Note: Descriptions are shown in the official language in which they were submitted.
20~ 2337
VACUUM FILL SYSTEM
TECHNICAL FIELD OF THE INVENTION
This invention relates to a vacuum fill system for
deaerating flowable material for storage in a container,
and in particular to a vacuum fill system for deaerating
and compacting flowable material used in flexible bulk
containers.
2052337
-- 2
BACKGROUND OF THE INVENTION
Containers used in the storage, transportation and
dispensation of flowable material have been around for as
long as civilization itself. The use of such containers,
however, has always been limited by (1) the weight, density
and other physical properties of the material being stored
and (2) by the process and type of container used to store
the material.
Traditional filling processes and containers have
long been encumbered by a simple phenomenon that has
exasperated consumers for decades - settling. Settling,
as any purchaser of a bag of potato chips knows, means the
bag is never completely filled when opened. This occurs
due to the settling of the product inside during its
filling and shipment. This simple settling phenomenon
causes tremendous economic waste each year because of the
misuse of storage space and container material. This has
been particularly true in the storage, transportation and
dispensation of flowable material in semi-bulk quantities
such as grains, chemicals and other bulky substances stored
in flexible bulk containers, such as those disclosed in
U.S. Patent Nos. 4,143,796 and 4,194,652.
It has long been known that the settling process is
caused by the natural aeration of flowable material as the
material is placed inside a container. As the container
2052337
is shipped to its final destination, the air escapes from
the aerated material causing the product to compact and
reduce in volume. Thus, when the container is opened, the
flowable material has settled to the bottom of the
container, i.e. the bag of potato chips is only half full.
Any process or system, such as the present
invention, for storing material in a container for shipment
that allows all of the container to be filled with product
and eliminates the excess air results in an enormous cost
savings. Indeed, the shipment of smaller sized containers
using vacuum-sealed packages such as, e.g., vacuum-sealed
coffee containers, has alleviated many of the above
problems of cost and time.
Although vacuum-sealed packaging has proved to be
an efficient, cost-saving and consumer-pleasing method of
shipping small quantities of goods, before now, it has been
impossible to apply such techniques to other areas of
storage, transportation and dispensation of flowable
material. This has been particularly true in the market
for semi-bulk flowable material.
20 5 2337
SUMMARY OF THE INVENTION
The present invention relates to a vacuum fill
system for deaerating flowable material, and in particular
to a vacuum fill system for use with flexible bulk
containers used to store, transport and dispense flowable
material in semi-bulk quantities.
The vacuum fill system of the present invention
generally comprises a cylindrical container having a
plurality of chambers; means for intermittently rotating
the chambers; means for establishing a vacuum for
deaerating the flowable material; and means for compacting
the deaerated flowable material.
In accordance with one aspect of the invention there
is provided a vacuum fill system for deaerating flowable
material comprising: means defining a plurality of
chambers; enclosed, airtight housing means surrounding
chamber-defining means and defining a plurality of zones
equal in number to the plurality of chambers; means for
sequentially aligning each of the chambers with each of the
zones of the housing means; means for filling each chamber
with flowable material when the chamber is aligned with one
of the zones; means for creating a vacuum in each chamber
when the chamber is aligned with the next adjacent zone for
deaerating the flowable material; and means for thereafter
returning the pressure in each chamber to atmospheric
. ~
"
20 5 23 37
pressure substantially instantaneously for compacting the
deaerated flowable material.
In accordance with another aspect of the invention
there is provided a vacuum fill system for deaerating
flowable material comprising: an enclosed, airtight housing
defining four zones of equal size; means mounted within the
housing and comprising four chambers of equal size which
rotate about an axis; a geneva mechanism for sequentially
aligning each of the four chambers with each of the four
zones; means for filling each chamber with flowable
material when the chamber is aligned with a predetermined
one of the zones; at least one vacuum pump for creating a
vacuum in the filled chamber when the filled chamber is
subsequently aligned with the next adjacent zone for
deaerating the flowable material within the filled chamber;
and the interior of each chamber being substantially
instantaneously returned to atmospheric pressure when the
chamber is aligned with the next adjacent zone to compact
the deaerated flowable material therein.
In the preferred embodiment of the invention, a
cylindrical container encloses a rotating member which
partitions the container into four chambers and
sequentially positions the four chambers. Conventional
vacuum pumps capable of pulling a vacuum of eighteen (18)
inches of mercury for deaerating the flowable material are
connected to two of the chambers through vacuum lines.
2052337
-- 6
Compressed air for ejecting the compacted, deaerated
flowable material is connected to another chamber through
an air line.
Operation of the vacuum fill system is simple and
easy. A vacuum is established through the use of a
conventional vacuum pump in empty chamber one. A geneva
2052337
mechanism sequentially moves the chambers in a
counterclockwise direction to a position where empty
chamber one is aligned with an intake spout. Flowable
material is poured from a holding/storage device into
chamber one When chamber one is full, the geneva
mechanism repositions the chambers such that empty chamber
two is aligned with the intake spout. While flowable
material enters chamber two, a vacuum is established in
chamber one through the use of a conventional vacuum pump.
Simultaneously, a vacuum is created in empty chamber three.
After sufficient deaeration of the flowable material
is achieved in chamber one, chamber two is filled with
flowable material, and air is evacuated from empty chamber
three, the geneva mechanism moves the chambers again. A
vacuum is created in empty chamber four, flowable material
is poured into chamber three, a vacuum is established in
chamber two, and chamber one is aligned with the discharge
spout.
When the vacuum is released in chamber one, the
interior of chamber one is returned to atmospheric pressure
substantially instantaneously, causing the deaerated
flowable material to compact. The compacted, deaerated
flowable material then drops from chamber one through the
discharge spout into a flexible container. Compressed air
may be used to eject the compacted, deaerated material.
. ..
~,,~, ~, .
- - -
2.os2337
After the compacted, deaerated flowable material
drops from chamber one into the flexible container, a
vacuum is created in chambers two and four, and flowable
material fills chamber three, the geneva device repositions
the chambers. Empty chamber one is returned to its
original position and the vacuum fill system begins a new
cycle.
By deaerating and compacting the flowable material
before filling the flexible container through the use of
the vacuum fill system of the present invention, the
flowable material is presettled and will not settle during
shipment. Thus, the present invention allows for complete
utilization of the flexible container, eliminating wasted
space and allowing for the shipment of more material
without any increase in the container volume. The use of
the present invention thus provides numerous advantages
over the prior art.
2 0 5 2 3 37
BRIEF DESCRIP~ION OF THE D~AWINGS
A more complete understanding of the invention may
be had by reference to the following Detailed Description
when taken in coniunction with the accompanying Drawings,
in which:
FIGURES 1 through 4 demonstrate operation of the
vacuum fill system, showing the sequential steps as they
occur in each chamber, and wherein:
FIGURE 1 is a partial sectional view of the vacuum
fill system illustrating its use with semi-bulk
containers used for flowable material, and illustrating
the filling of chamber one with flowable material
before deaerating;
FIGURE 2 is a partial sectional view of the vacuum
fill system illustrating the deaeration process in
chamber one;
FIGURE 3 is a partial sectional view of the vacuum
fill system illustrating the compacted, deaerated
flowable material being released from chamber one; and
FIGURE 4 is a partial sectional view of the vacuum
fill system illustrating compacted, deaerated flowable
material inside the flexible container and a new vacuum
being created in chamber one;
2052337
- 10 -
FIGURE 5 is a perspective view of the four-walled
partition mounted within the cylindrical container to
separate the container into four chambers; and
FIGURES 6 through 9 illustrate an alternate embodiment
of the vacuum fill system, wherein:
FIGURE 6 is a perspective view of an alternate
embodiment of the vacuum fill system illustrating the
four vertically-oriented, cylindrically-shaped chambers
which rotate counterclockwise in a horizontal plane;
FIGURE 7 is a top sectional view of one of the
vertically-oriented chambers, illustrating its
connection with a vacuum line;
FIGURE 8 is a top view of a vertically-oriented,
four-chambered container illustrating the cycle as it
occurs in each chamber; and
FIGURE 9 is a partial sectional view of a
vertically-oriented, four-chambered container
illustrating the filling process in the left chamber
and compacted, deaerated flowable material being
released from the right chamber.
20 ~2337
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGURE 1, there is shown a vacuum fill
system 10 incorporating a first embodiment of the present
invention. The vacuum fill system 10 has a hollow,
cylindrical container 20 enclosing a rotating member 30
attached to a partition 34 which defines four chambers 32
of equal size.
Attached to the first end 21 of the hollow,
cylindrical container 20 defining an intake spout is a
holding/storage device 16 through which flowable material
enters the container 20. The hollow, cylindrical
container 20 also has a second end 22 defining a discharge
spout through which the compacted, deaerated flowable
material 50 exits the container 20.
The hollow, cylindrical container 20 has a plurality
of openings 23 into which vacuum lines 24 run. In the
preferred embodiment of the invention, there are at least
two openings 23 and two vacuum lines 24 running in opposite
directions. The two vacuum lines 24 are connected to
conventional vacuum pumps 25.
Although any conventional vacuum pump may be
utilized with the present invention, the vacuum pump must
be capable of pulling a minimum of eighteen (18) inches of
mercury during operation. Throughout the remainder of the
specification, the term vacuum is used for clarity, it
C
,-- 2052337
- 12 -
~eing understood that the term means a partial vacuum of
at least eighteen (18) inches of mercury, a total or
perfect vacuum being impossible to achieve.
The container 20 may also have an opening 23
connecting an air line 26 to a compressed air source 27.
FIGURES 1 through 4 illustrate the operation of the
vacuum fill system of the present invention. Although the
vacuum fill system 10, as illustrated in FIGURES 1 through
4, is used in connection with the filling of a semi-bulk
container for handling flowable material, it must be
understood that the present invention is capable of being
utilized with any type of container, no matter how large
or small, where it is desired to compact, deaerate and
densify the flowable material for packing into a container
for shipment and storage.
Initially, a vacuum line 24 to a vacuum pump 25 is
open, creating a vacuum in empty chamber one. Air is
evacuated through the action of the vacuum pump 25 which
draws air from chamber one through the vacuum line 24.
Once chamber one has been deaerated, a geneva mechanism 30,
which converts rotary motion to intermittent motion,
sequentially moves the four chambers 32 in a
counterclockwise direction to a position where chamber one
is aligned with the holding/storage device 16 and the
intake spout 21.
2~52337
- 13 -
In FIGURE 1, chamber one is shown filled with
flowable material 50. The flowable material 50 is
contained within a conventional holding/storage device 16,
such as a hopper. During operation of the vacuum fill
system 10, a flexible container 40 is connected to the
vacuum fill system 10 through conventional means such as
hooks 43 mounted in a frame 42. Support loops 44 on the
container 40 are placed over the hooks 43 to suspend the
container 40 below the discharge spout 22 of the hollow
container 20. A filling tube 45 on the container 40 is
placed around the discharge spout 22 comprising the second
end of the hollow container 20 to prevent spillage while
filling the container 40.
The movement of flowable material 50 into chamber
one is controlled either by weight or height level. When
the predetermined height or weight is reached, the geneva
mechanism 30 sequentially moves the chambers 32 in a
counterclockwise direction.
In FIGURE 2, chamber two is shown filled with
flowable material 50, and the vacuum lines 24 to the vacuum
pumps 25 are open, creating vacuums in chambers one and
three.
When the air ls evacuated from chamber one, the
volume of flowable material 50 actually increases slightly
as the internal air passes through it and the vacuum is
. ~
~5~337
- 14 -
created. Thus, there is actually a volume gain until the
chamber 32 is returned to atmospheric pressure.
Once the vacuum in chamber one reaches the level
necessary to achieve the desired deaeration of the flowable
material 50, chamber two is filled with flowable material
50, and a vacuum is established in empty chamber three, the
geneva device 30 repositions the chambers 32.
Turning to FIGURE 3, the flowable material 50 in
chamber one has been deaerated and compacted, and the
volume of flowable material 50 is now significantly less
than when first introduced into the hollow, cylindrical
container 20. Compaction of the flowable material 50 is
achieved when chamber one is rotated to the fourth
position. This causes the interior of chamber one to
return to atmospheric pressure substantially
instantaneously, whereby the previously deaerated flowable
material 50 is compacted.
Compressed air may be fed through the air line 26
from the compressed air source 27 into chamber one after
compaction has occurred. If used, the compressed air
functions to eject the compacted, deaerated flowable
material S0 from the chamber 32.
The compacted, deaerated flowable material 50 moves
as a compact "slug" of material into the flexible container
40. Since the compacted and deaerated flowable material
- 20 5 Z337
50 is highly densified and only drops a short distance
before entering the f~exi~le container 40, reaeration is
avoided.
Turning now to FIGURE 4, the compacted, deaerated
5flowable material 50 from chamber one is contained within
the flexible container 40. Newly compacted, deaerated
flowable material 50 from chamber two drops into the
- flexible container 40. Chamber one has been returned to
the first position and is connected to the vacuum pump 25
through the vacuum line 24.
After the filling of chamber four with flowable
material 50 and deaeration of flowable material 50 in
chamber three, the geneva device 30 rotates the chambers
32 again, and the chambers are positioned as shown in
FIGURE 1.
In FIGURE 5 there is illustrated the four-walled
partition 34 which is mounted in the cylindrical container
20 to separate the container 20 into four chambers 32 of
equal size.
20Referring now to FIGURE 6, there is illustrated a
vacuum fill system 100 comprising a second embodiment of
the present invention. The vacuum fill system 100 has a
hollow, cylindrically-shaped container 120 with a lid 128,
which holds four vertically-oriented, cylindrically-shaped
25chambers 132. These chambers 132 are positioned 90 degrees
205233-7
apart in the same horizontal plane and rotate
counterclockwise. Flowable material 150 moves from the
holding/ storage device 116 through the intake spout 121
into chamber one. Vacuum lines 124 run from vacuum pumps
125 into openings 123 in the hollow container 120.
As with the first embodiment of the invention,
although the vacuum fill system 100 is preferably used in
connection with the filling of a semi-bulk container 140
for handling flowable material 150, it must be understood
that the vacuum fill system 100 is capable of being
utilized with any type of container, no matter how large
or small, where it is desired to compact, deaerate, and
densify the flowable material for packing into a container
for shipment and storage.
lS Before flowable material 150 is introduced into the
hollow, cylindrical container 120, air is evacuated through
the action of the vacuum pump 125 which draws air from
chamber one through the vacuum line 124. After a vacuum
is created in chamber one, a geneva device 130 sequentially
moves the chambers 132 in a counterclockwise direction to
a position where empty chamber one is aligned with the
holding/storage device 116 and the intake spout 121. Empty
chamber one is then filled with flowable material 150.
When chamber one is filled with flowable material
150, the geneva mechanism 130 repositions the four chambers
.,,~,
.~
.~ .,
2052337
- 17 -
132. A vacuum is created in chamber one to deaerate the
flowable material 150 through the vacuum line 124 connected
to the vacuum pump 125.
Once the vacuum reaches the level necessary to
achieve the desired deaeration of the flowable material
150 in chamber one, the geneva device 130 rotates the
chambers 132 again. As chamber one reaches the fourth
position, the interior of the chamber 132 is substantially
instantaneously returned to atmospheric pressure, thereby
compacting the previously deaerated flowable material 150.
Compressed air may be injected from the compressed air
source 127 through the air line 126 into chamber one to
eject the compacted, deaerated flowable material 150 as a
compact "slug" of material from chamber one into the
flexible container 140.
After the "slug" of flowable material 150 is ejected
from chamber one, the geneva mechanism 130 sequentially
moves the chambers 132, and the vacuum fill system 100
begins a new cycle.
In FIGURE 7, one of the vertically-oriented chambers
132 is shown positioned within the cylindrical container
120. The vacuum line 124 connects the vacuum pump 125 to
the container 120 through the opening 123. O-rings 129
provide a seal between the container 120 and the vacuum
C
205233~
- 18 -
line 124, and aid in the establishment of a vacuum in the
chamber 132.
Turning to FIGURE 8, the four vertically-oriented
chambers 132 are shown within the cylindrical container
120. The filling, deaeration and compaction cycles of the
vacuum fill system 100 occur sequentially in each chamber
132.
In FIGURE 9, there is illustrated the process
occurring in two of the four chambers 132. Flowable
material 150 contained in the holding/storage device 116
enters the left chamber 132 through the intake spout 121.
After deaeration (not shown), the interior of the
right chamber 132 is returned substantially instantaneously
to atmospheric pressure, thereby compacting the deaerated
flowable material 150. The compacted, deaerated flowable
material 150 exits the chamber 132 and drops into a
flexible container 140 (not shown).
Compressed air may be used to eject the compacted,
deaerated flowable material 150 from the chamber 132. If
used, compressed air from the air source 127 moves through
the air line 126 into the chamber 132.
Although not shown, it should be understood that the
operation of the first and second embodiments of the vacuum
fill system 10 and 100 may be performed either manually or
~,
2052337
- 19 -
automatically through the use of conventional electronic
circuitry.
Although preferred embodiments of the present
invention have been illustrated in the accompanying
Drawings and described in the foregoing Detailed
Description, it will be appreciated by those skilled in the
art that various modifications and rearrangements of the
component parts and elements of the present invention are
possible within the scope o the present invention.
OPERATION
Chamber one is aligned with the first zone of the
cylindrically-shaped container. Air is evacuated from the
chamber, creating a vacuum, through the use of a vacuum
line connected to a vacuum pump. The device for
sequentially aligning each of the four chambers with each
of the four zones repositions the chambers such that
chamber one is aligned with the second zone.
Flowable material moves from the holding/storage
device through an intake spout into chamber one. When a
predetermined level of height or weight of flowable
material is reached in chamber one, the device for
sequentially aligning each chamber with each zone moves
chamber one to a position in alignment with the third zone.
~ ,.
2052337
- 20 -
A vacuum is established in chamber one through the
use of the vacuum pump and vacuum line for deaerating the
flowable material. Thereafter, the geneva device
repositions the chambers such that chamber one is aligned
with the fourth zone.
Substantially instantaneously, the interior of
chamber one is returned to atmospheric pressure for
compacting the deaerated flowable material. The compacted,
deaerated flowable material drops from chamber one into a
flexible container. The device for sequentially aligning
each of the chambers with each of the zones repositions the
chambers such that chamber one is returned to its original
position in alignment with the first zone. The vacuum fill
system begins a new cycle.
