U.S. patent application number 12/630794 was filed with the patent office on 2010-10-07 for systems and methods for preparing and packaging wax, such as scented wax for use with wickless candles, and other similar products.
This patent application is currently assigned to Scentsy, Inc.. Invention is credited to Kevin D. Preece, Steven Sircy, Richard O. Thompson, Dennis Van Acker.
Application Number | 20100251671 12/630794 |
Document ID | / |
Family ID | 42825027 |
Filed Date | 2010-10-07 |
United States Patent
Application |
20100251671 |
Kind Code |
A1 |
Thompson; Richard O. ; et
al. |
October 7, 2010 |
SYSTEMS AND METHODS FOR PREPARING AND PACKAGING WAX, SUCH AS
SCENTED WAX FOR USE WITH WICKLESS CANDLES, AND OTHER SIMILAR
PRODUCTS
Abstract
Systems and methods for preparing and packaging scented wax for
use with wickless candles, and for preparing and packaging other
types of wax and non-wax products, are disclosed herein. A wax
product manufacturing machine configured in accordance with an
embodiment of the disclosure can include a container loading
assembly that loads a plurality of empty product containers onto a
conveyor for transfer to container filling assembly. The container
filling assembly can simultaneously fill the plurality of empty
product containers with colored and/or scented wax. The
manufacturing machine can further include a cooling assembly
through which the filled wax containers move for cooling and
hardening of the wax therein. The manufacturing machine can
additionally include a discharge assembly that closes the product
containers to encapsulate the wax product therein, and transfers
the closed product containers to a labeling machine for automatic
application of a suitable label.
Inventors: |
Thompson; Richard O.;
(Eagle, ID) ; Preece; Kevin D.; (Meridian, ID)
; Van Acker; Dennis; (Boise, ID) ; Sircy;
Steven; (Gainesville, GA) |
Correspondence
Address: |
PERKINS COIE LLP;PATENT-SEA
P.O. BOX 1247
SEATTLE
WA
98111-1247
US
|
Assignee: |
Scentsy, Inc.
Meridian
ID
|
Family ID: |
42825027 |
Appl. No.: |
12/630794 |
Filed: |
December 3, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61119707 |
Dec 3, 2008 |
|
|
|
Current U.S.
Class: |
53/440 ; 53/127;
53/250; 53/467 |
Current CPC
Class: |
B65B 63/08 20130101 |
Class at
Publication: |
53/440 ; 53/127;
53/250; 53/467 |
International
Class: |
B65B 63/08 20060101
B65B063/08; B65B 3/06 20060101 B65B003/06 |
Claims
1. A system for manufacturing wax for use with wickless candles,
the system comprising: a product conveyor; a plurality of product
containers moveably supported by the product conveyor; a filling
assembly having a plurality of wax dispensing outlets in fluid
communication with a wax hopper, wherein the filling assembly
automatically dispenses molten wax from the wax hopper into the
product containers through the dispensing outlets; and a cooling
assembly having a plurality of air movers, wherein the product
conveyor automatically moves the wax-filled product containers away
from the filling assembly and through the cooling assembly, and
wherein the air movers are operable to move cooling air over the
product containers.
2. The system of claim 1 wherein each of the wax dispensing outlets
includes a heater.
3. The system of claim 1 wherein the filling assembly automatically
dispenses a metered portion of molten wax from the wax hopper into
the product containers through the dispensing outlets.
4. The system of claim 1 wherein the wax hopper includes at least
one partition dividing the wax hopper into a first hopper portion
and a second hopper portion, wherein the first hopper portion can
hold a first wax mixture having a first composition and the second
hopper portion can hold a second wax mixture having a second
composition different from the first composition.
5. The system of claim 1 wherein the product conveyor moves the
product containers in a product feed direction, and wherein the
plurality of wax dispensing outlets are arranged in a row above the
product conveyor and transverse to the product feed direction.
6. The system of claim 1 wherein the product conveyor includes a
plurality of container pockets therein, and wherein each of the
product containers is releasably supported in one or more of the
container pockets.
7. The system of claim 6, further comprising a container loading
assembly, wherein the container loading assembly includes a
plurality of container extraction units that simultaneously load
the plurality of product containers into a row of the container
pockets on the product conveyor.
8. A system for manufacturing wax products, the system comprising:
at least one product container; a product conveyor that movably
supports the product container; a filling assembly having at least
one wax dispensing outlet in fluid communication with a wax hopper,
wherein the filling assembly automatically dispenses molten wax
from the wax hopper into the product container through the
dispensing outlet; and a cooling assembly having at least one air
mover, wherein the product conveyor automatically moves the product
container away from the filling assembly and through the cooling
assembly, and wherein the at least one air mover is operable to
move cooling air over the product container and harden the wax
therein.
9. The system of claim 8: wherein the product container includes a
lid portion; wherein the filling assembly automatically dispenses
molten wax from the wax hopper into the product container when the
lid portion is in an open position; wherein the product conveyor
automatically moves the product container through the cooling
assembly when the lid portion is in the open position; and wherein
the product conveyor automatically moves the product container away
from the cooling assembly and through a product discharge assembly
that automatically moves the lid portion from the open position to
a closed position to enclose the hardened wax in the product
container.
10. The system of claim 8 wherein the filling assembly includes a
plurality of wax dispensers, and wherein each of the wax dispensers
includes a corresponding wax dispensing outlet in fluid
communication with the wax hopper.
11. An automated method for producing wax products for use with
wickless candles, the method comprising: releasably engaging a
product container with a conveyor of a wax product manufacturing
machine; automatically moving the product container to a filling
assembly with the conveyor; automatically dispensing molten wax
into the product container from the filling assembly; and
automatically moving the filled product container from the filling
assembly through a cooling assembly to cool and harden the wax in
the product container.
12. The method of claim 11, further comprising automatically
closing a lid on the filled product container and discharging the
filled product container from the conveyor.
13. The method of claim 11 wherein the product container is a first
product container, and wherein the method further includes: while
releasably engaging the first product container with the conveyor,
simultaneously releasably engaging a second product container with
the conveyor; while automatically moving the first product
container to the filling assembly with the conveyor, simultaneously
moving the second product container to the filling assembly with
the conveyor; and while automatically dispensing molten wax into
the first product container from the filling assembly,
simultaneously dispensing molten wax into the second product
container from the filling assembly.
14. The method of claim 11 wherein the product container includes a
lid, and wherein the method further comprises automatically closing
the lid on the product container before discharging the product
container from the conveyor.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 61/119,707, entitled "SYSTEMS AND METHODS
FOR PREPARING AND PACKAGING WAX, SUCH AS SCENTED WAX FOR USE WITH
WICKLESS CANDLES, AND OTHER SIMILAR PRODUCTS" and filed on Dec. 3,
2008, which is incorporated herein by reference in its
entirety.
TECHNICAL FIELD
[0002] The following disclosure is directed generally to systems
and methods for preparing and packaging wax and other similar
products and, more particularly, to systems and methods for
preparing and packaging scented wax products for use with wickless
candles.
BACKGROUND
[0003] Conventional candles have been used for centuries, and
typically include a central wick encased in a wax body. As the wick
burns, the wax slowly melts. In scented candles, fragrant oils or
other additives are mixed with the wax so that it gives off a
pleasant aroma as it melts.
[0004] Flameless or wickless candles are relatively new. They
typically include a decorative ceramic or stoneware vessel (e.g., a
"warmer") that holds scented wax. Rather than use a flame, the
warmer melts the wax with an electrical heating element (e.g., a
25-Watt bulb) positioned beneath the wax. Wax for use with wickless
candles often comes in the form of segmented bars or "bricks" that
enable the user to break off the amount they wish to use. Users can
combine different types of wax in the warmer to create a desired
scent. As the wax melts and forms a pool, it gives off a pleasant
fragrance that fills the room as would a conventional scented
candle. In contrast to conventional candles, however, wickless
candles do not produce a flame, soot, or smoke. Moreover, the
warming vessel typically melts the wax at a relatively low
temperature.
[0005] One method of manufacturing wax for wickless candles
includes manually filling individual packaging containers with hot
wax from a storage tank. In this method, a hand-operated nozzle is
connected to a flexible hose that leads to the storage tank. The
operator can position the nozzle over an empty packaging container,
and then squeeze a handle on the nozzle to dispense wax from the
storage tank into the container. When one container is full, the
operator proceeds to fill the next container in a similar
manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a side elevation view of a wax product
manufacturing machine configured in accordance with an embodiment
of the disclosure.
[0007] FIG. 2A is an enlarged, rear isometric view of a product
infeed portion of the manufacturing machine of FIG. 1, configured
in accordance with an embodiment of the disclosure, and FIG. 2B is
further enlarged view of a portion of FIG. 2A.
[0008] FIG. 3 is an enlarged, rear isometric view of a container
loader configured in accordance with an embodiment of the
disclosure.
[0009] FIG. 4 is an enlarged, side elevation view of the infeed
portion of the manufacturing machine of FIG. 1, configured in
accordance with an embodiment of the disclosure.
[0010] FIGS. 5A and 5B are enlarged, rear isometric views
illustrating various stages of a method for loading wax product
containers on a product conveyor in accordance with an embodiment
of the disclosure.
[0011] FIGS. 6A and 6B are enlarged, rear and front isometric
views, respectively, of a drive assembly configured in accordance
with an embodiment of the disclosure.
[0012] FIG. 7 is an enlarged, front isometric view of a product
container filling assembly of the manufacturing machine of FIG. 1,
configured in accordance with an embodiment of the disclosure.
[0013] FIG. 8 is a rear isometric view of the container filling
assembly of FIG. 7.
[0014] FIG. 9 is an enlarged, partially exploded isometric view of
a wax dispenser configured in accordance with an embodiment of the
disclosure.
[0015] FIG. 10 is an enlarged isometric view illustrating operation
of the container filling assembly of FIGS. 7 and 8, in accordance
with an embodiment of the disclosure.
[0016] FIG. 11 is a schematic diagram of some of the pneumatic
systems of the manufacturing machine of FIG. 1, configured in
accordance with an embodiment of the disclosure.
[0017] FIG. 12 is a rear isometric view of a cooling assembly of
the manufacturing machine of FIG. 1, configured in accordance with
an embodiment of the disclosure.
[0018] FIG. 13 is a front isometric view of a discharge assembly of
the manufacturing machine of FIG. 1, configured in accordance with
an embodiment of the disclosure.
[0019] FIGS. 14A and 14B are enlarged isometric views of a portion
of the discharge assembly of FIG. 13, illustrating various stages
of a method of closing lids on wax product containers in accordance
with an embodiment of the disclosure.
[0020] FIGS. 15A and 15B are enlarged, rear and front isometric
views, respectively, of another portion of the discharge assembly
of FIG. 13, illustrating various stages in a method of discharging
packaged wax products onto a container labeling assembly in
accordance with an embodiment of the disclosure.
[0021] FIG. 16 is a front isometric view of a container labeling
assembly of the manufacturing machine of FIG. 1, configured in
accordance with an embodiment of the disclosure.
DETAILED DESCRIPTION
[0022] The following disclosure describes systems and methods for
preparing and packaging wax products, such as scented wax products
for use with wickless candles. Certain specific details are set
forth in the following description and in FIGS. 1-16 to provide a
thorough understanding of various embodiments of the invention.
Other details describing well-known structures and systems often
associated with wax products, scented wax products, and
manufacturing such products are not set forth in the following
disclosure to avoid unnecessarily obscuring the description of the
various embodiments of the invention.
[0023] Many of the details, dimensions, angles and other features
shown in the Figures are merely illustrative of particular
embodiments of the disclosure. Accordingly, other embodiments can
have other details, dimensions and specifications without departing
from the present disclosure. In addition, other embodiments may be
practiced without several of the details described below.
[0024] FIG. 1 is a side elevation view of a wax product
manufacturing machine 100 configured in accordance with an
embodiment of the disclosure. In one aspect of this embodiment, the
wax product manufacturing machine 100 ("manufacturing machine 100")
can be used to prepare and package wax products for use with
wickless candles. Such products can include, for example, scented
and/or colored wax bars, segmented wax bricks, etc. which are
individually packaged in suitable containers for sale to consumers
through retail and/or other distribution outlets. In other
embodiments, the manufacturing machine 100 and various systems and
methods thereof can be used as described herein to manufacture
other products. Such products can include, for example, other wax
products as well as other commercial and consumer products formed
from flowable and/or moldable materials, such as flowable and/or
moldable materials that demonstrate properties similar to those of
wax.
[0025] The manufacturing machine 100 includes a product infeed
portion 102 and a product discharge portion 104. As described in
greater detail below, in the illustrated embodiment the product
infeed portion 102 includes a container loading assembly 120 that
can automatically load a plurality of open receptacles or product
containers 132 (e.g., plastic "clam-shell" containers) onto a
product moving assembly 160. The product moving assembly 160
includes a product conveyor 162 operably supported by an elevated
support frame 180. In one embodiment, the product conveyor 162 can
include a plurality of pockets that receive the open product
containers 132 and move them to a container filling assembly 128.
The container filling assembly 128 includes a wax hopper 110 that
automatically dispenses hot, molten or liquid wax into the product
containers 132 through a plurality of dispensing nozzle outlets
118.
[0026] After filling, the product conveyor 162 moves the product
containers 132 through a cooling assembly 150. In the illustrated
embodiment, the cooling assembly 150 includes a plurality of upper
air movers or fans 152 (identified individually as upper fans
152a-152q) and a plurality of lower air movers or fans 154
(identified individually as lower fans 154a-154q). As the product
conveyor 162 moves the filled product containers 132 through the
cooling system 150, the fans 152 and 154 direct cooling air over
and around the containers 132 to cool and harden the wax
therein.
[0027] When the wax-filled containers 132 arrive at the end of the
cooling assembly 150, a container discharge assembly 126
automatically closes the lids on the containers 132. The container
discharge assembly 126 then displaces the containers 132 from the
product conveyor 162 and transfers them onto an adjacent labeling
assembly 140. The labeling assembly 140 can include one or more
conveyor belts 144 that move the closed containers 132 past a
labeling machine 142. As described in greater detail below, the
number of labeling machines 142 in operation at any given time can
vary depending on the number of different types of products coming
off the manufacturing machine 100. For example, if two different
types of wax products are being produced in parallel, two labeling
machines 142 can be employed in parallel so that a first labeling
machine 142 applies appropriate labels 146 to the first product,
and a second labeling machine 142 applies appropriate labels to the
second product. After labeling, an operator 103 can transfer the
individually packaged wax products to a nearby rack 107 for
temporary storage prior to bulk packaging.
[0028] Although the manufacturing machine 100 of the illustrated
embodiment is arranged at least generally horizontally, in other
embodiments the manufacturing machine 100 and variations thereof
can have other orientations or arrangements without departing from
the present disclosure. For example, in other embodiments the
manufacturing machine 100 and/or portions thereof can be arranged
vertically or on an incline to conserve floor space and/or for
other reasons. For example, in one embodiment the cooling assembly
150 and the associated portion(s) of the product conveyor 162 can
be arranged vertically so that the wax-filled containers 132 travel
on a vertical or inclined path for cooling. In such an embodiment,
the product discharge portion 104 of the manufacturing machine 100
can be positioned at a different elevation (e.g., higher) than the
product infeed portion 102. Accordingly, the present disclosure is
not limited to horizontal configurations of the manufacturing
machine 100, but extends to other configurations in which the
machine and/or portions thereof are arranged in curved paths, in
vertical or inclined orientations, and/or other configurations.
[0029] Returning to the product infeed portion 102, base wax 101
(e.g., unscented and uncolored natural wax, paraffin, polymer
additives and/or mixtures thereof, etc.) can be readied for use in
a heated (e.g., an electrically heated) storage tank 106. The
storage tank 106 can hold the base wax 101 in liquid form at
approximately 130 to about 170 degrees F., or at approximately 140
to about 160 degrees F., e.g., about 150 degrees F. When needed, a
pump or other suitable transfer system (not shown) flows the liquid
base wax 101 from the storage tank 106 to one or more heated (e.g.,
electrically heated) mixing tanks 108 (identified individually as a
first mixing tank 108a and a second mixing tank 108b) via
corresponding conduits 112.
[0030] An operator 105 can combine one or more colorings or dyes
116, fragrant oils 117, and/or other additives with the base wax
101 in the mixing tanks 108 to prepare a different wax mixture 103
in each of the mixing tanks 108. The different wax mixtures 103 can
have different colors and/or scent compositions, depending on the
particular type of wax product or products being produced at that
time. For example, the first mixing tank 108a can be holding a
brown wax mixture 103 having a musk scent, and the second mixing
tank 108b can be holding a green wax mixture 103 having a pine
scent. Using two or more mixing tanks 108 enables two or more
different types of wax products (having, for example, two different
colors and/or scents) to be produced simultaneously by the
manufacturing machine 100.
[0031] In operation, the mixing tanks 108 refill the wax hopper 110
as needed with the desired type or types of scented and colored wax
103 for dispensing into the product containers 132. The mixing
tanks 108 maintain the wax 103 in a flowable or liquid form at
about 140 to 160 degrees F., e.g., about 150 degrees F., as higher
temperatures could melt some product container materials (e.g.,
some plastics). These and other features of the manufacturing
machine 100 are described in greater detail below with reference to
FIGS. 2-16.
[0032] FIG. 2A is an enlarged rear isometric view of the infeed
portion 102 of the manufacturing machine 100 configured in
accordance with an embodiment of the disclosure, and FIG. 2B is a
further enlarged view taken from FIG. 2A. The mixing tanks 108, the
product conveyor 162, the cooling assembly 150, and other selected
structures have been omitted from FIGS. 2A and 2B for purposes of
illustration. In one aspect of this embodiment, the container
loading assembly 120 includes a container magazine 220 (sometimes
referred to as a "denester" assembly) having a plurality of
container loading chambers 227 (identified individually as
container loading chambers 227a-227h). As shown in FIG. 2B, each
container loading chamber 227 includes a plurality of alignment
rods 224 extending upwardly from a corresponding container tray 222
(identified individually as container trays 222a-222h). The
alignment rods 224 are positioned around corresponding openings 225
in each of the container trays 222 to align vertical stacks of open
containers 132 above the openings 225. The lower-most containers
132 in each of the stacks is releasably supported at the opening
225 by a first adjustable clip 226a that extends inwardly from one
side of the opening 225 and a second adjustable clip 226b that
extends inwardly from the opposite side of the opening 225.
[0033] In another aspect of this embodiment, the container loading
assembly 120 further includes a container loader 230 movably
positioned beneath the container magazine 220. The container loader
230 includes a plurality of container extraction units 232
(identified individually as container extraction units 232a-232h)
that reach up through the container tray openings 225 and pull the
lower-most containers 132 free of the clips 226 and downwardly
through the openings 225. For this purpose, each of the container
extraction units 232 includes a first suction cup 236a and a
plurality of second suction cups 236b-236g. In the illustrated
embodiment, the first suction cup 236a is larger than each of the
second suction cups 236b-236g. As explained in greater detail
below, the relative sizes of the suction cups 236 facilitate
attachment of the suction cups 236 to the bottom surfaces of the
containers 132. In other embodiments, however, and especially in
those other embodiments that may use different product container
configurations, extraction units configured in accordance with the
present disclosure can include more or fewer suction cups in other
arrangements and having other relative sizes. In still further
embodiments, suitable mechanisms other than suction cups can be
used to extract the product containers from the container trays
222.
[0034] Although only two stacks of containers 132 are shown in
FIGS. 2A and 2B for purposes of illustration, as described in
greater detail below, in operation all or any portion of the
container loading chambers 227 can be filled with empty containers
132 for loading onto the product conveyor 162, depending on the
desired rate of production and/or the number of different products
being produced at a particular time. Moreover, although in the
illustrated embodiment the manufacturing machine 100 includes eight
container loading chambers 227 and eight container extractions
units 232 for simultaneously loading up to eight product containers
132 at a time onto the product conveyor 162, in other embodiments
manufacturing machines configured in accordance with the present
disclosure can include more or fewer container loading chambers
227, container extractions units 232, etc. depending on the needs
and scale of the particular manufacturing operation.
[0035] FIG. 3 is an enlarged, rear isometric view of the container
loader 230 configured in accordance with an embodiment of the
disclosure. In the illustrated embodiment, the container extraction
units 232 are mounted in parallel on a movable support structure
334. The support structure 334 includes a plurality of individual
support members 345 extending outwardly from a base member 347. A
vacuum manifold 342 is attached to the base member 347. Each of the
suction cups 236 is coupled in fluid communication with the vacuum
manifold 342 via a corresponding system of air hoses 344, a
junction block 346, and a vacuum coupling 338. The vacuum manifold
342 is evacuated during operation of the manufacturing machine 100
via a first manifold coupling 340a and a second manifold coupling
340b. More particularly, as described in greater detail below the
manifold 342 is evacuated at preset times which in turn evacuates
the suction cups 236, causing them to attach to the lower-most
container 132 in the overhead stack.
[0036] FIG. 4 is a partially cut-away, enlarged side elevation view
of the product infeed portion 102 of the manufacturing machine 100.
A first air hose 442a operably connects a first vacuum valve 440a
to the first manifold coupling 340a (FIG. 3). Although not shown, a
second air hose operably connects a second vacuum valve to the
second manifold coupling 340b (FIG. 3) on the other side of the
manufacturing machine 100. As described in more detail below, the
vacuum valves 440 are controlled by signals from a machine
controller 410 that opens and closes the valves 440 at appropriate
times so that the suction cups 236 attach themselves to the
lower-most product containers 132 at an appropriate time, and then
release the containers 132 onto the product conveyor 162 at an
appropriate time.
[0037] The machine controller 410 can include or be a programmable
logic controller (PLC) or other microprocessor-based industrial
control system that communicates with the process control
components of the manufacturing machine 100 through data and/or
signal links to control switching tasks, machine timing, process
controls, data manipulation, etc. In this regard, the machine
controller 100 can include one or more processors 412 that operate
in accordance with computer-executable instructions stored or
distributed on computer-readable media 414. The computer-readable
media 414 can include magnetic and optically readable and removable
computer discs, firmware such as chips (e.g., EEPROM chips),
magnetic cassettes, tape drives, RAMs, ROMs, etc. Indeed, any
medium for storing or transmitting computer-readable instructions
and data may be employed. The machine controller 410 and
embodiments thereof can be embodied in a special purpose computer
or data processor that is specifically programmed, configured or
constructed to perform one or more of the machine operations
explained in detail below. Those of ordinary skill in the relevant
art will appreciate, however, that the manufacturing machine 100
and embodiments thereof can be controlled with other types of
processing devices including, for example, multi-processor systems,
microprocessor-based or programmable consumer electronics, network
computers, and the like. Data structures and transmission of data
and/or signals particular to various aspects of the manufacturing
machine 100 are also encompassed within the scope of the present
disclosure.
[0038] Returning to FIG. 2A, in a further aspect of this embodiment
the container loader 230 is operably coupled to a lift assembly
270. The lift assembly 270 includes a first link 276a and a
corresponding second link 276b. The second link 276b has a first
end 273 pivotally attached to a second guide block 279b that slides
up and down on a corresponding second guide shaft 278b. The second
link 276b also has a second end 275 pivotally attached to a distal
end of a corresponding lifting arm 274b. Although not shown from
the perspective of FIG. 2A, the first link 276a is operably coupled
to a first guide block 279a and a first lifting arm 274a in the
same manner that the second link 276b is coupled to the second
guide block 279b and the second lifting arm 274b.
[0039] The first and second guide blocks 279 are fixedly attached
to opposite ends of the container loader base member 347 (FIG. 3).
The lifting arms 274 are fixedly attached to opposing ends of a
lifting shaft 272. As a result, when the lifting shaft 272 rotates,
the lifting arms 274 cause the links 276 to slide the container
loader 230 up and down on the opposing guide shafts 278.
[0040] In another aspect of this embodiment, the product infeed
portion 102 includes a drive assembly 250 that controls operation
of the container loader 230 and movement of the product conveyor
162. The drive assembly 250 includes an electric motor 212 operably
coupled to a drive shaft 214. The electric motor 250 can utilize
standard AC power from a facility outlet. The drive shaft 214 is
operably coupled to the lift shaft 272 by means of a sprocket and
chain arrangement 216. Accordingly, operation of the electric motor
212 causes the drive shaft 214 to rotate which in turn causes the
lift shaft 272 to rotate. In other embodiments, the drive shaft 214
can be operably coupled to the lift shaft 272 by other suitable
means, such as by a gear train, belt, etc.
[0041] Referring to FIGS. 2A and 2B together, during operation of
the container loading assembly 120 the electric motor 212 rotates
the drive shaft 214 which in turn rotates the lifting shaft 272.
The lifting shaft 272 in turn rotates the two lifting arms 274. As
the lifting arms 274 rotate upwardly, the links 276 move the
container extraction units 232 upwardly through openings or
"pockets" in the temporarily stationary product conveyor 162 (FIG.
1). At the top of the stroke, the suction cups 236 contact the
lower-most containers 132 in each of the container stacks. At this
time, the machine controller 410 moves the vacuum valves 440 (FIG.
4) to a first position that evacuates the suction cups 236, causing
them to attach to the lower-most containers 132. As the lifting
arms 274 continue rotating downwardly, the suction cups 236 pull
the lower-most containers 132 free from the container trays 222 and
downwardly toward the product conveyor 162. As the containers 132
move downwardly toward the product conveyor 162, the machine
controller 410 moves the vacuum valves 440 to a second position
that releases the vacuum in the suction cups 236, thereby releasing
the containers 132 in their respective pockets in the product
conveyor 162. Once the containers 132 have been suitably loaded
onto the product conveyor 162, the product conveyor 162 indexes
forward to position the empty product containers 132 beneath the
dispensing nozzle outlets 118 of the wax hopper 110. In other
embodiments, other systems can be used to suitably load the product
containers 132 onto the product conveyor 162 without departing from
the spirit or scope of the present disclosure.
[0042] FIGS. 5A and 5B are enlarged rear isometric views
illustrating various aspects of the product conveyor 162 and the
container loading sequence described above in more detail.
Referring first to FIG. 5A, in the illustrated embodiment the
product containers 132 can be formed from plastic (e.g., clear
polyethylene plastic) and/or other suitable package materials, and
can include a mold portion 534 and a cover or lid portion 536. The
mold portion 534 can include a plurality of cavities 538
(identified individually as cavities 538a-538f) that form the wax
into a bar having separate sections of equal size that can be
easily broken off as needed for use. The lid portion 536 can be
configured to fold about a hinge line 537 and fit snugly over the
mold portion 534 to close the product container 132 after filling,
as described in more detail below. In one embodiment, the product
containers 132 can be reusable, so that the user can pour molten
wax back into the container to store the wax when the wickless
candle is not in use, when the warmer is being cleaned, and/or when
changing waxes.
[0043] The product conveyor 162 can include a plurality of conveyor
sections 560 carried by a first conveyor chain 566a and a second
conveyor chain 566b. In the illustrated embodiment, the conveyor
sections 560 are positioned next to each other in a contiguous
arrangement, and extend around the entire loops of the conveyor
chains 566. The conveyor sections 560 can be formed from suitable
sheet metals, such as stainless steel, mild steel, aluminum, etc.
In other embodiments, however, the conveyor sections 560 can be
fabricated from other suitable materials including, for example,
other metals and non-metal materials such as plastics, composites,
etc. Each of the conveyor sections 560 can include plurality of
first pockets 562a configured to receive and hold the container
mold portions 534, and a plurality of second pockets 562b
configured to receive and hold the container lid portions 536. In
other embodiments, the pockets 562 can be omitted and conveyor
sections having other means of holding the product containers 132
can be used.
[0044] In the illustrated embodiment, the conveyor chains 566 can
be standard, industrial grade roller chains, e.g., standard
stainless steel roller chains having pinned links configured to
engage teeth on drive sprockets. In other embodiments, other
suitable chains, belts, gears, etc., and other drive mechanisms and
the like, can be used with the product conveyor 162. A plurality of
first mounting clips 568a having threaded fastener holes can be
fixedly attached to the first conveyor chain 566b. Similarly, a
plurality of second mounting clips 568b also having threaded
fastener holes can be fixedly attached to the second conveyor chain
566b.
[0045] The individual conveyor sections 560 can be mounted to the
conveyor chains 566 by means of a first fastener 569a (e.g., a
first threaded fastener) that attaches a first side portion 561a of
each conveyor section 560 to one of the first mounting clips 568a,
and a second fastener 569b (e.g., a second threaded fastener) that
attaches a second side portion 561b of each conveyor section 560 to
one of the second mounting clips 568b. Attaching each of the side
portions 561 to the corresponding conveyor chain 566 at a single
point enables the conveyor chains 566 to curve smoothly around
sprockets without derailing or damaging the conveyor sections 560.
The side portions 561 of each of the conveyor sections 560 can also
include a durable edge member 570 made out of ultrahigh molecular
weight (UHMW) plastic, polyurethane, Teflon, or other suitably
durable material that allows the conveyor section 560 to contact or
rub on the conveyor chains 566 and/or other support surfaces
without substantial wear or degradation.
[0046] During loading of the containers 132 onto the conveyor
section 560, the product conveyor 162 is momentarily stationary and
the container loader 230 moves (via the lift assembly 270) the
suction cups 236 upwardly through the open pockets 562 in the
conveyor section 560. The suction cups 236 continue moving upwardly
until they contact the lower-most container 132 in the
corresponding stack (FIGS. 2A and 2B). More particularly, the
larger suction cup 236a contacts the bottom surface of the
container lid portion 536, and the plurality of smaller suction
cups 236b-g contact the bottom surfaces of the individual mold
cavities 538 of the container mold portion 534. At this time, the
suction cups 236 are being evacuated so that they attach to the
container 132 when contact is made. The container loader 230 then
moves downwardly, pulling the container 132 into the respective
pockets 562 of the conveyor section 560. At this time, the vacuum
in the suction cups 236 is released so that they release the
container 132 in the pockets 562. The container loader 230 then
continues moving downwardly and away from the conveyor section 560.
As shown in FIG. 5B, the end result of this sequence is that a row
of (e.g., eight) empty containers 132 are positioned in their
respective pockets 562 of the conveyor section 560, and are ready
to be advanced to the container filling assembly 128 (FIG. 1).
[0047] FIG. 6A is an enlarged, rear isometric view, and FIG. 6B is
an enlarged, front isometric view of a portion of the drive
assembly 250 described above with reference to FIG. 2A. As
discussed above, the drive assembly 250 includes the electric motor
212 (e.g. a 1.5 HP electric motor) which is operably coupled to the
drive shaft 214. A first drive sprocket 616 is releasably engaged
with the drive shaft 214 by means of a clutch 650. A distal end
portion of the drive shaft 214 carries a vacuum control cam 694
(FIG. 6A) having a first lobe surface 697, and a conveyor control
cam 690 (FIG. 6B) having a second lobe surface 698.
[0048] A first proximity switch 696 (e.g., an optical sensor) is
positioned to detect the presence of the first lobe surface 697 on
the vacuum control cam 694 when the first lobe surface 697 is
directly in front of the first proximity switch 696. The first
proximity switch 696 is operably connected (via, e.g., an
electrical link, wired connection, etc.) to the machine controller
410 (FIG. 4). As described in greater detail below, the machine
controller 410 controls the vacuum pressure in the container
extraction unit suction cups 236 (FIGS. 2A, 2B and 3) in response
to the signal received from the first proximity switch 696.
[0049] A second proximity switch 692 (e.g., an optical sensor) is
positioned to detect the presence of the second lobe surface 698 on
the conveyor control cam 690 when the second lobe surface 698 is
directly in front of the second proximity switch 692. The second
proximity switch 692 is operably connected (via, e.g., an
electrical link, wired connection, etc.) to an indexer 652. The
indexer 652 transmits power from the electric motor 212 to a second
drive sprocket 654 in response to the signal received from the
second proximity switch 692.
[0050] As shown in FIGS. 2A and 4, the second drive sprocket 654 is
operably coupled to a third drive sprocket 458 via a drive chain
456 (e.g., a roller chain). In other embodiments, the second drive
sprocket 654 can be operably coupled to the third drive sprocket
458 with other suitable drive mechanisms including gears, belts,
etc. The third drive sprocket 458 is fixedly attached to a distal
end of a conveyor shaft 262 that extends transverse to the product
conveyor 162. The conveyor shaft 262 carries a first conveyor
sprocket 258a inboard of the third drive sprocket 458 toward one
end of the conveyor shaft 262. The conveyor drive shaft 262 also
carries a second conveyor sprocket 258b (not shown in FIG. 2A)
toward the opposite end of the conveyor shaft 262. As shown in FIG.
4, the teeth on the first conveyor sprocket 258a operably engage
the first conveyor chain 566a (FIG. 5A). Although not shown in FIG.
4, the teeth on the second conveyor sprocket 258b similarly engage
the second conveyor chain 566b. Accordingly, when the electric
motor 212 rotates the second drive sprocket 654 (counterclockwise
as seen in FIG. 4), the drive chain 456 rotates the third drive
sprocket 458 in the same direction, which in turn rotates the two
conveyor sprockets 258 and drives the product conveyor 162 forward.
As shown in FIG. 2A, the conveyor shaft 262 also carries a central
support roller 260. Although the product conveyor 162 has been
omitted from FIG. 2A for purposes of clarity, the central support
roller 260 supports a mid-section of the product conveyor 162 as it
turns around at the end of the manufacturing machine 100.
[0051] As discussed above, the movements of the product conveyor
162 and the container loader 230 are coordinated so that the
product conveyor 162 momentarily stops when the open pockets 562
(FIG. 5) are properly aligned with the corresponding container
extraction units 232. This coordinated movement enables the
container extraction units 232 to reach up through the pockets 562,
attach to product containers 132, and then pull the containers 132
down and into the proper pockets 562. This coordinated movement can
be achieved in one embodiment as follows.
[0052] During normal operation, the electric motor 212 is
continually rotating the drive shaft 214, which in turn continually
raises and lowers the container loader 230 by means of the lift
assembly 270. The second drive sprocket 654, however, only advances
or indexes the product conveyor 162 forward periodically. More
particularly, when the second proximity switch 692 (FIG. 6B)
detects the immediate presence of the second lobe surface 698 of
the conveyor control cam 690, the second proximity switch 692 sends
a corresponding signal to the indexer 652. The indexer 652 responds
to this signal by interrupting rotation of the second drive
sprocket 654 and stopping movement of the product conveyor 162
where the container pockets 562 (FIG. 5A) are positioned directly
above the corresponding container extraction units 232. In the
illustrated embodiment, the size of the second lobe surface 698
causes the product conveyor 162 to remain stopped for 180 degrees
of rotation, or at least approximately 180 degrees of rotation, of
the drive shaft 214. As shown by the relative positions of the lift
assembly 270 (e.g., at top-dead-center of the stroke) and the
conveyor control cam 690 (e.g., at the mid-point of the second lobe
surface 698) in FIG. 2, the 180 degrees of rotation of the drive
shaft 214 during which the product conveyor 162 remains stopped
corresponds to the period of time in which the container extraction
units 232 move upwardly and downwardly through the container
pockets 562. Once the second proximity switch 692 no longer detects
the presence of the second lobe surface 698, the indexer 652
provides power to the second drive sprocket 654, causing the
product conveyor 162 to advance forward until the next row of empty
product pockets 562 are positioned directly above the container
extraction units 232.
[0053] Returning to FIG. 6A, the vacuum control cam 694 controls
the vacuum in the extraction unit suction cups 236. More
particularly, as the suction cups 236 approach the uppermost
position and contact the bottom surfaces of the lower-most product
containers 132, the leading edge of the first lobe surface 697 is
directly adjacent to the first proximity switch 696 as shown in
FIG. 6A. This causes the first proximity switch 696 to transmit a
corresponding signal to the machine controller 410 (FIG. 4). The
machine controller 410 responds to the signal by opening the vacuum
valve 440 and evacuating the manifold 342 on the container loader
230 (FIG. 3). The resulting vacuum causes the suction cups 236 to
attach to the bottom surfaces of the product containers 132, which
are then pulled downwardly toward the product conveyor 162. As the
suction cups 236 move downwardly through the container pockets 562,
the first lobe surface 697 of the vacuum control cam 694 moves away
from the first proximity switch 696. This causes the first
proximity switch 696 to transmit a corresponding signal to the
machine controller 410, which responds by closing the vacuum valve
440 and releasing the vacuum in the suction cups 236. This causes
the suction cups 236 to release the containers 132 in the container
pockets 562. At this time, the conveyor control cam 690 causes the
indexer 652 to reengage the second drive sprocket 654 (FIG. 4),
causing the second drive sprocket 654 to start rotating and drive
the product conveyor 162 forward toward the container filling
assembly 128 (FIG. 1). The foregoing describes one system and
method of coordinating or indexing movements of the product
conveyor 162 and the container loader 230 in accordance with the
present disclosure. In other embodiments, other suitable systems
and methods of coordinating this movement can be used. Such systems
can include, for example, software controls, optical targets on the
product conveyor, digital sequencing devices, etc.
[0054] Referring back to FIGS. 2A and 4, a first row of proximity
sensors 264 (e.g., optical sensors; identified individually as
proximity sensors 264a-264h), is positioned above the product
conveyor 162 just downstream of the container magazine 220. Each of
the proximity sensors 264 is positioned directly above a
corresponding row of container pockets 562, and is operably coupled
to the machine controller 410. As the product containers 132 move
forward from the container loading assembly 120, the proximity
sensors 264 detect their presence in the corresponding pockets 562
of the product conveyor 162, and send corresponding signals to the
machine controller 410. As described in greater detail below, the
machine controller 410 uses these signals as confirmation of empty
containers 132 in the corresponding rows, and then commands the
container filling assembly 128 to dispense wax into the containers
132 through corresponding dispensing nozzles 480a-480h
accordingly.
[0055] FIG. 7 is an enlarged, front isometric view of the container
filling assembly 128 configured in accordance with an embodiment of
the disclosure. As this view illustrates, the each of the wax
mixing tanks 108 provides the wax 103 to the hopper 110 via a
corresponding outlet 714 (identified individually as a first outlet
714a and a second outlet 714b). In the illustrated embodiment, each
of the outlets 714 can include an electrical heater 756 (e.g., a
band-type heating element) to maintain wax temperature and reduce
clogging as the wax 103 flows through the outlet 714. Each of the
heaters 756 can receive power from a corresponding user-operable
mixing tank heat controller 758. Wax flow through the outlets 714
is controlled by corresponding valves 715 (identified individually
as a first valve 715a and a second valve 715b). As explained in
more detail below, in the illustrated embodiment the valves 715 are
pneumatically controlled to allow wax to flow from the mixing tanks
108 into the hopper 110 via corresponding ducts or conduits 720
(identified individually as a first conduit 720a and a second
conduit 720b). In other embodiments, electrically controlled valves
and/or other devices can be used to control wax flow from the
mixing tanks 108 to the hopper 110.
[0056] A first junction box 710a and a second junction box 710b are
mounted toward the front portion of the wax hopper 110. Each
junction box 710 includes a plurality of heater connectors 712 and
a plurality of corresponding thermocouple connectors 714. The
heater connectors 712 are electrically coupled to individual
heaters 716 (e.g., Watlow thinband, 120 volt, 125 watt heating
elements) which are mounted to individual dispensing nozzles 480.
The adjacent thermocouple connectors 714 are electrically coupled
to individual thermocouples 718 mounted to the dispensing nozzles
480 adjacent to the electrical heaters 716. In operation, the
heater connectors 712 provide electrical power to the heaters 716
to heat the dispensing nozzles 480 to a suitable operating
temperature (e.g., from about 140 degrees F. to about 160 degrees
F., or about 150 degrees F.), and the thermocouples 718 determine
whether or not the wax 103 is being dispensed at a suitable
temperature (e.g., about 140-150 degrees F.) to avoid or reduce
clogging without melting the receiving product container 132. If
temperature is too low, the junction box 710 increases the
electrical power to the appropriate nozzle heaters 716 as required
to increase the temperature of the corresponding dispensing nozzles
480.
[0057] Returning to FIG. 2, a main control box 210 includes
operator controls 211 for controlling operation of the container
loading assembly 120, the container filling assembly 128, and the
product conveyor 162. A dispensing nozzle heat control box 206
includes individual operator controls 207 for controlling the power
applied to the corresponding wax dispensing nozzle heaters 716
(FIG. 7) via the junction boxes 710 for heating the dispensing
nozzles 480.
[0058] FIG. 8 is a rear isometric view of the container filling
assembly 128 configured in accordance with an embodiment of the
disclosure. The mixing tanks 108, the container loading assembly
120, and other portions of the manufacturing machine 100 have been
omitted from this view for purposes of illustration. Similarly, an
outer portion of the wax hopper 110 has been removed in FIG. 8 to
better illustrate some of the operative components positioned
within the wax hopper 110. In one aspect of this embodiment, the
wax hopper 110 includes a plurality of planer side panels 811
(identified individually as side panels 811a-811d), and a
semi-circular sump or bottom portion 813. The semi-circular shape
of the bottom portion 813 causes the wax 103 (FIG. 7) to collect
near the dispensing nozzles 480 in the lower-most region of the
hopper 110 as the wax level in the hopper 110 drops. In other
embodiments, the bottom portion 813 can have other curved and/or
tapered shapes that act to funnel the wax 103 toward the dispensing
nozzles 480. In the illustrated embodiment, the wax hopper 110 and
the associated side panels 811 and bottom portion 813 can be formed
from a suitable sheet metal, such as stainless steel, using
fabrication methods known in the art. In other embodiments, these
structures can be made from other suitable materials known in the
art.
[0059] In the illustrated embodiment, the wax hopper 110 can
include one or more dividers or partitions 812 that separate the
wax hopper 110 into a plurality of separate hopper portions 810
(identified individually as a first hopper portion 810a and a
second hopper portion 810b). Each of the hopper portions 810
receives the wax 103 from the corresponding mixing tank 108 via the
corresponding inlet conduit 720. Dividing the wax hopper 110 into
two or more hopper portions 810 as illustrated in FIG. 8 enables
the wax hopper 110 to simultaneously dispense two or more different
types of wax (e.g., waxes having different colors and/or scents,
etc.) into product containers 132 as they proceed forward through
the manufacturing machine 110 (FIG. 1). Although the illustrated
embodiment includes two separate hopper portions 810, in other
embodiments, more or fewer separate hopper portions can be used.
For example, in another embodiment, a wax hopper 110 having three
or more separate hopper portions can be used to enable the
manufacturing machine 100 to produce three or more different types
of wax products simultaneously. Alternatively, in another
embodiment, a manufacturing machine configured in accordance with
the present disclosure can include a wax hopper 110 having only a
single hopper portion. This could be accomplished in the present
embodiment by simply removing the partition 812 from the wax hopper
110.
[0060] In the illustrated embodiment, each hopper portion 810
includes a wax mixer 852 and a wax level controller 850 (identified
individually as a first wax mixer 852a and a first wax level
controller 850a associated with the first hopper portion 810a, and
a second wax mixer 852b and a second wax level controller 850b
associated with the second hopper portion 810b). Each of the wax
mixers 852 can include a mixing device 853 (e.g., a mixing blade or
blades, a mixing drum, a cage-type mixer, a Squirrel Mixer.RTM., or
other type of mixing apparatus) driven by an electric motor 854.
For example, in the illustrated embodiment a cage type Squirrel
Mixer.RTM. is shown. In operation, the motor 854 rotates the mixing
device 853 to keep the wax (not shown) in the respective hopper
portion 810 suitably mixed prior to dispensing into the product
containers 132. In one embodiment, this mixing can ensure wax
products with consistent colors, scents, and/or other qualities. In
other embodiments, other suitable apparatuses and systems can be
used to mix the wax in the hopper portions 810 without departing
from the spirit or scope of the present disclosure.
[0061] Each of the wax level controllers 850 can include a
plurality of visual markers 857 that move up or down relative to a
proximity sensor 855 (e.g., an optical sensor) in response to
vertical movement of a float 851 positioned in a tube 858. As
incoming wax raises the float 851, the sensor 855 detects which of
the markers 857 is directly in front of the sensor 855, and sends a
corresponding signal to the machine controller 410. As shown in
FIG. 4, the machine controller 410 is operably connected to two air
control valves 451 (e.g., two-position, electrically actuated
solenoid air valves; identified individually as a first air control
valve 451a on one side of the manufacturing machine 100 and a
second air control valve 451b (not shown) on the other side of the
machine 100). Each air control valve 451 is operably coupled to a
corresponding one of the valves 715 by means of a first air hose
453a and a second air hose 453b. When the signal from the sensor
855 indicates that the corresponding wax hopper portion 810 is
full, the machine controller 410 sends a corresponding signal to
the appropriate air control valve 451. The signal causes the air
control valve 451 to open a first passage that allows pressurized
air to flow through the first air hose 453a and into the valve 715,
thereby closing the valve 715 and stopping the flow of wax from the
mixing tank 108 into the hopper portion 810. When the level of wax
in the hopper portion 810 drops, the sensor 855 sends a
corresponding signal to the machine controller 410, which in turns
sends another signal to the air control valve 451. The air control
valve 451 responds to the signal by closing the first passage and
opening a second passage, allowing pressurized air to flow through
the second air hose 453b and into the valve 715, thereby opening
the valve 715 and letting more wax flow into the hopper portion 810
from the mixing tank 108.
[0062] Although the valves 715 of the illustrated embodiment are
pneumatically controlled, in other embodiments, other types of
valves, including various types of manually and electrically
actuated valves, can be employed. In other embodiments, other
suitable apparatuses and systems can be used to control the level
of wax in the hopper portions 810 without departing from the spirit
or scope of the present disclosure. Such wax level control systems
and apparatuses can include, for example, simple float-type
shut-off valves that are mechanically and/or electrically actuated.
In yet other embodiments, these automated systems can be omitted
and wax level control and/or wax mixing can be performed
manually.
[0063] In the illustrated embodiment, each hopper portion 810
further includes a plurality of wax dispensers 840 (e.g., eight wax
dispensers; identified individually as wax dispensers 840a-840d
associated with the first hopper portion 810a, and wax dispensers
840e-840h associated with the second hopper portion 810b) extending
in a series or row above and across the product conveyor 162 in a
direction transverse to the product feed direction. In this
embodiment, the wax dispensers 840 extend vertically through the
wax hopper 110, terminating in the dispensing nozzle outlets 118
which are positioned directly above respective longitudinal rows of
product container pockets 562 in the product conveyor 162. As
described in greater detail below with reference to FIG. 9, the wax
dispensers 840 are configured to dispense wax into the open
containers 132 through the dispensing nozzle outlets 118.
[0064] In a further aspect of this embodiment, the container
filling assembly 128 includes a hold-down member 830 and a row of
filling sensors 864 (identified individually as filling sensors
864a-864h) positioned above the product conveyor 162. The hold-down
member 830 can include a plate or other structure that extends
across the product conveyor 162 and ensures that the product
containers 132 are properly seated in the conveyor pockets 562 as
they move under the wax hopper 110. The filling sensors 864 (e.g.,
ultrasonic proximity sensors) are positioned just downstream of the
hold-down member 830 adjacent to individual dispensing nozzles 480.
The filling sensors 864 detect the upper surface of the wax as it
flows into the product containers 132 from the dispensing nozzles
480, and can send corresponding signals to the machine controller
410 (FIG. 4) when the containers 132 have been filled to the
desired level. The machine controller 410 responds to the signals
by shutting off the corresponding wax dispensers 840, as described
in greater detail below with reference to FIG. 9.
[0065] FIG. 9 is an enlarged, partially exploded isometric view of
one of the wax dispensers 840 configured in accordance with an
embodiment of the disclosure. In the illustrated embodiment, all of
the wax dispensers 840 are at least generally similar in structure
and function. In one aspect of this embodiment, the wax dispenser
840 includes a cylindrical, two-way piston 946 operably coupled to
an elongate rod 948. The piston 946 slides fore and aft in a
cylinder 942. A first flow control valve 944a is operably coupled
to the cylinder 942 on one side of the piston 946, and a second
flow control valve 944b is operably coupled to the cylinder 942 on
the opposite side of the piston 946.
[0066] A distal end of the rod 948 includes a plunger portion 950
that carries one or more seals or O-rings 952 (e.g., rubber
O-rings). The O-rings 952 form a seal between the plunger portion
950 and a nozzle bore 984 as the plunger portion 950 moves into,
and out of, the wax dispensing nozzle 480 through an opening 982
during operation of the wax dispenser 840. The wax dispensing
nozzle 480 includes a circular flange 985 that is sealably mated to
a corresponding outlet flange (not shown) on the bottom of the wax
hopper 110 with a tube clamp 954 and a gasket 956. The electrical
heater 716 (e.g., a Watlow thinband, 120 volt, 125 watt heating
element) is clamped around the wax dispensing nozzle 480, and the
thermocouple 718 is operably coupled to the nozzle 480 with a
collar 958 positioned below the heating element 716.
[0067] The wax dispenser 840 can operate in one embodiment as
follows: Pressurized fluid (e.g., air) flows into the cylinder 942
through the second flow control valve 944b to drive the piston 946
upwardly toward the first flow control valve 944a. As the piston
946 moves upwardly, back pressure in the cylinder 942 escapes
through the first flow control valve 944a. Moreover, as the piston
946 moves upwardly, the plunger 950 retracts from the nozzle bore
984. This permits wax from the hopper 110 to flow into the nozzle
bore 984 through the opening 982, and then into the waiting product
container 132 (not shown) through the nozzle outlet 118. When the
product container 132 is full, pressurized air flows into the
cylinder 942 through the first flow control valve 944a, driving the
piston 946 downwardly toward the opposite end of the cylinder 942.
As the piston 946 moves downwardly, back pressure in the cylinder
942 escapes through the second flow control valve 944b. Moreover,
downward movement of the piston 946 drives the plunger 950 back
into the nozzle bore 984 to close off the opening 982 and stop the
flow of wax through the outlet 118. The cycle repeats as the next
product container 132 moves into position beneath the nozzle outlet
118.
[0068] FIG. 10 is an enlarged isometric view illustrating a portion
of the container filling assembly 128 (FIG. 1) simultaneously
filling a plurality of product containers 132 with wax 103.
Referring to FIGS. 10 and 4 together, as the product conveyor 162
advances the empty product containers 132 forward from the
container loading assembly 120, the product containers 132 pass
beneath the row of proximity sensors 264. When the proximity
sensors 264 detect an empty product container 132 passing beneath
them, they send a corresponding signal to the machine controller
410. The machine controller 410 is operably connected to a
plurality of air control valves 450 (e.g., two-position,
electrically actuated solenoid air valves; identified individually
as air control valves 450a-450d on one side of the manufacturing
machine 100, and air control valves 450e-450h (not shown) on the
other side of the machine 100). Each air control valve 450 is
operably coupled to a corresponding one of the wax dispensers 840
by means of a first air hose 452a and a second air hose 452b. As
shown in FIG. 9, the first air hose 452a is operably connected to
the first flow control valve 944a on the dispenser cylinder 942,
and the second air hose 452b is operably connected to the second
flow control valve 944b.
[0069] When the machine controller 410 receives a signal from one
of the proximity sensors 264 indicating that an empty product
container 132 is in position on the product conveyor 162, the
machine controller 410 responds by sending a corresponding signal
to the appropriate air control valve 450 when the product container
132 is momentarily stopped beneath the associated wax dispensing
nozzle 480. The signal causes the air control valve 450 to open a
first passage allowing pressurized air to flow through the second
air hose 452b and into the wax dispenser cylinder 942 (FIG. 9)
through the second flow control valve 944b. The air pressure drives
the piston 946 upwardly in the cylinder 942. As the piston 946
moves upwardly, the plunger 950 retracts from the nozzle bore 984.
This permits wax from the hopper 110 to flow into the product
container mold portion 534 through the nozzle outlet 118, as shown
in FIG. 10.
[0070] When the adjacent filling sensor 864 detects that the mold
portion 534 is sufficiently full of wax, the filling sensor 864
sends a corresponding signal to the machine controller 410. The
machine controller 410 responds by sending another signal to the
air control valve 450. The air control valve 450 responds to the
signal from the machine controller 410 by closing the first passage
and opening a second passage, allowing pressurized air to flow
through the first air hose 452a and into the dispenser cylinder 942
(FIG. 9) through the first flow control valve 944a. The pressurized
air drives the piston 946 downwardly toward the opposite end of the
cylinder 942. Downward movement of the piston 946 drives the
plunger 950 back into the nozzle bore 984 to stop the flow of wax
through the nozzle outlet 118, thereby metering the amount of wax
dispensed into the product container 132. Once the container mold
portion 534 has been filled as shown in FIG. 10, the product
conveyor 162 indexes forward (by means of the drive assembly 250
described above with reference to, e.g., FIGS. 6A and 6B) and
places a new row of empty product containers 132 beneath the wax
dispensing nozzles 480, and the cycle repeats.
[0071] In one embodiment, the drive assembly 250 described above
with reference to FIGS. 6A and 6B can be operated at a rate of from
about five to about 15 indexes of the product conveyor 162 per
minute. For example, in one embodiment the drive assembly 250 can
be operated at a rate of about four indexes per minute,
corresponding to filling about 48 product containers per minute. In
another embodiment, the drive assembly 250 can be operated at a
rate of about 10 indexes per minute, corresponding to filling about
80 product containers per minute. In further embodiments, the
manufacturing machine 100 can be configured to fill more or fewer
product containers 132 at different rates. Filling rates can depend
on various factors including, for example, the number of product
containers 132 in a given row or rows of the product conveyor 162
and the corresponding number of dispensing nozzles 480, the
conveyor indexing rate, etc.
[0072] FIG. 11 is a schematic diagram illustrating aspects of the
pneumatic systems and components described above with reference to
FIGS. 1-10. For example, FIG. 11 illustrates the pneumatic
connections between the vacuum control valves 440 and the vacuum
manifold 342 of the container loading assembly 120. FIG. 11 also
illustrates the pneumatic connections between the air control
valves 450 and the corresponding wax dispenser cylinders 942 of
container filling assembly 128.
[0073] FIG. 12 is a rear isometric view of the cooling assembly 150
configured in accordance with an embodiment of the disclosure.
Certain portions of the manufacturing machine 100 (e.g., the
container loading assembly 120, the container filling assembly 128,
the container labeling assembly 140, etc.) have been omitted from
FIG. 12 for purposes of illustration. In one aspect of this
embodiment, the cooling assembly 150 includes a plurality of side
panels 1222 (identified individually as side panels
1222a-1222.eta.) and top panels 1223 (identified individually as
top panels 1223a-1223.eta.) that form an enclosure 1220 around the
upper air movers 152. The enclosure panels 1222 and 1223 can be
manufactured from a suitable sheet metal, such as stainless steel,
aluminum, etc. In the illustrated embodiment, the fan enclosure
1220 extends between the container filling assembly 128 and the
container discharge assembly 126 (FIG. 1). In this regard, the fan
enclosure can be from about 10 feet long to about 35 feet long,
such as from about 15 feet long to about 30 feet long, or about 25
feet long. The fan enclosure 1220 can be supported by a series of
legs 1224 that elevate the fan enclosure 1220 a given distance
(e.g., from about five inches to about two feet, or from about
eight inches to about one foot) above the product conveyor 162.
[0074] As the filled product containers 132 move forward underneath
the fan enclosure 1220, the upper air movers 152 and the lower air
movers 154 direct cooling air over the wax-filled containers 132
from above and below, respectively, to cool and harden the wax
therein. In one embodiment, the air movers 152 and 154 can include
electric motor-driven axial or propeller fans. In other
embodiments, other types of suitable air movers (e.g., centrifugal
(radial) fans, mixed flow fans, cross flow fans, etc.) can be used
with the cooling assembly 150. In further embodiments, chilled air
from one or more air conditioning units (either remote or local)
utilizing refrigerants, water, and/or other coolants etc., can be
directed over the wax-filled product containers 132 via ducting or
other suitable means to cool the wax therein.
[0075] FIG. 13 is an enlarged front isometric view of the container
discharge assembly 126 configured in accordance with an embodiment
of the disclosure. Certain portions of the manufacturing machine
100 (e.g., the container labeling assembly 140) have been omitted
from FIG. 13 for purposes of clarity. In one aspect of this
embodiment, the container discharge assembly 126 includes a
hold-down plate 1350 and a skid plate assembly 1352. The hold-down
plate 1350 extends transversely across and slightly above the
product conveyor 162. The skid plate 1352 is positioned downstream
of the hold-down plate 1350, and also extends across and slightly
above the product conveyor 162. As described in greater detail
below with reference to FIG. 14A, the skid plate assembly 1352
causes the lid portions 536 (FIG. 5A) of the oncoming product
containers 132 to rotate up and aft for container closure. The
closed product containers 132 then proceed forward under the skid
plate assembly 1352 to a lift ramp 1354 where they are moved off of
the product conveyor 162 and onto the container labeling assembly
140 (FIG. 1).
[0076] At the discharge portion 104 of the manufacturing machine
100, the conveyor chains 566 (FIG. 5A) of the product conveyor 162
wrap around and operably engage a first conveyor sprocket 1358a and
a second conveyor sprocket 1358b. The conveyor sprockets 1358 can
be at least generally similar in structure and function to the
conveyor sprockets 258 located at the infeed portion 102 of the
manufacturing machine 100 and described above with reference to
FIG. 4. The conveyor sprockets 1358 are carried on an idler shaft
1364 which extends transversely beneath the product conveyor 162. A
support roller 1360 is mounted to the idler shaft 1264 toward the
center thereof to provide support for the center portion of the
product conveyor 162 as it reverses direction. In addition to the
support roller 1360, the idler shaft 1264 also carries a plurality
of product lifters 1362 (identified individually as product lifters
1362a-1362h) which are fixedly attached thereto and aligned with
respective rows of the product conveyor 162. As described in
greater detail below with reference to FIG. 15A, the product
lifters 1362 rotate with the idler shaft 1364 to sequentially knock
the oncoming product containers 132 off of the product conveyor 162
and onto the lift ramp 1354.
[0077] A first drive sprocket 1366 is fixedly coupled to an outer
end of the idler shaft 1364, and is operably coupled to a second
drive sprocket 1370 by means of a drive chain 1368 (e.g., a
conventional steel roller chain). The second drive sprocket 1370 is
fixedly attached to an outer end of a lid-lifter shaft 1374 which
extends transversely beneath the product conveyor 162. A plurality
of lid lifters 1372 (identified individually as lid lifters
1372a-1372h) which are generally similar in structure and function
to the product lifters 1362, are fixedly attached to the lid-lifter
shaft 1374 in alignment with respective rows of the product
conveyor 162. As described in greater detail below with reference
to FIG. 14A, the lid lifters 1372 rotate with the lid-lifter shaft
1374 to sequentially push the lid portions 536 of the oncoming
product containers 132 upwardly and onto an upwardly facing surface
of the skid plate assembly 1352 as the product containers 132 move
forward from underneath the hold-down plate 1350.
[0078] FIGS. 14A and 14B are enlarged isometric views illustrating
how the lid lifters 1372 cooperate with the skid plate assembly
1352 and the hold-down plate 1350 to close the product container
lid portions 536, in accordance with one embodiment of the
disclosure. As shown in FIG. 14A, in this embodiment each of the
lid lifters 1372 includes four arms 1420 extending outwardly from a
central hub 1422 at right angles to each other. Each of the arms
1420 carries a pusher 1424 on a distal end thereof. The pushers
1424 can have cylindrical or other suitable shapes, and can be made
from plastic, Teflon, rubber, metals, and/or other suitable
materials known in the art. The arms 1420 can be fabricated from
metal rods and/or other suitable materials known in the art. The
product lifters 1362 can be at least generally similar in structure
and function to the lid lifters 1372.
[0079] As the product conveyor 162 moves forward, the drive chain
1368 rotates the lid-lifter shaft 1374, which in turn rotates the
lid lifters 1372. The movement of the lid lifters 1372 is
coordinated with the movement of the product conveyor 162, so that
the pushers 1424 rotate upwardly through the lid pockets 562b (FIG.
5A) and raise the container lid portions 536 as they move out from
under the hold-down plate 1350. As the product containers 132
proceed forward, the lid portions 536 slide over a leading edge
portion 1460 of the skid plate assembly 1352. As shown in FIG. 14B,
continued forward movement of the product containers 132 causes the
lid portions 536 to fold backwardly about the hinge lines 537 (FIG.
5A) and sealably engage a rim or lip on the container mold portions
534 in a press-fit relationship, thereby closing the product
containers 132 around the scented wax product therein.
[0080] FIGS. 15A and 15B are enlarged isometric views illustrating
how the product lifters 1362 move the closed product containers 132
off of the product conveyor 162 and onto the lift ramp 1354, in
accordance with an embodiment of the disclosure. Referring first to
FIG. 15A, as the closed product containers 132 emerge from under a
trailing edge portion 1562 of the skid plate assembly 1352, pushers
1524 on the product lifters 1362 rotate upwardly through the
container pockets 562a to dislodge the product containers 132 and
move them onto parallel support rails 1572 of the lift ramp 1354.
As the product containers 132 continue sliding forward on the
support rails 1572, a plurality of rollers 1570 (e.g., rubber
rollers) on a transverse, rotating shaft 1574 propel the product
containers 132 forward and over a ridge in the lift ramp 1354. As
shown in FIG. 15B, the product containers 132 slide down the
backside of the lift ramp 1354 and onto the awaiting conveyor belt
144 for delivery to the labeling assembly 140.
[0081] FIG. 16 is a front isometric view of the container labeling
assembly 140 configured in accordance with an embodiment of the
disclosure. In the illustrated embodiment, the conveyor belt 144
can direct the product containers 132 onto two or more separate
conveyor belts 1644 (identified individually as conveyor belts
1644a and 1644b) associated with two or more corresponding labeling
machines 142 (identified individually as labeling machines 142a and
142b). In the illustrated embodiment, the container labeling
assemblies 140 are commercially available labeling machines. In
other embodiments, however, other types of suitable labeling
machines known in the art can also be used. The use of multiple
labeling machines 142 enables the container labeling assembly 140
to apply different labels 146 to different product lines when two
or more different types of product are being produced
simultaneously by the manufacturing machine 100. Even when only a
single type of product is being manufactured, the use of multiple
labeling machines 142 can enable faster labeling by labeling the
product containers 132 coming off the manufacturing machine 100 in
parallel rather than in series. The product labels 146 can include
conventional paper or plastic labels having an adhesive back for
adherence to the product containers 132.
[0082] From the foregoing, it will be appreciated that specific
embodiments of the invention have been described herein for
purposes of illustration, but that various modifications may be
made without deviating from the spirit and scope of the various
embodiments of the invention. Further, while various advantages
associated with certain embodiments of the invention have been
described above in the context of those embodiments, other
embodiments may also exhibit such advantages, and not all
embodiments need necessarily exhibit such advantages to fall within
the scope of the invention. Accordingly, the invention is not
limited, except as by the appended claims.
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