Patent ID: 12227371

DETAILED DESCRIPTION

Various technologies pertaining to a roller gap filler system are now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more aspects. It may be evident, however, that such aspect(s) may be practiced without these specific details. Further, it is to be understood that functionality that is described as being carried out by certain system components may be performed by multiple components. Similarly, for instance, a component may be configured to perform functionality that is described as being carried out by multiple components.

Moreover, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form.

Terms such as “first” and “second” are used herein for identification purposes. These terms are not intended to imply any sort of order; for instance, a second mounting bracket can be installed prior to, subsequent to, or concurrent with installation of a first mounting bracket.

FIG.1illustrates a perspective view of a roller conveyor system100having an example roller gap filler system102installed. The roller conveyor system100has a length L1, a width W, and utilizes a plurality of evenly spaced apart, rotatable cylindrical rollers104to move objects along the length L1of the roller conveyor system100. The roller gap filler system102is configured to mount to the roller conveyor system100to block the objects being conveyed from falling between the rollers104. The roller conveyor system100may be configured in a variety of ways. Any type of roller conveyor system100that utilizes a plurality of spaced apart, rotatable cylindrical rollers104to move objects along the roller conveyor system100may use the exemplary roller gap filler system102. The rollers104may be free-rotating rollers, such as in a gravity roller conveyor, or may be driven, such as by a belt, chains, motors, or other drive mechanisms.

In the illustrated implementation, the plurality of evenly spaced apart, rotatable cylindrical rollers104are mounted in series between a first frame member106and a second frame member108. The frame members106,108may be mounted on a plurality of legs110that support the frame members106,108and rollers104at an elevated position off of the ground. Each of the plurality of rollers104is rotatably mounted on a corresponding axle120, as shown inFIG.2. Each axle120spans between the first frame member106and the second frame member108and is fixed relative to the frame members106,108. In the illustrated implementation, each axle120has a hexagon shaped cross-section. In other implementations, however, each axle120may have any suitable cross-section, such as round, square, or other suitable shape.

The roller gap filler system102may be configured in a variety of ways. In the illustrated implementation, as shown inFIG.3, the roller gap filler system102includes a first mounting bracket124, a second mounting bracket126, and one or more filler bars128extending between, and supported by, the first mounting bracket124and the second mounting bracket126. Each of the one or more filler bars128is releasably attached to the first mounting bracket124and the second mounting bracket126. Each filler bar128includes a latching mechanism129(FIG.7) for releasably attaching the filler bar128to the second mounting bracket126.

FIG.4illustrates an example filler bar128of the roller gap filler system102. The filler bar128has an elongated body130extending along a longitudinal axis A. The filler bar body130includes a first end portion132and a second end portion134(FIG.3) opposite the first end portion132. The filler bar128has a length L2(FIG.3) that spans the width W, or most of the width W, of the roller conveyor system100. The filler bar128may be configured in a variety of ways. Any configuration that allows the filler bar128to be positioned in a gap or space S (FIG.2) between two adjacent rollers104to block objects being conveyed from falling between the rollers104may be used.

In the illustrated implementation, the filler bar128includes an upper wall136, a first side wall138extending from the upper wall136, and a second side wall140opposite the first side wall138and extending from the upper wall136. The first and second side walls138,140taper inwards (i.e., converge toward each other) as the first and second wall138,140extend away from the upper wall136to form a trapezoid-shaped cross-section. The filler bar128includes an open lower end142such that the filler bar128forms a channel144. Each filler bar128can be made from any suitable material or materials. In the illustrated implementation, the filler bar128is made from galvanized steel.

FIG.5illustrates an example first mounting bracket124of the roller gap filler system102. The first mounting bracket124may be configured in a variety of ways. Any configuration that can support the first end portion132of one or more filler bars128may be used. In the illustrated implementation, the first mounting bracket124has an elongated body150having a planar inner face152, a planar outer face154(FIG.3) opposite and parallel the inner face152, a top edge156extending between the inner face152and the outer face154, a bottom edge158opposite the top edge156and extending between the inner face152and the outer face154, a first side edge160extending between the top edge156and the bottom edge158, and a second side edge162opposite the first side edge160and extending between the top edge156and the bottom edge158.

The first mounting bracket124is configured to mount to the roller conveyor system100with the inner face152facing inward (i.e., toward the rollers104). The first mounting bracket124may mount to the roller conveyor system100in any suitable manner. In the illustrated implementation, the first mounting bracket124is configured to mount to the roller conveyor system100without the use of fasteners or need for tools. In particular, the bottom edge158includes a series of recesses or cut-outs164. Each recess164is configured to receive an axle120such that the first mounting bracket124sits on top of, and is supported by, the axles120. Each recess164may have a shape that is complimentary to the cross-section shape of the portion of the axle120in contact with the first mounting bracket124(e.g., a shape complementary to a hexagon cross-section of the axle).

The first mounting bracket124has a length L3. The length L3may be long enough to span two or more axles120. In the illustrated implementation, the first mounting bracket124includes three full recesses164and two half recesses at the first and second side edges160,162. Thus, the first mounting bracket124contacts and is supported on five axles120. In other implementations, the first mounting bracket124may contact and be supported by more or less than five axles120.

The first mounting bracket124is configured to support the first end portion132of one or more filler bars128. The first mounting bracket124may support the first end portion132in a variety of ways. In the illustrated implementation, the first mounting bracket124includes one or more mounting tabs166. Each mounting tab166extends inward from the inner face152at a position adjacent the top edge156. Each mounting tab166extends perpendicular to the inner face152and is configured to be received within the channel144at the first end portion132of the filler bar128. Thus, the upper wall136of the filler bar128engages and is supported by the mounting tab166.

In the illustrated implementation, the first mounting bracket124includes four mounting tabs166evenly spaced along the length L3of the first mounting bracket124. Each mounting tab166is generally positioned equidistant between recesses164along the length L3of the first mounting bracket124. Thus, the first mounting bracket124contacts and supports four filler bars128. In other implementations, the first mounting bracket124may contact and support more or less than four filler bars128.

FIG.6illustrates an example second mounting bracket126of the roller gap filler system102. The second mounting bracket126may be configured in a variety of ways. Any configuration that can support the second end portion134of one or more filler bars128may be used. In the illustrated implementation, the second mounting bracket126has an elongated body170having a planar inner face172, a planar outer face (not shown) opposite and parallel the inner face172, a top edge176extending between the inner face172and the outer face (not shown), a bottom edge178opposite the top edge176and extending between the inner face172and the outer face (not shown), a first side edge180extending between the top edge176and the bottom edge178, and a second side edge182opposite the first side edge180and extending between the top edge176and the bottom edge178.

The second mounting bracket126is configured to mount to the roller conveyor system100with the inner face172facing inward. The second mounting bracket126may mount to the roller conveyor system100in any suitable manner. In the illustrated implementation, the second mounting bracket126is configured to mount to the roller conveyor system100without the use of fasteners and in a similar manner to which the first mounting bracket124mounts to the roller conveyor system100. In particular, the bottom edge178includes a series of recesses or cut-outs184. Each recess184is configured to receive an axle120such that the second mounting bracket126sits on top of and is supported by one or more of the axles120. Each recess184may have a shape that is complimentary to the cross-section shape of the portion of the axle120in contact with the second mounting bracket126(e.g., a shape complementary to a hexagon cross-section of the axle).

The second mounting bracket126has a length L4. The length L4may be long enough to span two or more axles120. In the illustrated implementation, the second mounting bracket126includes three full recesses184and two half recesses at the first and second side edges180,182. Thus, the second mounting bracket126contacts and is supported on five axles120. In other implementations, the second mounting bracket126may contact and be supported by more or less than five axles120.

The second mounting bracket126is configured to support the second end portion134of one or more filler bars128. The second mounting bracket126may support the second end portion134in a variety of ways. In the illustrated implementation, the second mounting bracket126includes one or more mounting tabs186. Each mounting tab186includes a first portion188extending inward from the inner face172(e.g., perpendicular to the inner face172) and adjacent the top edge176. The first portion188includes a first aperture190extending through the first portion188. Each mounting tab186includes a second portion192extending downward from the first portion188(e.g., parallel to the inner face172toward the bottom edge178). The second portion192includes a second aperture194for engaging the latching mechanism129. The second mounting bracket126may also include a third portion196extending inward from the second portion192below the second aperture194(i.e., opposite the first portion).

In the illustrated implementation, the second mounting bracket126includes four mounting tabs186evenly spaced along the length L4of the second mounting bracket126. Each mounting tab186is generally positioned equidistant between recesses184along the length L4of the second mounting bracket126. Thus, the second mounting bracket126contacts and supports four filler bars128. In other implementations, the second mounting bracket126may contact and support more or less than four filler bars128.

FIGS.7-8illustrate an example latching mechanism129of the roller gap filler system102. The roller gap filler system102includes a plurality of latching mechanisms129. Each filler bar128has a corresponding one of the plurality of latching mechanisms129associated therewith. Each latching mechanism129is configured to attach the second end portion134of the filler bar128to the second mounting bracket126. The latching mechanism129may be configured in a variety of ways. In the illustrated implementation, the latching mechanism129includes a moveable member or plunger200configured to be positioned, at least partially, within the channel144of the filler bar128.

The plunger200is moveable between a coupling position to couple the filler bar128to the second mounting bracket126and a release position to uncouple the filler bar128from the first mounting bracket. The plunger200may be configured in a variety of ways. In the illustrated implementation, the plunger200has a plunger body202shaped as a trapezoidal prism with rounded corners. The plunger body202has an upper surface204, a lower surface206opposite the upper surface204, a first side surface208extending between the upper surface204and the lower surface206, and a second side surface210opposite the first side surface208and extending between the upper surface204and the lower surface206. The first side surface208and the second side surface210taper inward (i.e., converge toward each other) from the upper surface204to the lower surface206.

As shown inFIG.9, the cross-section shape of the plunger200is complementary to the cross-section shape of the channel144. Furthermore, the maximum width MW of the plunger200is greater than the width WO of the open lower end142of the filler bar128. Thus, the complementary shape of the plunger200allows the plunger200to easily move longitudinally along the axis A (i.e., axial movement) while being prevented from falling out of the channel144due to the maximum width MW of the plunger200being greater than the width WO of the open lower end142.

The plunger200includes a distal end212and a proximal end214opposite the distal end212. The distal end212is configured to be received through the second aperture194of the mounting tab186of the second mounting bracket126. In the illustrated implementation, the distal end212is flat and generally perpendicular to the upper and lower surfaces204,206. In other implementations, however, the distal end212can have any suitable shape, such as tapered, pointed, rounded, or other suitable shapes.

In the illustrated implementation, at least a portion of the plunger body202converges or tapers inward from the distal end212to the proximal end214such that the cross section of the plunger body202at the proximal end214is smaller in area than the cross section of the plunger body202at the distal end212. The smaller cross section at the proximal end214makes movement of the plunger200in the channel144easier.

The latching mechanism129further includes an anchor member220, a connector221, and a biasing member223. The anchor member220is configured to anchor the latching mechanism129within the channel144of the filler bar128. The anchor member220may be configured in a variety of ways. Any configuration that can anchor the latching mechanism129within the channel144may be used.

In the illustrated implementation, the anchor member220has an anchor body222shaped as a trapezoidal prism with rounded corners. The anchor body222has an upper surface224, a lower surface226opposite the upper surface224, a first side surface228extending between the upper surface224and the lower surface226, and a second side surface230opposite the first side surface228and extending between the upper surface224and the lower surface226. The first side surface228and the second side surface230taper inward (i.e., converge toward each other) from the upper surface224to the lower surface226.

The cross-section shape of the anchor member220is complementary to the cross-section shape of the channel144in a similar way as the plunger200. Thus, the anchor member220is prevented from falling out of the channel144due to being wider than the open lower end142of the filler bar128. The plunger200includes a distal end232and a proximal end234opposite the distal end232. In the illustrated implementation, the distal end232and the proximal end234are flat and generally perpendicular to the upper and lower surfaces224,226. In other implementations, however, the distal end232and the proximal end234can have any suitable shape, such as tapered, pointed, rounded, or the like.

The anchor member220is configured to be fixed within the channel144of the filler bar128. The anchor member220may be fixed within the channel144in a variety of ways, such as press fit, adhesives, fasteners, or any other suitable manner of fixing the anchor member220within the channel. In the illustrated implementation, the anchor member220is press fit. Therefore, the size of the anchor member220is configured to provide an interference fit with the walls136,138,140of the filler bar128. The anchor member220may include one or more features to account for the tolerance of the channel cross section. In the illustrated implementation, the anchor member220includes one or more longitudinal ridges235on one or more of the upper surface224, the lower surface226, the first side surface228and the second side surface230. The ridges235extend sufficiently from the surfaces to account for the tolerance in the channel144size and ensure a secure press fit of the anchor member220.

The anchor member220includes a passage236extending through the anchor member220from the distal end232to the proximal end234. The connector221extends through the passage236and connects the anchor member220to the plunger200. The connector221may be configured in a variety of ways. In the illustrated implementation, the connector221is a screw or bolt having an elongated shaft240with an externally threaded distal end242and an enlarged head244defining a proximal end246.

The proximal end234of the plunger200includes an internally threaded passage248configured to threadably engage the externally threaded distal end242of the connector221. The enlarged head244is configured to be too large to fit through the passage236in the anchor member220. Thus, the proximal end234of the anchor member220acts as a stop preventing the connector221from pulling through the passage236.

With the connector221threaded into the internally threaded passage248, the connector221and the plunger200are fixed to move together relative to the anchor member220. The coupled position corresponds to when the enlarged head244abuts the proximal end234of the anchor member220and the plunger200is extended. As shown by arrow B inFIG.8, the plunger200is moveable axially closer to the anchor member220to an uncoupled position. The biasing member223is positioned to bias the plunger200to the extended coupled position.

The biasing member223may be configured in a variety of ways. Any biasing member(s)223capable of biasing the plunger200to the coupled position may be used. In the illustrated implementation, the biasing member223is a spring positioned around the shaft240of the connector221between the plunger200and the anchor member220. The biasing member223is compressed between the proximal end214of the plunger200and the distal end232of the anchor member220.

The roller gap filler system102is configured to be retrofitted onto the roller conveyor system100or incorporated with the roller conveyor system100when first assembled. To add the roller gap filler system102to the roller conveyor system100, the first mounting bracket124is positioned adjacent the first frame member106with the outer face154facing the first frame member106and the inner face152facing inward (i.e., toward the rollers104). The first mounting bracket124is installed by placing the first mounting bracket124onto the axles120such that the axles120are received within the recesses164of the first mounting bracket124as shown inFIG.10. In this position, the first mounting bracket124is supported by the axles120and each of the mounting tabs166are positioned along the length L1of the roller conveyor system100in between successive rollers104.

The second mounting bracket126is installed opposite, but in a similar manner to, the first mounting bracket124. In particular, the second mounting bracket126is positioned adjacent the second frame member108with the outer face (not shown) facing the second frame member108and the inner face172facing inward (i.e., toward the rollers104). The second mounting bracket126is installed by placing the second mounting bracket126onto the axles120such that the axles120are received within the recesses184of the second mounting bracket126. In this position, the second mounting bracket126is supported by the axles120and each of the mounting tabs186are positioned along the length L1of the roller conveyor system100in between successive rollers104. Thus, each of the mounting tabs186of the second mounting bracket126are positioned to align with a corresponding one of the mounting tabs166of the first mounting bracket across the width W of the roller conveyor system100.

With both the first and second mounting brackets124,126in place, the filler bars128may be installed. Each of the filler bars128can be installed on the first mounting bracket124by positioning the filler bar128such that the open lower end142is facing downward. The first end portion132of the filler bar128can be slide onto such the mounting tab166such that the mounting tab166is received in the channel144. In this position, the mounting tab166supports the first end portion132.

The latching mechanism129is configured to be received in the channel144of one of the filler bars128at the second end portion134.FIG.11illustrates the latching mechanism129installed in the channel144of one of the filler bars128.FIG.11illustrates the filler bar128turned upside down for ease of illustration. The anchor member220may be press fit into the channel144such that the proximal end234is facing inward (i.e., away from the second end portion134of the filler bar128).

The plunger200is also received within the channel144at a position outward of the anchor member (i.e., closer to the second end portion134). The plunger200can be attached to the anchor member220after, or prior to, the anchor member220has been press fit into the channel144. As described above, the plunger200is fixably attached to the connector221which is received through the passage236in the anchor member220and is biased by the biasing member223away from the anchor member220. To connect the second end portion134of the filler bar128to the second mounting bracket126, the plunger200is pushed toward the anchor member220such that the distal end212of the plunger200does not interfere with placing the second end portion134of the filler bar128adjacent the second portion192of the mounting tab186of the second mounting bracket126. For example, the distal end212of the plunger200may be pressed into the channel144, or nearly into the channel, to avoid contacting the mounting tab186. The plunger200is in the uncoupled position when retracted to avoid interfering with the mounting tab186.

Once the second end portion134of the filler bar128is adjacent the second portion192of the mounting tab186, the plunger200is aligned with the aperture194and released. The biasing member223biases the plunger200away from the anchor member220such that the distal end212of the plunger200is received through the aperture194in the second mounting bracket126to couple the second end portion134of the filler bar128to the second mounting bracket126. The location of the anchor member220within the channel144is set to allow the plunger200to extend through the aperture194in the second mounting bracket126.

As indicated above, both the first and second mounting brackets124,126include four mounting tabs166,186. Thus, three additional filler bars128can be mounted on the roller conveyor system100in the same way described above. Furthermore, additional first and second mounting brackets124,126can be placed, in series, next to each other on the roller conveyor system100such that a filler bar128can be mounted between all of the plurality of rollers104in the roller conveyor system100. As shown inFIG.2, each filler bar128is positioned between two successive rollers of the plurality of rollers104to fill the gap or space S between the rollers104along the length L1of the roller conveyor system100. As a result, small objects being conveyed are prevented from falling between the rollers104.

To remove the roller gap filler system102from the roller conveyor system100, or to replace one or more components, one of the filler bars128is decoupled from the second mounting bracket126. In particular, the plunger200is moved from the coupled position to the uncoupled positioned (i.e., retracted against the bias of the biasing member223). The second mounting bracket126is configured to provide access to the plunger200from both above and below the plunger200when the plunger200is in the coupled position. In particular, the distal end212of the plunger200can be accessed from above via the first aperture190in the first portion188of the second mounting bracket126. Further, as shown inFIG.11, the distal end212of the plunger200is exposed from the bottom and can be easily accessed.

As shown inFIG.11, the third portion196of the second mounting bracket126extends under the second end portion134of the filler bar128when the second end portion134is coupled to the second mounting bracket126. Thus, when the second end portion134is released from the second mounting bracket126, the third portion196of the second mounting bracket126acts as a ledge to prevent the second end portion134from inadvertently falling down between the rollers104during assembly or disassembly. With the second end portion134decoupled from the second mounting bracket126, the filler bar128can be pulled away from the first mounting bracket124to pull the channel144off of the mounting tab166and disconnect the filler bar128from the roller conveyor system100. Once all of the filler bars128are disconnected, the first and second mounting brackets124,126can be lifted off of axles120and removed from the roller conveyor system100. Thus, the roller gap filler system102can be installed and uninstalled from the roller conveyor system100without tools or external fasteners.

System and method have been described herein in accordance with at least the examples set forth below.(A1) In one aspect, a roller gap filler system for a roller conveyor system having a plurality of spaced apart rotating cylindrical rollers includes a first mounting bracket, a second mounting bracket, a first filler bar, and a plunger associated with the first filler bar. The first mounting bracket is configured to mount adjacent a first end of the plurality of rollers. The second mounting bracket is configured to mount adjacent a second end of the plurality of rollers, where the second end is opposite the first end. The first filler bar is configured to extend between the first mounting bracket and the second mounting bracket and be positioned between a first roller and a second roller of the plurality of rollers. The plunger is moveable between a coupling position to couple the first filler bar to the second mounting bracket and a release position to uncouple the first filler bar from the second mounting bracket. The plunger is biased to the coupling position.(A2) In some embodiments of the system of (A1), the plunger is moveable along a longitudinal axis of the first filler bar between the release position and the coupling position.(A3) In some embodiments of the system of (A2), a biasing member is configured to bias the plunger to the coupling position.(A4) In some embodiments of the system of (A3), the biasing member is a spring.(A5) In some embodiments of the system of (A2)-(A4), the filler bar defines a longitudinal channel, and the plunger is mounted within the longitudinal channel.(A6) In some embodiments of the system of (A5), an anchor member is fixed within the channel and coupled to the plunger by the biasing member.(A7) In some embodiments of the system of (A6), the anchor member is press-fit into the channel.(A8) In some embodiments of the system of (A5) or (A6), the longitudinal channel is shaped to prevent movement of the plunger in a direction other than along a longitudinal axis of the channel.(A9) In some embodiments of the system of (A1)-(A8), the second mounting bracket is configured to provide access to a forward end the plunger from both a top side of the plunger and a bottom side of the plunger when the plunger is in the coupling position and attached to the second mounting bracket such that the plunger can be moved to the release position.(A10) In some embodiments of the system of (A1)-(A9), the system further includes a second filler bar configured to extend between the first mounting bracket and the second mounting bracket and be positioned between the second roller and a third roller of the plurality of rollers and a third filler bar configured to extend between the first mounting bracket and the second mounting bracket and be positioned between the third roller and a fourth roller of the plurality of rollers.(A11) In some embodiments of the system of (A1)-(A10), the first mounting bracket and the second mounting bracket are configured to mount to the roller conveyor system without fasteners.(A12) In some embodiments of the system of (A1)-(A11), the second mounting bracket further comprises a ledge extending under an end of the filler bar when the end is in a position to couple to the second mounting bracket.(B1) In one aspect, a method of filling a gap between rollers of a roller conveyor system includes supporting a first mounting bracket on the axles at a first end of the rollers, supporting a second mounting bracket on the axles at a second end of the rollers, positioning a filler bar in the gap between the rollers, supporting a first end of the filler bar with the first mounting bracket, and coupling a second end of the filler bar to the second mounting bracket with a latching mechanism having a moveable member. The moveable member is configured to move between a coupling position to couple the second end to the second mounting bracket, and a release position to uncouple the second end from the second mounting bracket. The moveable member is biased to the coupling position.(B2) In some implementations of the method of (B1), supporting a first mounting bracket on the axles further comprises receiving the axles in recesses on the first mounting bracket.(B3) In some implementations of the method of (B1) or (B2), the moveable member is biased by a spring.(B4) In some implementations of the method of (B1)-(B3), coupling the second end of the filler bar to the second mounting bracket further comprises receiving the moveable member through an aperture in the second mounting bracket.(B5) In some implementations of the method of (B1)-(B4), the method further includes anchoring an anchor member of the latching mechanism to the filler bar.(B6) In some implementations of the method of (B5), anchoring the anchor member further comprises press-fitting the anchor member within a channel of the filler bar.(B7) In some implementations of the method of (B6), supporting the first end of the filler bar with the first mounting bracket further comprises receiving a portion of the first mounting bracket in the channel of the filler bar.(B7) In some implementations of the method of (B1)-(B7), the method further includes supporting a second end of the filler bar on a portion of the second mounting bracket when the second end is not coupled to the second mounting bracket.

What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable modification and alteration of the above devices or methodologies for purposes of describing the aforementioned aspects, but one of ordinary skill in the art can recognize that many further modifications and permutations of various aspects are possible. Accordingly, the described aspects are intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.