Patent Description:
The invention is defined by a folding conveyor according to claim <NUM> and a method of transitioning a conveyor from an operational configuration to a transport configuration according to claim <NUM>.

Referring to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, <FIG> schematically illustrate a conveyor <NUM> having a tail end <NUM> to which material is supplied and a head end <NUM> from which material is deposited (e.g., by a conveyor belt extending along the length of the conveyor). The head end <NUM> optionally includes a forward pulley <NUM>. The forward pulley <NUM> is optionally driven by a motor <NUM>. In operation, a conveyor belt (not shown) is optionally driven about the driven forward pulley <NUM> and the rear pulley <NUM>. In other embodiments the rear pulley <NUM> may alternatively or additionally be driven by a motor or other mechanism. A tow eye (not shown) is optionally provided at or near the tail end <NUM> and/or to the forward end or other part of the conveyor for towing and/or reconfiguration of the conveyor <NUM>.

The conveyor <NUM> optionally has a conveyor frame <NUM> comprised of a plurality of sections. The sections of the conveyor frame <NUM> are optionally foldable about pivotal connections. The sections of the conveyor frame <NUM> is optionally selectively foldable between a transport configuration (e.g., as illustrated in <FIG>) and an operational configuration (e.g., as illustrated in <FIG>). In the transport configuration, the sections are optionally stacked such that each section is disposed generally parallel to the other sections.

In the illustrated embodiment, the conveyor frame <NUM> comprises tail section <NUM>, a medial section <NUM>, and a head section <NUM>. The tail section <NUM> is optionally pivotally coupled to the medial section <NUM> by a pivot assembly 200a. The pivot assembly 200a is optionally disposed generally at an underside of the conveyor frame <NUM> on the view of <FIG>, and optionally defines a pivot axis generally beneath (and/or on an lower side of) the conveyor frame when the conveyor frame is in a horizontal orientation. The medial section <NUM> is optionally pivotally coupled to the head section <NUM> by a pivot assembly 200b. The pivot assembly 200b is optionally disposed generally at an upper side of the conveyor frame <NUM> on the view of <FIG>, and optionally defines a pivot axis disposed at an upper end of the conveyor frame (and/or at least partially above the conveyor frame) when the conveyor frame is in a horizontal orientation. In other embodiments, the vertical positions of the pivot assemblies 200a, 200b may be reversed from those shown in the illustrated embodiment. In some embodiments, the conveyor frame comprises two or more frame sections optionally foldable about pivot assemblies in order to stack the conveyor frame (e.g., reconfigure the conveyor frame from an operational configuration to a transport configuration).

Turning to <FIG>, a conveyor <NUM> is shown having a support assembly <NUM> rollingly supporting the conveyor at an incline angle relative to the ground. The conveyor <NUM> optionally includes a conveyor frame <NUM> having a tail section <NUM> pivotally coupled to a medial section <NUM> by a pivot assembly 200a. The conveyor frame <NUM> optionally includes a head section <NUM> pivotally coupled to the medial section <NUM> by a pivot assembly 200b. The upper and lower positions of the pivot assemblies may be reversed in other embodiments.

Turning to <FIG>, a conveyor <NUM> is shown having a support assembly <NUM> rollingly supporting the conveyor and optionally including an actuator for selectively adjusting an incline angle A of the conveyor relative to the ground. The conveyor <NUM> optionally includes a conveyor frame <NUM> having a tail section <NUM> pivotally coupled to a medial section <NUM> by a pivot assembly 200a. The conveyor frame <NUM> optionally includes a head section <NUM> pivotally coupled to the medial section <NUM> by a pivot assembly 200b. The upper and lower positions of the pivot assemblies may be reversed in other embodiments.

Turning to <FIG>, the pivot assemblies 200a and 200b are shown in more detail according to one embodiment. The pivot assemblies <NUM> may comprise one or more pairs of pivot plates <NUM>, <NUM>. First pivot plate <NUM> is optionally mounted (e.g., by welding) to a first section of the conveyor frame (e.g., the tail section <NUM> as illustrated in <FIG>). Second pivot plate <NUM> is optionally mounted (e.g., by welding) to a second section of the conveyor frame (e.g., the medial section <NUM> as illustrated in <FIG>). The pivot plates <NUM>, <NUM> are optionally pivotally connected about a joint <NUM> such that the associated conveyor sections may pivot about the joint <NUM>. Each joint <NUM> optionally defines a pivot axis Ap which is optionally generally at a lower end of (and/or at least partially below) the conveyor frame <NUM> in the assembly 200a and optionally generally at an upper end of (and/or at least partially above) the conveyor frame <NUM> in the assembly 200b.

As shown in <FIG>, the pivot assemblies <NUM> may comprise a first plate subassembly <NUM> disposed generally on a first lateral side of the conveyor and a second plate subassembly <NUM> disposed generally on a second lateral side of the conveyor. The joints <NUM> in the first and second subassemblies are optionally aligned along the pivot axis Ap.

The pivot assemblies <NUM> may be selectively lockable in the transport and/or operational configurations. For selectively locking the conveyor frame <NUM> in the operational configuration, the pivot plate <NUM> optionally includes an opening <NUM> which may be aligned with a corresponding opening (not shown) in the pivot plate <NUM> such that the relative position of the openings may be selectively locked or unlocked (e.g., by inserting or removing a pin P). For selectively locking the conveyor frame <NUM> in the transport configuration, the pivot plate <NUM> optionally includes an opening <NUM> which may be aligned with a corresponding opening (not shown) in the pivot plate <NUM> such that the relative position of the openings may be selectively locked or unlocked (e.g., by inserting or removing the pin P). As described with respect to other embodiments herein, in alternative embodiments the frame sections may be selectively locked to one another (e.g., by fasteners such as bolts).

In alternative embodiments, the pivot assemblies <NUM> may comprise one or more pivot structures disclosed in US. Patent No. <CIT> and<CIT>.

Turning to <FIG>, conveyors 100a and 100b are shown in their transport configurations stored in a container <NUM> (e.g., a sea container, cargo trailer, etc.). A height of the conveyor <NUM> in the transport configuration (e.g., the cumulative height of the conveyor frame sections) is optionally less than a standard container height dimension, e.g., a minimum height (and/or inlet portal height) of a standard container. The standard container height dimension may be <NUM> feet or approximately <NUM> feet (e.g., <NUM> meters or <NUM> meters). A width of the conveyor <NUM> in the transport configuration (e.g., the width of the widest conveyor frame section) is optionally less than a standard container width dimension, e.g., a minimum width (and/or inlet portal width) of a standard container. The standard container width dimension may be <NUM> feet or approximately <NUM> feet (e.g., <NUM> meters or <NUM> meters). In some embodiments, the width of the conveyor <NUM> may be less than one half of the standard container width dimension such that a plurality of conveyors 100a, 100b may be stored in the container as illustrated in <FIG>. A length of the conveyor <NUM> in the transport configuration (e.g., the length of the longest conveyor frame section which in some embodiments may be the first, second or third frame section) is optionally less than a standard container length dimension, e.g., a minimum length (and/or inlet portal length) of a standard container. The standard container length dimension may be <NUM> feet or approximately <NUM> feet (e.g., <NUM> meters).

Referring to <FIG>, a conveyor <NUM> is illustrated having a conveyor frame <NUM> comprising two frame sections <NUM> and <NUM>. The frame sections <NUM>, <NUM> optionally fold relative to one another about a hinge <NUM>. The hinge <NUM> optionally joins upper portions (e.g., upper truss chords) of the frame sections <NUM>, <NUM>. In the various embodiments described herein, each chord of the conveyor frame may comprise any structure such as an angle (see <FIG>), I-beam, square beam, rectangular beam, beam, partial beam, channel beam, channel, or assembly or combination of structures. The hinge <NUM> may comprise one of the hinge embodiments described elsewhere herein. The frame sections <NUM>, <NUM> each support a plurality of idler assemblies <NUM> (e.g., 1100a and 1100d) configured to operably support an endless belt B. A subset <NUM> of idler assemblies (e.g., in a loading zone near a rearward end of the conveyor) are optionally closer together than the other idler assemblies. The frame section <NUM> operably supports a tail pulley assembly <NUM>. The frame section <NUM> operably supports a head pulley assembly <NUM>. The head and tail pulley assemblies cooperatively support the belt B in operation; in some embodiments the head pulley assembly <NUM> is driven by a motor in order to advance the belt B.

Referring to <FIG>, one or more idler assemblies <NUM> comprises a troughing idler assembly as illustrated. The idler assembly <NUM> comprises a horizontal medial roll <NUM> which may be rollingly (or rotationally) supported on left and right inner perch supports <NUM>-<NUM>, <NUM>-<NUM>. The idler assembly comprises a left angled roll <NUM>-<NUM> rollingly supported on an outer perch support <NUM>-<NUM> and an inner perch support <NUM>-<NUM>. The idler assembly <NUM> comprises a right angled roll <NUM>-<NUM> rollingly supported on a right inner perch support <NUM>-<NUM> and a right outer perch support <NUM>-<NUM>. The inner and outer perch supports <NUM>, <NUM> are optionally supported on a cross brace <NUM>. The belt B is optionally operably supported in a generally troughing shape on the rolls <NUM>, <NUM>; e.g., the rolls <NUM>, <NUM> optionally roll as the belt B moves longitudinally (e.g., along conveyance direction Dc) over the rolls. It should be appreciated that although the exemplary embodiment shown is a certain style of troughing or carry idler, in other embodiments the idler assembly <NUM> may comprise a garland, a flat carrier, wire rope, or a variable pitch idler, among others. In various embodiments, the idler roller assembly may comprise one, two, three or more idler rollers which may be arranged in a symmetrical arrangement, in a non-symmetrical arrangement, or in a horizontal or parallel fashion.

Returning to <FIG>, the conveyor optionally includes a support assembly <NUM>. The support assembly <NUM> optionally includes an undercarriage <NUM> coupled (e.g., pivotally coupled) to the conveyor frame <NUM> (e.g., to the frame section <NUM>). The undercarriage <NUM> is optionally rollingly supported by a wheel assembly <NUM>. In some embodiments, the conveyor may be supported and/or moveable on tracks or other structure. A brace <NUM> is optionally coupled (e.g., pivotally coupled) at a first end thereof to the undercarriage <NUM>; the brace <NUM> is optionally coupled (e.g., pivotally coupled) at a second end thereof to the conveyor frame <NUM> (e.g., to the frame section <NUM>).

Referring to <FIG>, an overall length Lo of the conveyor <NUM> in the operational configuration may be measured between a rearward end (e.g., towing eye) of the conveyor and a forward end (e.g., head pulley assembly) of the conveyor. The length Lo may comprise the sum of the lengths L1, L2 of the frame sections <NUM>, <NUM>, respectively. Referring to <FIG>, the length L1 of the frame section <NUM> is optionally less (e.g., slightly less) than the length Lc (e.g., <NUM> feet) of container <NUM> or another container in which the conveyor <NUM> is stored. The transport length Lt of the conveyor frame <NUM> in the transport configuration is optionally equal to or approximately the same as (e.g., slightly greater than) the length L1 of frame section <NUM>.

Referring to <FIG>, the conveyor frame <NUM> is illustrated in a transport configuration. The conveyor frame <NUM> optionally reconfigures into the transport configuration by rotating the frame section <NUM> about the hinge <NUM> (e.g., pivot assembly) from an operational position 1020A through a plurality of intermediate positions (e.g., 1020B, 1020C) into a transport position 1020D. In the transport position 1020D, the frame section <NUM> is optionally parallel with the frame section <NUM>. In the transport position 1020D, the frame section <NUM> optionally rests on top of the frame section <NUM> (e.g., at one or more supports or stops along the length of the frame section <NUM> or along the length of the frame section <NUM>). In some embodiments, one or more chords (which in some embodiments described herein may be described as rails) of frame section <NUM> rest on top of one or more chords of frame section <NUM> In the transport position 1020D, the frame section <NUM> is optionally upside-down relative to the operational position 1020A.

Referring to <FIG> and <FIG>, the conveyor <NUM> (e.g., the conveyor frame <NUM> in its transport configuration and the support assembly <NUM>) is shown disassembled and stored in the container <NUM>. In some examples the support assembly <NUM> may be disassembled and stored above the conveyor frame <NUM>. The height of the disassembled conveyor <NUM> is optionally less than the height Hc of the container <NUM>.

Two conveyors are optionally stored on the container <NUM>. In some examples, a second conveyor frame 1002b is optionally stored in side-by-side relation with a first frame 1002a. In some examples, the second conveyor frame may have a different length and/or configuration from the first conveyor frame. The sum of the overall widths Wo of the first and second conveyor frames <NUM> are optionally less than (e.g., slightly less than) a width Wc of the container (e.g., <NUM> feet). The widths of the first and second conveyor frames may be the same or different according to various embodiments.

Referring to <FIG>, a conveyor <NUM> is illustrated having a conveyor frame <NUM> comprising three frame sections <NUM>, <NUM>, and <NUM>.

The frame sections <NUM>, <NUM> optionally fold relative to one another about a hinge <NUM>-<NUM>. The hinge <NUM>-<NUM> optionally pivotally couples upper portions (e.g., upper structural elements such as upper truss chords) of the frame sections <NUM>, <NUM>. The hinge <NUM>-<NUM> optionally comprises one of the hinge embodiments described herein. The frame section <NUM> optionally pivots in a first angular (e.g., pivotal, rotational) direction relative to the frame section <NUM> about the hinge <NUM>-<NUM>.

The frame sections <NUM>, <NUM> optionally fold relative to one another about a hinge <NUM>-<NUM>. The hinge <NUM>-<NUM> optionally pivotally couples lower portions (e.g., lower structural elements such as lower truss chords) of the frame sections <NUM>, <NUM>. The hinge <NUM>-<NUM> optionally comprises one of the hinge embodiments described herein. The frame section <NUM> optionally pivots in a second angular direction (e.g., opposite to the first angular direction) relative to the frame section <NUM> about the hinge <NUM>-<NUM>.

It should be appreciated that in some implementations, the conveyor belt may be installed on the conveyor prior to folding between the transport and operating configurations. In some such implementations, the belt may be folded at first and second folds in the transport configuration.

In the illustrated embodiment, the hinge <NUM>-<NUM> is disposed generally at or above an upper end of the conveyor frame and the hinge <NUM>-<NUM> is disposed generally at or below a lower end of the conveyor frame (e.g., when the conveyor frame is in the operational configuration and oriented horizontally). However, according to various embodiments, the positions of the hinges <NUM>-<NUM>, <NUM>-<NUM> may be reversed (e.g., the hinge <NUM>-<NUM> may be disposed at a lower end of the conveyor frame and the hinge <NUM>-<NUM> may be disposed at an upper end of the conveyor frame).

The frame sections <NUM>, <NUM>, <NUM> each support a plurality of idler assemblies <NUM> (e.g., forwardmost idler assemblies of each frame section <NUM>, 1100d, and 1100a) configured to operably support an endless belt B. A subset <NUM> of idler assemblies (e.g., in a loading zone near a rearward end of the conveyor) are optionally closer together than the other idler assemblies. The frame section <NUM> optionally operably supports a tail pulley assembly <NUM>. The frame section <NUM> optionally operably supports a head pulley assembly <NUM>. The head and tail pulley assemblies optionally cooperatively operably support the belt B (e.g., an endless belt such as a flexible belt) in operation for conveying materials (e.g., aggregate materials such as rock, stone, sand, gravel, minerals, etc.) along a conveyance direction Dc; in some embodiments the head pulley assembly <NUM> is driven by a motor in order to advance the belt B.

The conveyor <NUM> optionally includes a support assembly <NUM>. The support assembly <NUM> optionally includes an undercarriage <NUM> coupled (e.g., pivotally coupled) to the conveyor frame <NUM> (e.g., to the frame section <NUM>). The undercarriage <NUM> is optionally coupled to the conveyor frame <NUM> at a position rearward (e.g., along direction Dc) of hinge <NUM>-<NUM>. The undercarriage <NUM> is optionally rollingly supported by a wheel assembly <NUM>. A brace <NUM> (e.g., a fixed-length or telescoping brace) is optionally coupled (e.g., pivotally coupled) at a first end thereof to the undercarriage <NUM>; the brace <NUM> is optionally coupled (e.g., pivotally coupled) at a second end thereof to the conveyor frame <NUM> (e.g., to the frame section <NUM>). The brace <NUM> is optionally pivotally coupled to the conveyor frame <NUM> at a position rearward (e.g., along direction Dc) of hinge <NUM>-<NUM>.

Referring to <FIG>, a plane P intersects the tail pulley (e.g., a rotational axis thereof) and the head pulley (e.g., a rotational axis thereof). In some embodiments, the plane P extends between the hinges <NUM>-<NUM>, <NUM>-<NUM>. In some embodiments, the hinge <NUM>-<NUM> is disposed above (e.g., on a first side of) the plane P and the hinge <NUM>-<NUM> is disposed below (e.g., on a second side of, opposite the first side of) the plane P. In some embodiments, the hinge <NUM>-<NUM> is disposed below the plane P and the hinge <NUM>-<NUM> is disposed above the plane P.

Referring to <FIG>, an overall length Lo of the conveyor <NUM> in the operational configuration may be measured between a rearward end (e.g., towing eye) of the conveyor and a forward end (e.g., head pulley assembly) of the conveyor. The length Lo may comprise the sum of the lengths L1, L2, L3 of the frame sections <NUM>, <NUM>, <NUM>, respectively. Referring to <FIG>, the length L2 of the frame section <NUM> is optionally less (e.g., slightly less) than the length Lc (e.g., <NUM> feet) of container <NUM> or another container in which the conveyor <NUM> is stored. The transport length Lt of the conveyor frame <NUM> in the transport configuration is optionally equal to or approximately the same as (e.g., slightly greater than) the length L1 of frame section <NUM>.

Referring to <FIG>, the conveyor frame <NUM> is illustrated in an intermediate configuration between the operational configuration and a transport configuration. The conveyor frame <NUM> optionally reconfigures into the intermediate configuration by rotating the frame section <NUM> about the hinge <NUM>-<NUM> from an operational position 1420A through a plurality of intermediate positions (e.g., 1420B, 1420C) into an intermediate position 1420D. In the intermediate position 1420D, the frame section <NUM> is optionally generally parallel with the frame section <NUM>. In the intermediate position 1420D, the frame section <NUM> optionally rests on top of the frame section <NUM> (e.g., at one or more supports or stops and/or along the length of the frame section <NUM>). In the intermediate position 1420D, the frame section <NUM> is optionally upside-down relative to the operational position 1020A. In some implementations, in the intermediate positions 1420B, 1420C, 1420D, the frame section <NUM> remains parallel to the frame section <NUM> (e.g., in intermediate positions 1430A, 1430B, 1430C, 1430D). In alternative implementations, the frame section <NUM> may fold relative to the frame section <NUM> while the frame section <NUM> folds relative to the frame section <NUM>.

Referring to <FIG>, the conveyor frame <NUM> is shown in a transport configuration. The conveyor frame <NUM> optionally reconfigures into the transport configuration by rotating the frame section <NUM> about the hinge <NUM>-<NUM> from an intermediate position (e.g., 1430D) through a plurality of intermediate positions (e.g., 1420E, 1430F) into a transport position <NUM>. In the transport position <NUM>, the frame section <NUM> optionally rests on top of the frame section <NUM> (e.g., at one or more supports or stops and/or along the length of the frame section <NUM>). In some embodiments, one or more chords of the frame section <NUM> rest directly on one or more chords of the frame section <NUM>. In the transport position <NUM>, the frame section <NUM> is optionally in the same orientation as (e.g., parallel to) the operational position 1430A.

Referring to <FIG>, the conveyor <NUM> (e.g., the conveyor frame <NUM> in its transport configuration and the support assembly <NUM>) is shown disassembled and stored in the container <NUM>. In some examples the support assembly <NUM> may be disassembled and stored above the conveyor frame <NUM>. The height of the conveyor frame <NUM> in the transport configuration (e.g., the some of the heights of the frame sections <NUM>, <NUM>, <NUM>) is optionally less than the height Hc of the container <NUM>.

Referring to <FIG>, two conveyors are optionally stored on the container <NUM>. In some examples, a second conveyor frame 1402b is optionally stored in side-by-side relation with a first frame 1002a. In some examples, the second conveyor frame may have a different length and/or configuration from the first conveyor frame. In some examples, a motor driving the head pulley on the frame section <NUM> of a first conveyor extends above a frame section of the second conveyor when both conveyors are loaded on the container. In some examples, the first and second conveyors are oriented in opposite directions when loaded on the conveyor (e.g., with the head pulley assembly of the two conveyors pointing in opposite directions). The sum of the overall widths Wo of the first and second conveyor frames <NUM> are optionally less than (e.g., slightly less than) a width Wc of the container (e.g., <NUM> feet). The widths of the first and second conveyor frames may be the same or different according to various embodiments.

Referring to <FIG>, the frame section <NUM> is illustrated having truss chords <NUM> extending substantially along the length of the frame section (e.g., upper left chord <NUM>-1a, upper right cord <NUM>-2a, lower left chord <NUM>-1b, and lower right chord <NUM>-2b). One or more cross braces <NUM> are optionally mounted at a left end thereof to a left chord <NUM>-<NUM> and is optionally mounted at a right end thereof to a right chord <NUM>-<NUM>.

Turning to <FIG>, a plurality of struts is optionally disposed on each transverse side of each of the frame sections (e.g., the struts may be mounted to the chords of each frame section). A first subset of struts <NUM> are optionally generally parallel with one another. A second subset of struts <NUM> are optionally generally parallel with one another. One or more struts <NUM> are optionally not parallel to either subset of struts <NUM>, <NUM>. The strut <NUM> may be disposed adjacent to a hinge <NUM> between frame sections; in other embodiments, the strut <NUM> is disposed remote from a hinge.

Returning to <FIG>, each strut <NUM> is optionally mounted an upper chord at an upper portion thereof and to a lower chord at a lower portion thereof. One or more struts <NUM> is optionally mounted outboard of (e.g., farther from a central longitudinal plane of belt B along a horizontal direction than) one or more chords to which the strut is mounted. For example, strut <NUM>-<NUM> is optionally mounted outboard of (e.g., on a left side of) chords <NUM>-1a and/or <NUM>-1b. For another example, strut <NUM> is optionally mounted outboard of (e.g., on a right side of) chords <NUM>-1b and/or <NUM>-2b. Each strut <NUM> is optionally mounted to an outboard-facing face of one or more chords <NUM>. In some alternative embodiments, one or more struts may be mounted inboard of the chords to which they are mounted (e.g., for ease of manufacture and/or to reduce exposure of the struts to contact with foreign objects). A lateral clearance Lc between inboard surface of the strut and the belt (and/or outboard end of the outer conveyor roller) is optionally greater for a given overall width of the conveyor truss in some embodiments in which the struts are mounted outboard of the chords than in embodiments in which the struts are mounted inboard of the chords.

In the embodiment illustrated in <FIG>, the idler assembly <NUM> is optionally contained within the envelope (e.g., bounding volume) of the frame section. In other embodiments, the idler assembly <NUM> may extend out of the envelope of the frame section (e.g., the idler assembly <NUM> may extend upward through a plane defined by the upper ends (e.g., chords) of the frame section. In such embodiments, the idler assemblies <NUM> are optionally positioned such that the idler assemblies of one frame section (e.g., the first frame section) do not interfere with (e.g., contact) idler assemblies of a second frame section (e.g., the second frame section) when the conveyor is folded in the transport configuration.

In some embodiments, one or more chords <NUM> are disposed between a strut <NUM> mounted to the chord <NUM> and the side of belt B disposed closest to the strut <NUM> mounted to the chord <NUM>.

In some embodiments, one or more outboard ends (e.g., left and/or right ends such as outer perch supports <NUM>) of one or more idler assemblies <NUM> are disposed vertically between an upper chord <NUM> (e.g., and outboard end thereof) and a lower chord <NUM> (e.g., an outboard end thereof). In some embodiments, one or more outboard ends of idler assemblies <NUM> intersect (or are disposed adjacent to) a plane defined by outboard ends (e.g., outboard surfaces) of a pair of chords <NUM>.

The other frame sections <NUM> and <NUM> optionally have common features and/or characteristics with the frame section <NUM> described above. For example, the struts of frame sections <NUM>, <NUM> may be disposed generally outboard of the chords thereof.

Referring to <FIG>, an exemplary embodiment of the tail pulley assembly <NUM> is illustrated supported on the frame section <NUM>. The tail pulley assembly <NUM> optionally comprises a dead shaft pulley (e.g., in which the shaft is stationary in operation) as illustrated; in other embodiments, the tail pulley assembly may comprise a different style of pulley (e.g., in which the shaft rotates in operation). In some embodiments, the tail pulley assembly <NUM> may comprise and/or have one or more common features with one or more pulley embodiments described in <CIT>. The tail pulley assembly <NUM> optionally comprises a shaft <NUM> supported (e.g., in a stationary manner) on one or more supports <NUM>. The supports <NUM> may be mounted to and/or supported on a cross brace <NUM> (e.g., upper and/or lower cross brace) of the frame section <NUM>. The cross brace <NUM> is optionally mounted to and/or supported on chords <NUM>-<NUM>, <NUM>-<NUM>. The chords <NUM> are illustrated in <FIG> angles; in other embodiments, the chords may comprise beams, channel beams, channels, partial beams, or other structure including other chord embodiments described herein. Struts <NUM> are optionally mounted outboard of chords <NUM>. The tail pulley assembly <NUM> optionally comprises a pulley <NUM> having left and right bearing assemblies <NUM>-<NUM>, <NUM>-<NUM>, respectively, rollingly supported on the shaft <NUM>. In some embodiments, each bearing assembly <NUM> is optionally disposed inboard of the outboard end of pulley <NUM> closest to (e.g., adjacent to) the bearing assembly <NUM>.

Referring to <FIG>, the hinges <NUM>-<NUM>, <NUM>-<NUM> (e.g., pivot assemblies) are illustrated in more detail according to some embodiments.

Referring to <FIG>, the hinge <NUM>-<NUM> optionally includes a first hinge arm <NUM> mounted to the first frame section <NUM> (e.g., to an upper end thereof, an upper truss chord thereof, etc.) and extending upward from the first frame section. The hinge <NUM>-<NUM> optionally includes a second hinge arm <NUM> mounted to the second frame section <NUM> (e.g., to an upper end thereof, an upper truss chord thereof, etc.) and extending upward from the second frame section. A pivot <NUM> (e.g., pin, rod or other structure) optionally pivotally couples the first hinge arm <NUM> to the second hinge arm <NUM>. The pivot <NUM> of hinge <NUM>-<NUM> is optionally disposed generally at an upper end of (e.g., at least partially above) the conveyor frame <NUM> when the conveyor truss is in a horizontally extending orientation and has not been folded for transport. In some embodiments, a first hinge <NUM>-1a is mounted to on a first transverse side (e.g., right side) of the conveyor frame <NUM> and a second hinge <NUM>-1b is mounted on a second transverse side (e.g., left side) of the conveyor frame <NUM>; in such embodiments, the first and second hinges may be either joined by a common pivot <NUM> or may have separate co-axial pivots.

Referring to <FIG>, the hinge <NUM>-<NUM> optionally includes a first hinge arm <NUM> mounted to the second frame section <NUM> (e.g., to a lower end thereof, a lower truss chord thereof, etc.) and extending downward from the second frame section. The hinge <NUM>-<NUM> optionally includes a second hinge arm <NUM> mounted to the third frame section <NUM> (e.g., to a lower end thereof, a lower truss chord thereof, etc.) and extending downward from the third frame section. A pivot <NUM> (e.g., pin, rod or other structure) optionally pivotally couples the first hinge arm <NUM> to the second hinge arm <NUM>. The pivot <NUM> of hinge <NUM>-<NUM> is optionally disposed generally at a lower end of (e.g., at least partially below) the conveyor frame <NUM> when the conveyor truss is in a horizontally extending orientation and has not been folded for transport. In some embodiments, the conveyor frame <NUM> optionally includes downwardly extending structure (e.g., one or more stops <NUM> mounted to the conveyor truss) which optionally prevents the hinge <NUM>-<NUM> from contacting the ground when the conveyor truss is rested on the ground before being folded for transport; in other examples, the hinge may be positioned such that the truss chords protect the hinge from contacting the ground, or alternatively structure other than the truss chords may be used to protect the hinge from contacting the ground. In some embodiments, a first hinge <NUM>-2a is mounted to on a first transverse side (e.g., right side) of the conveyor frame <NUM> and a second hinge <NUM>-2b is mounted on a second transverse side (e.g., left side) of the conveyor frame <NUM>; in such embodiments, the first and second hinges may be either joined by a common pivot <NUM> or may have separate co-axial pivots.

Referring to <FIG>, the first and second frame sections <NUM>, <NUM> are optionally selectively retained in position relative to one another (e.g., in the operational configuration) at one or more connections <NUM>-<NUM>. The second and third frame sections <NUM>-<NUM>, <NUM>-<NUM> are optionally selectively retained in position relative to one another (e.g., in the operational configuration) at one or more connections <NUM>-<NUM>.

Each connection <NUM> optionally includes a fastener <NUM> (e.g., a removable fastener such as a nut-and-bolt assembly or a pin). The fastener <NUM> optionally selectively rigidly couples a first portion <NUM> (e.g., plate, tab, lip, or other structure) of one frame section to a second portion <NUM> (e.g., plate, tab, lip, or other structure) of another frame section. The first and second portions <NUM>, <NUM> are optionally disposed generally inboard of the outboard surfaces (e.g., struts <NUM>) of the conveyor frame <NUM> and are optionally oriented in a generally inboard direction (e.g., toward a central longitudinal plane of the conveyor <NUM>). It should be appreciated that one or more of the connections <NUM> may be disengaged (e.g., the fastener may be removed and/or disconnected) in order to reconfigure the frame from the operational configuration into the transport configuration. It should be appreciated that one or more of the connections <NUM> may be engaged (e.g., the fastener may be installed and/or connected) after reconfiguring the frame from the transport configuration into the operational configuration.

Referring to <FIG>, another conveyor embodiment is illustrated having one or more hinges <NUM>-<NUM>', <NUM>-<NUM>' (e.g., pivot assemblies). The hinges <NUM>-<NUM>', <NUM>-<NUM>' are generally similar to the hinges <NUM>-<NUM>, <NUM>-<NUM> illustrated in <FIG> except that the pivot <NUM> is aligned with a plane defined by surfaces and/or chords of the frame sections joined by the pivot when the truss is in the operational configuration. For example, in some embodiments in the operational configuration a plane P1 intersecting (and/or parallel to) an upper surface of sections <NUM> and <NUM> also intersects the pivot <NUM> of hinge <NUM>-<NUM>'. In some embodiments in the operational configuration a plane P2 intersecting (and/or parallel to) a lower surface of sections <NUM> and <NUM> also intersects the pivot <NUM> of hinge <NUM>-<NUM>'.

In some embodiments, section <NUM> pivots about the pivot <NUM> of hinge <NUM>-<NUM>' (e.g., a pivot axis defined by the pivot) relative to section <NUM> in a first rotational direction. In some embodiments, section <NUM> rests directly (or in some embodiments indirectly) on section <NUM> in the transport configuration. In some embodiments, a first side (e.g., upper side) of the conveyor truss in the operational configuration comprises first (e.g., upper) surfaces Su-<NUM>, Su-<NUM> respectively of the sections <NUM>, <NUM>. Surfaces Su-<NUM>, Su-<NUM> optionally contact one another in the transport configuration.

In some embodiments, section <NUM> pivots about the pivot <NUM> of hinge <NUM>-<NUM>' (e.g., a pivot axis defined by the pivot) relative to section <NUM> in a second rotational direction (e.g., opposite to the first rotational direction). In some embodiments, section <NUM> rests directly (or in some embodiments indirectly) on section <NUM> in the transport configuration. In some embodiments, a second side (e.g., lower side) of the conveyor truss in the operational configuration comprises second (e.g., lower) surfaces Sl-<NUM>, Sl-<NUM> respectively of the sections <NUM>, <NUM>. Surfaces Sl-<NUM>, Sl-<NUM> optionally contact one another in the transport configuration.

Referring to <FIG>, in embodiments such as upper hinge <NUM>-<NUM>'', the pivot axis and/or pivot <NUM> is optionally level with and/or above upper rails 2518a, 2528a of the frame sections <NUM>, <NUM>, respectively and the pivot assembly (e.g., one or more pivot plates thereof) is optionally mounted to and/or supported on lower rails 2518b, 2528b.

Referring to <FIG>, in embodiments such as lower hinge <NUM>-<NUM>", the pivot axis and/or pivot <NUM> is optionally level with and/or above upper rails 2528a, 2538a of the frame sections <NUM>, <NUM>, respectively and the pivot assembly (e.g., one or more pivot plates thereof) is optionally mounted to and/or supported on lower rails 2528b, 2538b.

In some embodiments, adjacent frame sections are optionally selectively rigidly coupled in the transport configuration (e.g., by coupling two portions of the frame sections by a removable fastener such as a pin or bolt).

In various alternative embodiments, the hinges between one or more pairs of frame sections may be disposed on the sides of the frame sections such that the frame sections fold into side-by-side relation for transport. For example, in the embodiment shown in <FIG>, a conveyor <NUM> includes a conveyor frame <NUM> having three sections <NUM>, <NUM>, and <NUM>. The Pivotal connections <NUM> (e.g., hinges) are optionally provided on the sides of the frame <NUM> such that the frame sections are enabled to pivot into the transport configuration shown in <FIG>. For example, a first pivotal connection 2550a optionally pivotally couples the left sides of the frame sections <NUM> and <NUM> (e.g., left chords thereof); a second pivotal connection 2550b optionally pivotally couples the right sides of the frame sections <NUM> and <NUM> (e.g., right thereof). In some embodiments, a plurality of conveyors <NUM> (e.g., <NUM>) may be stacked vertically inside of a container (e.g., standard shipping container, sea container, etc.).

Referring to <FIG>, conveyor truss embodiment is illustrated optionally having a first frame section <NUM> pivotally coupled to a second frame section <NUM> by a first pivot assembly 3102a. Referring to <FIG>, the second frame section <NUM> is also optionally pivotally coupled to a third frame section <NUM> by a second pivot assembly 3102b which is optionally disposed on a generally opposing side of the conveyor from the first pivot assembly 3102a. The second pivot assembly 3102b is optionally otherwise generally similar to (e.g., optionally has common features with) the first pivot assembly 3102a. The third frame section <NUM> is optionally generally similar to (e.g., optionally has common features with) the second frame section <NUM> and/or the first frame section <NUM>.

The first frame section <NUM> optionally comprises a plurality of longitudinally extending truss chords, e.g., first upper chord 3010b-<NUM>, second upper chord 3010b-<NUM>, first lower chord 3010a-<NUM>, and second chord 3010a-<NUM> (the terms upper and lower as applied to the chords of the embodiment shown in <FIG> may refer to the relative orientation in the operational configuration). A plurality of angled struts <NUM> are optionally mounted to the upper and lower chords and optionally disposed outboard of the chords. A first end strut <NUM>-<NUM> (e.g., vertical strut, vertical strut plate, etc.) is optionally mounted to a longitudinal end of the first upper chord 3010b-<NUM> and is optionally mounted to a longitudinal end of the first lower chord 3010a-<NUM>. A second end strut <NUM>-<NUM> is optionally mounted to a longitudinal end of the second upper chord 3010b-<NUM> and is optionally mounted to a longitudinal end of the second lower chord 3010a-<NUM>. A first mounting plate <NUM>-<NUM> (e.g., transversely extending mounting plate) is optionally mounted to and/or formed as a part with the first end strut <NUM>-<NUM> (e.g., at a lower end thereof or elsewhere along the length of the end strut). A second mounting plate <NUM>-<NUM> (e.g., transversely extending mounting plate) is optionally mounted to and/or formed as a part with the second end strut <NUM>-<NUM> (e.g., at a lower end thereof or elsewhere along the length of the end strut). A plurality of idler assemblies (e.g., idler assembly 1100y) are supported in longitudinally spaced relation along the frame section <NUM> to operably support the belt B. One or more return rollers <NUM> are optionally supported on the sides (e.g., chords) of the frame section <NUM> and disposed adjacent a returning portion of the belt B.

The second frame section <NUM> optionally comprises a plurality of longitudinally extending truss chords, e.g., first upper chord 2910b-<NUM>, second upper chord 2910b-<NUM>, first lower chord 2910a-<NUM>, and second chord 2910a-<NUM> (the terms upper and lower as applied to the chords of the embodiment shown in <FIG> may refer to the relative orientation in the operational configuration). A plurality of angled struts <NUM> are optionally mounted to the upper and lower chords and optionally disposed outboard of the chords. A first end strut <NUM>-<NUM> (e.g., vertical strut, vertical strut plate, etc.) is optionally mounted to a longitudinal end of the first upper chord 2910b-<NUM> and is optionally mounted to a longitudinal end of the first lower chord 2910a-<NUM>. A second end strut <NUM>-<NUM> is optionally mounted to a longitudinal end of the second upper chord 2910b-<NUM> and is optionally mounted to a longitudinal end of the second lower chord 2910a-<NUM>. A first mounting plate <NUM>-<NUM> (e.g., transversely extending mounting plate) is optionally mounted to and/or formed as a part with the second end strut <NUM>-<NUM> (e.g., at a lower end thereof or elsewhere along the length of the end strut). A second mounting plate <NUM>-<NUM> (e.g., transversely extending mounting plate) is optionally mounted to and/or formed as a part with the second end strut <NUM>-<NUM> (e.g., at a lower end thereof or elsewhere along the length of the end strut). A plurality of idler assemblies (e.g., idler assembly 1100x) are supported in longitudinally spaced relation along the frame section <NUM> to operably support the belt B. One or more return rollers <NUM> are optionally supported on the sides (e.g., chords) of the frame section <NUM> and disposed adjacent a returning portion of the belt B.

Each pivot assembly <NUM> optionally comprises a first hinge <NUM>-<NUM> and a second hinge <NUM>-<NUM>. The first and second hinges are optionally disposed on opposing lateral sides of the conveyor. The hinges are optionally disposed at least partially inboard of the end struts.

Each hinge <NUM> optionally comprises at least one plate <NUM> which is optionally mounted to an upper truss chord 2910b. Each hinge <NUM> optionally comprises a pivot <NUM> (e.g., tube, rod or pin) which is optionally mounted to an upper truss chord 3010b. The pivot <NUM> optionally extends generally transversely. The plate <NUM> optionally includes an opening (e.g., circular hole) through which the pivot <NUM> extends such that the plate is pivotally coupled to the pivot. In alternative embodiments, the plate may be mounted to chord 3010b and the pivot may be mounted to chord 2910b.

Referring to <FIG>, the hinges <NUM>-<NUM> and <NUM>-<NUM> optionally define a common pivot axis. For example, the pivots <NUM> of both hinges and/or the opening in plates <NUM> of both hinges are optionally aligned along a common axis.

In the operational configuration, the mounting plate <NUM>-<NUM> is optionally in contact with the mounting plate <NUM>-<NUM>. The mounting plate <NUM>-<NUM> is optionally mounted to the mounting plate <NUM>-<NUM> in the operational configuration (e.g., by one or more fasteners such as nut-and-bolt assemblies). In the operational configuration, the mounting plate <NUM>-<NUM> is optionally in contact with the mounting plate <NUM>-<NUM>. The mounting plate <NUM>-<NUM> is optionally mounted to the mounting plate <NUM>-<NUM> in the operational configuration (e.g., by one or more fasteners such as nut-and-bolt assemblies). In some alternative embodiments, adjacent frame sections may be rigidly coupled for prevention of relative pivotal motion (e.g., by welding of adjacent truss chords and/or end struts); in some such embodiments, the mounting plates may be omitted.

In some alternative embodiments, the pivotal connections between one or more pairs of frame sections may be omitted; for example, one or more frame sections may be configured to disconnect from an adjacent frame section and slide on top of another frame section (e.g., supported by rollers engaging the other frame section) for transport.

Unless otherwise indicated expressly or by the context or function of various components, in various embodiments the components described herein may be made of metal such as steel.

Claim 1:
A folding conveyor (<NUM>), comprising:
a conveyor frame (<NUM>) having a transport configuration and an operational configuration, said conveyor frame comprising a first frame section (<NUM>), a second frame section (<NUM>), and a third frame section (<NUM>), wherein when said conveyor frame is in said operational configuration, said conveyor frame has an upper end and a lower end, wherein at least one of the first, second and third frame sections (<NUM>, <NUM>, <NUM>) comprise:
an upper truss chord;
a lower truss chord;
a plurality of struts (<NUM>) mounted to said upper truss chord and said lower truss chord, wherein said struts (<NUM>) are disposed outboard of said upper truss chord and said lower truss chord; and
a tail pulley (<NUM>) operably supported on said conveyor frame (<NUM>), the tail pulley (<NUM>) having a tail pulley rotational axis; and
a head pulley (<NUM>) operably supported on said conveyor frame (<NUM>), the head pulley (<NUM>) having a head pulley rotational axis, wherein said tail pulley (<NUM>) and said head pulley (<NUM>) are configured to support an endless belt, wherein a plane (P) intersects both the tail pulley rotational axis and the head pulley rotational axis;
a first pivot assembly (<NUM>-<NUM>) pivotally coupling said first frame section (<NUM>) to said second frame section (<NUM>), said first pivot assembly defining a first pivot axis;
a second pivot assembly (<NUM>-<NUM>) pivotally coupling said second frame section (<NUM>) to said third frame section (<NUM>), said second pivot assembly defining a second pivot axis, wherein said plane (P) extends between said first and second pivot axes, said folding conveyor being characterized in that it comprises a troughing idler assembly (<NUM>) having a horizontal medial roll (<NUM>) rotationally supported on a left inner perch support (<NUM>-<NUM>) and a right inner perch support (<NUM>-<NUM>) and a left angled roll (<NUM>-<NUM>) supported on a left outer perch support (<NUM>-<NUM>) and said left inner perch support (<NUM>-<NUM>) and a right angled roll (<NUM>-<NUM>) supported on a right outer perch support (<NUM>-<NUM>) and said right inner perch support (<NUM>-<NUM>); and in that
in said transport configuration said second frame section (<NUM>) rests on said first frame section (<NUM>) and said third frame section (<NUM>) rests on said second frame section (<NUM>).