U.S. patent application number 14/541920 was filed with the patent office on 2016-05-19 for automated system and method for shrink wrapping plants.
The applicant listed for this patent is David M. Paynter. Invention is credited to David M. Paynter.
Application Number | 20160137328 14/541920 |
Document ID | / |
Family ID | 55961021 |
Filed Date | 2016-05-19 |
United States Patent
Application |
20160137328 |
Kind Code |
A1 |
Paynter; David M. |
May 19, 2016 |
AUTOMATED SYSTEM AND METHOD FOR SHRINK WRAPPING PLANTS
Abstract
The present invention relates in general to an automated, high
through-put system and method for shrink wrapping potted plants for
packaging and shipping. In particular, the system provides the
ability to shrink wrap plants by utilizing a conveyor system and a
heating area with heating units having adjustable, directional
nozzle heads. The system may safely shrink wrap a variety of plant
container sizes and types without causing damage to the plant in
the process.
Inventors: |
Paynter; David M.;
(Dillsboro, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Paynter; David M. |
Dillsboro |
IN |
US |
|
|
Family ID: |
55961021 |
Appl. No.: |
14/541920 |
Filed: |
November 14, 2014 |
Current U.S.
Class: |
53/442 ;
53/557 |
Current CPC
Class: |
B65B 53/066 20130101;
B65B 25/026 20130101; B65B 53/063 20130101 |
International
Class: |
B65B 53/06 20060101
B65B053/06; B65B 25/02 20060101 B65B025/02 |
Claims
1. A system of shrink wrapping a plant, the system comprising: a
motor; a conveyor connected to the motor; a shrink wrap film
machine; heat shields comprising heat shrinkable film, wherein the
shrink wrap film machine deposits the heat shields onto the
conveyor; plants potted in plant containers, wherein a plant and a
plant container are deposited inside a heat shield; a heating area
comprising a first and second heating unit with adjustable,
directional nozzles, wherein the first heating unit discharges
heated air towards a lower portion of the heat shield and the
second heating unit discharges heated air towards an upper portion
of the heat shield through the nozzles; a vacuum, wherein the first
and second heating units allow for an instant on-off effect at the
nozzles by creating the vacuum that pulls air back into the
nozzles; and wherein the heated air safely secures the heat
shrinkable film of the heat shield around the plant and plant
container without damaging the plant in preparation for transport
and shipping.
2. The system of claim 1, wherein the heat shields are individually
deposited into slots on the conveyor to maintain the heat shields
in an upright position, wherein the slots are formed by flat bar
stock panels.
3. The system of claim 2, wherein the slots further comprise height
adjustable pedestals.
4. The system of claim 2, further comprising side rails located on
each side of the conveyor to further maintain the heat shields in
an upright position.
5. The system of claim 1, wherein said first and second heating
units comprise an electrical duct, a squirrel cage fan, heating
coils, an electrical air flow switch, air cylinders, exhaust pipes,
and dampers.
6. The system of claim 5, wherein the shrink wrap film machine
further comprises a photo eye to trigger dispensing a heat shield
onto the conveyor as the panel passes by the photo eye.
7. The system of claim 6, wherein adjusting the dampers located on
the exhaust pipes controls flow rate of heated air through the
nozzles.
8. The system of claim 7, wherein the heating area only raises
plant temperature 6-10.degree. F. above ambient temperature while
heat shrinking the heat shield around the plant and plant
container.
9. The system of claim 1, wherein the heat shields contain
perforations, tear strips, weakened areas, zippers, colors,
designs, and/or scents.
10. The system of claim 1, further comprising: a second conveyor,
wherein the second conveyor comprises two belts; a funnel, wherein
the second conveyor grips the plant between the two belts, removes
the plant from the first conveyor, and deposits it inside the
funnel; and a third conveyor comprising shipping tubes, wherein the
plant is removed from the funnel into a shipping tube for transport
and shipping.
11. A system of shrink wrapping a plant, the system comprising: a
motor; a first conveyor connected to the motor; a shrink wrap film
machine; heat shields comprising heat shrinkable film, wherein the
shrink wrap film machine deposits the heat shields onto the
conveyor; plants potted in plant containers, wherein a plant and a
plant container are deposited inside a heat shield; a heating area
comprising a first and second heating unit, wherein said heating
units each comprise an electrical duct, a squirrel cage fan,
heating coils, an electrical air flow switch, air cylinders,
exhaust pipes, dampers, and adjustable, directional nozzles,
further wherein the first heating unit discharges heated air
towards a lower portion of the heat shield and the second heating
unit discharges heated air towards an upper portion of the heat
shield through the nozzles; a vacuum, wherein the first and second
heating units allow for an instant on-off effect at the nozzles by
creating the vacuum that pulls air back into the nozzles; a plant
environment and a separate shrink wrap environment, wherein the
heat shield acts as a barrier between the environments, further
wherein the plant environment is stable and temperature controlled
to protect the plant from stress and damage from the heated air;
wherein the heated air safely secures the heat shrinkable film of
the heat shield around the plant and plant container without
damaging the plant in preparation for transport and shipping; a
second conveyor, wherein the second conveyor comprises two belts; a
funnel, wherein the second conveyor grips the plant between the two
belts, removes it from the first conveyor, and deposits it inside
the funnel; and a third conveyor comprising shipping tubes, wherein
the plant is removed from the funnel into a shipping tube for
transport and shipping.
12. The system of claim 11, wherein the shrink wrap film machine
further comprises a photo eye to trigger dispensing a heat shield
onto the conveyor as the panel passes by the photo eye.
13. The system of claim 12, wherein the heat shields are maintained
in an upright position on the conveyor via slots and side
rails.
14. The system of claim 13, wherein adjusting the dampers located
on the exhaust pipes controls flow rate of heated air through the
nozzles.
15. The system of claim 14, wherein the heating area only raises
plant temperature 6-10.degree. F. above ambient temperature while
heat shrinking the heat shield around the plant and plant
container.
16. A method of shrink wrapping a plant, the method comprising:
providing a conveyor with slots and side rails, wherein the
conveyor is driven by a motor with variable speed control;
providing a shrink wrap film machine with a photo eye; providing
heat shields comprising heat shrinkable film; depositing a heat
shield onto the conveyor via the shrink wrap film machine, wherein
the heat shield is deposited in an upright position between the
slots and side rails of the conveyor; placing a pre-potted plant
into a top opening of the heat shield; providing a heating area
comprising a first and second heating unit, wherein said heating
units each comprise an electrical duct, a squirrel cage fan,
heating coils, an electrical air flow switch, air cylinders,
exhaust pipes, dampers, and adjustable, directional nozzles;
transitioning the plant in the heat shield into the heating area
via the conveyor; discharging heated air towards a lower portion of
the heat shield through the nozzles of the first heating unit and
further discharging heated air towards an upper portion of the heat
shield through the nozzles of the second heating unit, wherein the
heated air safely secures the heat shrinkable film of the heat
shield around the plant and plant container without damaging the
plant; providing a vacuum, wherein the first and second heating
units allow for an instant on-off effect at the nozzles by creating
the vacuum that pulls air back into the nozzles; and exiting the
plant from the heating area via the conveyor for shipping and
transport.
17. The method of claim 16, further comprising: providing a second
conveyor comprising two belts; providing a funnel; providing a
third conveyor comprising shipping tubes; wherein the second
conveyor removes the plant from the first conveyor by gripping the
bottom portion of the plant between the two belts and transporting
it to the funnel where it is deposited therein; further wherein the
plant is removed from the funnel into a shipping tube on the third
conveyor for transport and shipping.
18. The method of claim 17, further comprising controlling flow
rate of heated air through the nozzles by adjusting the dampers
located on the exhaust pipes.
19. The method of claim 18, wherein plants are in front of the
nozzles discharging heated air for about two second intervals.
20. The method of claim 19, wherein the heating area only raises
plant temperature 6-10.degree. F. above ambient temperature while
heat shrinking the heat shield around the plant and plant
container.
21. A system of shrink wrapping a plant, the system comprising: a
potted plant; a heat shield comprising heat shrinkable film,
wherein the potted plant is inserted into the heat shield; a plant
environment surrounding the potted plant, wherein the plant
environment has a first temperature; a shrink wrap environment,
wherein the shrink wrap environment has a second temperature; a
conveyor, wherein the potted plant moves in and out of the shrink
wrap environment via the conveyor; a barrier between the plant
environment and the shrink wrap environment formed by the heat
shield; wherein the first temperature of the plant environment is
stable and causes no adverse effect on the potted plant; wherein
the second temperature of the shrink wrap environment is at least
hot enough to shrink the heat shrinkable film of the heat shield;
further wherein the second temperature secures the heat shrinkable
film of the heat shield around the potted plant without damaging
the plant in preparation for transport and shipping; and wherein
the temperature of the shrink wrap environment can be instantly
reduced via a vacuum effect while the potted plant is within the
shrink wrap environment.
Description
FIELD OF THE INVENTION
[0001] The present invention relates in general to a system and a
method that provides for high volume, high through-put, automated
shrink wrapping around plants ("SWAP"). In particular, the SWAP
system provides the ability to safely shrink wrap plants while
minimizing stress by utilizing heat shields, a conveyor system, and
a heating area with heating units having adjustable, directional
nozzle heads. Such heat shields further provide protection to the
plants during transport and shipping.
BACKGROUND OF THE INVENTION
[0002] This invention relates to the automated and high through-put
packaging of plants for shipping and storage. There are several
major problems encountered in providing for the shipment of flowers
and plants so that they arrive at their destination in fresh
condition after a journey of many hours and considerable handling.
The first problem is that current shipping systems typically
utilize manual labor for the packaging of plants. Such manual
systems are slow, low through-put and time-consuming, thus, adding
unnecessary stress to the plants. The second problem is that the
delicate flowers or plant foliage must be securely held and
protected during shipment. A desirable solution is to provide a
protective covering (e.g. a plastic sleeve which is heat shrinkable
about a potted plant and requires no additional securing device).
However, difficulties arise when heat shrinking the plastic sleeve
around the plant as the plant can be stressed and even damaged
during the heat shrinking process. The present invention solves the
above problems in a manner not disclosed in the known prior art by
utilizing heat shields to deflect heat away from the plant as it
travels on an automated conveyor system through a heating area to
safely apply the shrink wrapping for shipping and
transportation.
BRIEF SUMMARY OF THE INVENTION
[0003] Therefore, it is a principal object, feature, and/or
advantage of the present invention to overcome the aforementioned
deficiencies in the art and provide an automated shrink wrapping
system for plants that does not damage or stress the plant while
shrink wrapping in a high through-put manner.
[0004] A further object, feature, and/or advantage of the present
invention is to provide a means of shipping articles such as plants
over long distances of many hours duration under rough handling
conditions so that they arrive at their destination in a fresh
condition.
[0005] An additional object, feature, and/or advantage of the
present invention is to provide a heat shield around the plant as
it travels through the heating area of the automated shrink
wrapping system to deflect heat away from the plant and protect it
from stress and damage.
[0006] Another object, feature, and/or advantage of the present
invention is provide a plant container for potting a plant inside
the container, a heat shield disposed about the potted plant, and a
shipping tube for receiving the potted plant therewithin including
means for holding the potted plant in a stable condition during
shipping.
[0007] A still further object, feature, and/or advantage of the
present invention is to provide that the heat shield disposed about
the plant is formed from shrink-wrap plastic and includes an upper
vented portion supporting the plant and a lower portion wrapped
around the plant container in shrink-wrap relation.
[0008] Yet another object, feature, and/or advantage of the present
invention is to provide that the heat shield is formed from a
single panel, each panel including a tear perforation to facilitate
removal of the sleeve from the plant and the plant container.
[0009] An additional object, feature, and/or advantage of the
present invention is to provide an environment with a constant,
stable temperature for the plant and a separate environment for
shrink wrapping heat shrinkable material around the plant and the
plant container, wherein the environments are separated by a heat
shield.
[0010] It is another object, feature, and/or advantage of the
present invention to provide that the shipping tube include a
bottom wall and peripheral side walls, and the means holding the
plant container include means extending between the shipping tube
and the plant container.
[0011] According to one aspect of the present invention, a system
is provided to shrink wrap potted plants by utilizing heat shields,
a high through-put conveyor system and an automated heating area
with heating units having adjustable, directional nozzle heads.
[0012] According to another aspect of the present invention, a
method of packaging plants for shipment can include placing
water-containing absorbent material in the lower portion of a plant
container; potting the plant in the water absorbent material;
covering the potted plant with a heat shield of shrink wrap
plastic; applying heated air to the heat shield to connect it to
the plant and plant container; and, fitting the plant container
into a shipping tube.
[0013] Different aspects may meet different objects of the
invention. Other objectives and advantages of this invention will
be more apparent in the following detailed description taken in
conjunction with the figures. The present invention is not to be
limited by or to these objects or aspects.
DESCRIPTION OF FIGURES
[0014] FIGS. 1-4 represent examples of systems of the present
invention, and a method of utilizing the present invention.
[0015] FIG. 1 is an assembly line view of the system of the present
invention.
[0016] FIG. 2 is a flow diagram of the method of the present
invention.
[0017] FIG. 3 is a frontal view of the system of FIG. 1.
[0018] FIG. 4 is a view of the different environments of FIG.
1.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present invention contemplates a system and a method
that provides for high volume, high through-put, automated shrink
wrapping around potted plants for transportation and shipment. The
term "potted plant" as used herein means a plant and the pot or
plant container, such as a flower pot, within which the plant is
contained. The term "plant container" means any type of floral
container used to hold a botanical item. Examples of plant
containers used in accordance with the present invention include
clay flower pots, plastic flower pots, Ellepots, and flower pots
comprised of other natural or synthetic materials. The plant
container has potting soil or any other growing medium or filler,
such as foam, known in the art to secure a plant or other botanical
item within the plant container. The term "growing medium" as used
herein means any liquid, solid or gaseous material used for plant
growth or for the cultivation of plants, including organic and
inorganic materials such as soil, humus, perlite, vermiculite,
sand, water, and including the nutrients, fertilizers or hormones
or combinations thereof required by the plants for growth. One end
of the plant is secured in the plant container and the other end
exposed through the opening in the plant container. The potted
plant has an exterior surface comprising the outer surface of the
plant container, about which a cover may be placed or applied. The
term "plant" as used herein means a natural or artificial
herbaceous or woody plant, taken singly or in combination. The term
"plant" also means any portion or portions of natural or artificial
herbaceous or woody plants including stems, leaves, flowers,
blossoms, buds, blooms, cones, or roots, taken singly or in
combination, or in groupings of such portions such as a bouquet or
cut flowers.
[0020] FIGS. 1 and 2 illustrate a side assembly view of the SWAP
system (10) and method of the present invention. The SWAP system
comprises a first conveyor (12) driven by a motor (14). The motor
(14) can be electric, hydraulic, pneumatic, or other like motors
with variable speed control. The motor (14) may be connected to a
gear box (not shown) such as a right angle gear box or variable
gear box with a compatible gear ratio such as 60 to 1, 50 to 1, or
between 40-80 to 1. In another aspect of the present invention the
gear ratio is a variable ratio. In preference, chain sprockets (16)
may be attached to an output shaft (18) of the gear box and a drive
shaft (20) of the first conveyor (12). These two chain sprockets
(16) can be connected by a drive chain (22) to form a continuous
loop. When initiated, this continuous loop allows the motor (14) to
turn the first conveyor (12) for the SWAP system (10).
[0021] Slots (24) may be mounted or configured on the first
conveyor (12). Slot sizes (24) may be modified via interchangeable
chains or sections to fit shrink-wrap plastic tubular heat shields
(26) of various diameters. Slots (24) include two steel flat bar
stock panels. In one aspect, the panels can be 5'' high, 1'' wide,
and 1/8'' thick. These panels ensure that heat shields (26) remain
in an upright position on the first conveyor (12) with an opening
at the top of each heat shield (26). Furthermore, each of these
slots (24) may include a height adjustable pedestal. The height
adjustable pedestal may be 1'' in diameter, more preferably 1/2''
in diameter, and most preferably 3/8'' in diameter. The head of the
adjustable pedestal may be in the range between 3/8 to 2'',
preferably with a 1/2'' mushroom head. This pedestal may be height
adjustable (e.g. 1'' to 2'' above the first conveyor) to compensate
for plant containers of various types (e.g. soft-sided Ellepots or
rigid containers) and various sizes (e.g. 2''.times.2'';
3''.times.3''; 3.5''.times.3.5''; 4''.times.4''; 4.5''.times.4.5'';
30 mm; 45 mm; 60 mm; 65 mm; 80 mm) being used in the SWAP system.
For instance, soft-sided Ellepots require more of a bottom surface
to be surrounded by the heat shields to ensure protection when
shipping, whereas rigid containers only require their sides to be
covered to be adequately protected.
[0022] FIG. 1 further illustrates that the SWAP system may have
height and width adjustable side rails (28) located on each side of
the first conveyor (12). The side rails (28) may be between 5-10''
in height above the conveyor (12). The side rails (28) are
preferably made of sheet metal covered with Teflon.TM. tape. Side
rails (28) serve a dual purpose of maintaining heat shields in an
upright position and eliminating static cling that is intrinsic to
shrink-wrap plastic film.
[0023] The SWAP system and method of the present invention is a
high volume, high through-put system capable of automatically
running approximately 10-50 plants per minute through at any given
time. The system of the present invention further comprises a
standard automated industry shrink wrap film machine (30) known in
the art and commercially available, such as those manufactured by
Uline, U.S. Packaging & Wrapping, and Astroseal. The shrink
wrap film machine further comprises a photo eye (32). An electrical
signal from the photo eye (32) triggers the shrink wrap film
machine (30) to automatically dispense a preformed heat shield (26)
into the slot (24) between each flat bar stock panel when the
panels pass by the photo eye (32). The preformed heat shield (26)
may comprise a tubular shape (e.g. cylindrical, square, octagonal,
trapezoidal, etc.) having an open upper end, a lower end, and an
interior space. The heat shield (26) comprises a shrinkable
material which, in a preferred embodiment, is made up of shrink
wrap or heat shrinkable material. The shrinkable material can be
shrunk by a heat source to constrict or crimp the heat shield such
that when a plant (34) and plant container (36) are disposed within
the heat shield (26), the shield is held or secured about the plant
(34) and plant container (36). The heat shield (26) may be
detachable from the plant and plant container via perforations,
tear strips, weakened areas, or zippers. The upper portion of the
heat shield may also be detachable and have an extended portion for
serving as a handle or support device.
[0024] The heat shield (26) may be constructed of a single sheet of
material or a plurality of sheets. Any thickness of the sheet of
material may be utilized in accordance with the present invention
as long as the sheet of material may be wrapped about at least a
portion of a plant container, as described herein. The heat shield
(26) may have a thickness of less than about 1 mil to about 30
mils. Typically, the heat shield (26) has a thickness in a range of
less than about 0.2 mils to about 10 mils. In a preferred
embodiment, the heat shield (26) is constructed from one sheet of
man-made organic polymer film having a thickness in a range of from
less than about 0.5 mils to about 2.5 mils.
[0025] The heat shield (26) may vary in color. Further, the heat
shield (26) may consist of designs which are printed, etched,
and/or embossed; in addition, the heat shield (26) may have various
colorings, coatings, flocking and/or metallic finishes, or be
characterized totally or partially by pearlescent, translucent,
transparent, iridescent, or the like, characteristics. Each of the
above-named characteristics may occur alone or in combination.
Moreover, each surface of the heat shield (26) may vary in the
combination of such characteristics.
[0026] The heat shield (26) may further comprise at least one
scent. Examples of scents utilized herein include (but are not
limited to) floral scents (flower blossoms, or any portion of a
plant), food scents (chocolate, sugar, fruits), herb or spice
scents (cinnamon), and the like. Additional examples of scents
include flowers (such as roses, daisies, lilacs), plants (such as
fruits, vegetables, grasses, trees), foods (for example, candies,
cookies, cake), food condiments (such as honey, sugar, salt),
herbs, spices, woods, roots, and the like, or any combination of
the foregoing. Such scents are known in the art and are
commercially available. The scent may be disposed upon the heat
shield by spraying the scent thereupon, painting the scent
thereupon, brushing the scent thereupon, lacquering the scent
thereupon, immersing the sheet of material to scent-containing gas,
or any combination thereof. The scent may be contained within a
lacquer, or other liquid, before it is disposed upon the sheet of
material. The scent may also be contained within a dye, ink, and/or
pigment (not shown). Such dyes, inks, and pigments are known in the
art, and are commercially available, and may be disposed upon or
incorporated in the sheet of material by any method described
herein or known in the art.
[0027] Plants (34) are pre-potted in the plant containers (36) and
inspected by an operator for quality assurance. As heat shields
(26) automatically travel down the first conveyor (12), the
pre-potted plants (34) are manually loaded (38) by the operator
into the opening at the top of each heat shield (26) at a
preferable rate of approximately thirty plants per minute. Thus, a
heat shield (26) may extend entirely circumferentially about the
plant (34) in its plant container (36). Although the present
invention discloses manual placement of the plants (34) into the
heat shields (26), it is contemplated that robotics may be utilized
instead. At this point the plants (34) located within the heat
shields (26) automatically continue down the first conveyor (12) to
the heating area (40).
[0028] As illustrated in FIG. 3, the heating area (40) can be
divided into a first heating unit (42) and a second heating unit
(44). Heating units (42, 44) can include, for example, electrical
ducts; fans; heating coils; electrical air flow switches; air
cylinders; exhaust pipes; exhaust (damper) flaps; and, rotatable,
adjustable, directional nozzles. In one example, each heating unit
(42, 44) can include one 6''.times.6''.times.24'' NEMA electrical
duct; one squirrel cage fan with an output of 130 CFM; two 2200
watt, 220 volt, single phase resistant heating coils encased in a
cylindrical 10'' ceramic pipe capable of withstanding 2600.degree.
F.; one electrical air flow switch; two air cylinders; two 2.5''
diameter standard automotive exhaust pipes; two agricultural
implement exhaust (damper) flaps; and, two rotatable, adjustable,
directional nozzles. The adjustable directional nozzles can be in
any shape advantageous for directing airflow, but preferably either
circular in shape, wedge shaped, and/or with extensions that
prevent air flow from traversing upwards or downwards. In one
aspect, heating unit (42, 44) can be configured so that a first set
of up to six adjustable, directional nozzles (46) are positioned on
opposite sides of the first conveyor (12) at a first elevation to
discharge heated air towards a lower portion of the heat shield
(26) to heat shrink or constrict the shield around the plant
container (36) while the shields are traveling past the heating
units on the first conveyor (12). In this aspect a lower extension
can be included on the nozzle to prevent air flow from traversing
downwards. In another aspect, heating unit (42, 44) can be
configured so that a second set of up to six adjustable,
directional nozzles (48) are positioned on opposite sides of the
first conveyor (12) at a second elevation to discharge heated air
towards an upper portion of the heat shield (26) to heat shrink or
constrict the shield (26) around the plant (34). In this aspect an
upper extension can be included on the nozzle to prevent air flow
from traversing upwards. In at least one example, the first heating
unit (42) can be configured so that a pair of rotatable,
adjustable, directional nozzles (46), including lower extensions,
are positioned on opposite sides of the first conveyor (12) at a
first elevation to discharge heated air towards a lower portion of
the heat shield (26) to heat shrink or constrict the shield around
the plant container (36), including the bottom of the plant
container (36), while the shields are traveling past the first
heating unit (42) on the first conveyor (12). The second heating
unit (44) can be configured so that a second pair of rotatable,
adjustable, directional nozzles (48), including upper extensions,
are positioned on opposite sides of the first conveyor (12) at a
second elevation to discharge heated air towards an upper portion
of the heat shield (26) to heat shrink or constrict the shield (26)
around the plant (34) while the shields are traveling past the
second heating unit (44) on the first conveyor (12). In another
example, the heat shield (26) on the first conveyor (12) travels
past the first heating unit (42) wherein heated air heat shrinks or
constricts the shield (26) around the plant container (36) before
the heat shield (26) travels past the second heating unit (44)
wherein heated air heat shrinks or constricts the shield around the
plant (34).
[0029] Returning to FIGS. 1 and 2, an operator may conduct a
pre-heating process for the SWAP system prior to starting the first
conveyor (12). For instance, squirrel cage fans (50) may be turned
on to trigger the air flow switch and activate the heating coils
(not shown), thus forcing air over the heating coils at a
controlled rate. During this pre-heating process, damper flaps (52)
will be fully opened by the de-activated air cylinders (54) and
heated air will be discharged through openings in the exhaust pipes
(56).
[0030] After the operator initiates the first conveyor (12) to
begin the heating process, the air cylinders (54) may be activated
and the dampers (52) closed to pre-determined incremental settings.
Thus, heated air will now flow at a controlled rate through the
adjustable, directional nozzles (46, 48) onto the first conveyor
(12). This rate may be adjusted by changing the size of the
openings of the exhaust pipes (56) via the dampers (52). Changing
the size of these openings allows for a temperature drop at the
nozzles (46, 48) directed at the heat shields (26) (i.e. a larger
opening at the exhaust pipes creates greater air flow, thus
lowering the temperature at the nozzles). Thus, fully opening the
dampers (52) allows heated air to escape through the exhaust pipes
(56) and create a vacuum that pulls cool air back through the
nozzles (46, 48) to create an instant on/off effect. This also
makes it possible for the first conveyor (12) to shut down with
plants (34) directly in line with the nozzles (46, 48) as there is
no need to remove the plants (34) from the first conveyor (12) to
prevent heat damage. This also makes it possible for an instant
restart without loss or delay of production. As a result, the
unique design of the SWAP system allows for the first conveyor (12)
to be stopped without having to also shut down the heating units
(42, 44).
[0031] As illustrated in FIGS. 3-4, the heat shield (26) creates
separate, temperature controlled environments around the plant (34)
as it travels through the heating area (40) of the automated, high
through-put SWAP system. The heat shield (26) is critical to the
safety of the plant (34) by creating a barrier between shrink wrap
environments (T.sup.C, T.sup.D) and plant environments
(T.sup.A,T.sup.B). Shrink wrap environments (T.sup.C, T.sup.D)
typically combine high temperatures and air flow rates (68, 70),
generated by heating units (42, 44) and discharged through
adjustable, directional nozzles (46, 48), needed to shrink wrap the
heat shrinkable material around the plant (34), plant container
(36), and the bottom of the plant container (36). Fixture (37)
allows the heat shield (26) to wrap around the bottom of plant
container (36) as it traverses through the SWAP system.
Temperatures in shrink wrap environments (T.sup.C, T.sup.D)
typically range between 50 to 500.degree. F. Moreover, heat shrink
environment (T.sup.C) may be set at a different temperature level
then heat shrink environment (T.sup.D), according to the
preferences of the operator. Likewise, heat ranges and air flow
rates (68, 70), emitted from the heating units (42, 44) and
discharged through the adjustable, directional nozzles (46, 48),
may also be set at different parameters according to the
preferences of the operator. Thus, the heat shield (26) protects
the plant (34) from the stressful shrink wrap environments
(T.sup.C, T.sup.D) that could potentially damage the plant (34)
during the shrink wrapping process. The heat shield (26)
accomplishes this by deflecting heat and air flow (68, 70) away
from the plant and thus creating a stable, temperature controlled
plant environment (T.sup.A,T.sup.B). Temperature levels in plant
environments (T.sup.A,T.sup.B) are consistently between the ranges
of 50 to 100.degree. F., and more preferably ambient temperature.
This is illustrated in Table 1, which compares temperatures in
plant environments (T.sup.A,T.sup.B) to shrink wrap environments
(T.sup.C, T.sup.D) as plants (34) traverse through the SWAP
system.
TABLE-US-00001 TABLE 1 Prior to Heat Heat After Heat Shrink Shrink
Shrink Temperature in Plant 78.0.degree. F. 89.0.degree. F.
90.0.degree. F. Environments (T.sup.A, T.sup.B) Temperature in
Shrink Wrap 78.0.degree. F. 150.0.degree. F. 89.0.degree. F.
Environments (T.sup.C, T.sup.D) Soil Temperature 70.0.degree. F.
82.0.degree. F. 87.0.degree. F.
[0032] The automated, high through-put process of the present
invention generates product movement on the first conveyor (12) so
that plants (34) are only in front of the adjustable, directional
nozzles (42, 44) for brief intervals. In one aspect the plants (34)
are in front of the nozzles (42, 44) for two brief intervals
between 1-5 seconds per interval. This process raises the
temperature of plant environments (T.sup.A,T.sup.B) approximately
1-15.degree. F. above ambient temperature, more preferably
6-10.degree. F., thus, causing no adverse effect on the plant.
Moreover, plant environment (T.sup.A) may be set at a different
temperature level then plant environment (T.sup.B), according to
the preferences of the operator.
[0033] As shown in FIG. 1, after the plants (34) travel through the
heating units (42, 44) and the heat shields (26) are heat shrunk
safely around the plants (34) and plant containers (36), each plant
and its respective container is picked up by a second conveyor (58)
comprising one to four belts, preferably two. Thus, one belt may be
positioned on each side of the first conveyor (12). These belts may
be fabricated from a very soft durometer material so that plant
root balls will not be damaged while gripped by the belts. As the
plant (34) enters the center of these belts the plant (34) is
lifted from the first conveyor (12) and transferred to the end of
the second conveyor (58) wherein the plant (34) is deposited into a
funnel (60). Once the plant (34) enters the funnel (60) it sits at
the bottom in an upright position. At the same time the plant (34)
is released into the funnel (60), a third conveyor (64) can
position a shipping tube (66) under the funnel (60). The shipping
tube (66) can be configured with a diameter larger than the plant's
root ball. When in this position, the shipping tube (66) can also
sit over an assortment of holes connected to a vacuum system (not
shown). The vacuum system then pulls the plant (34) into the
shipping tube (66).
[0034] All conveyors (12, 58, 64) in the SWAP system are automated,
high through-put, and may run in a continuous loop and may be
driven by the same motor (14). However, the third conveyor (64) may
be configured to move slower as compared to the first and second
conveyors (12, 58) to allow twice the amount of time to load the
plant (34) into the shipping tube (66). After the shipping tube
(66) is loaded with a plant (34) the third conveyor (64) removes
the shipping tube (66) from under the funnel (60) wherein it exits
the SWAP system for shipping and transportation. This process may
run continuously without manually stopping and starting the
conveyors.
[0035] The automated, high volume, high through-put SWAP system and
method of the present invention are universally applicable to
plants and plant containers of all shapes and sizes, makes, models,
and manufacturers. Furthermore, the SWAP system can be used with
any standard manufacturer shrink wrap film machine. Although the
invention has been described and illustrated with respect to
preferred aspects thereof, it is not to be so limited since changes
and modifications may be made therein which are within the full
intended scope of the invention.
* * * * *