (<NUM>), the fill plate (<NUM>) having a plurality of holes (<NUM>) therethrough through which food product is configured to pass, the wear plate (<NUM>) being releasably attached to the fill plate (<NUM>); and
a cylindrical drum (<NUM>) having an inner surface (48a), an outer surface (48b) and mold cavities (<NUM>) into which food product is configured to be deposited, the outer surface (48b) of the drum (<NUM>) being proximate to the outlet surface of the fill plate (<NUM>); and
wherein the wear plate (<NUM>) is releasably attached to the stripper plate (<NUM>) by a plurality of retainer bars (<NUM>) and wherein each retainer bar (<NUM>) defines a recess (<NUM>) into which the stripper plate (<NUM>) seats, the stripper plate (<NUM>) being capable of being removed relative to the retainer bars (<NUM>).