Note: Descriptions are shown in the official language in which they were submitted.
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PATENT
APPARATUS FOR PRODUCING SLICES WIT~I BIASED
SPRING-LOADED FEED MECHANISM
Cross-Reference to Related Application
The present application is a continuation-in-
part of pending U.S. patent application Serial No.
07/722,600, filed June 27, 1991.
Field of the Invention
The invention relates to an apparatus for
slicing objects, such as potatoes, into portions,
such as helical or spiral-shaped portions.
Background of the Invention
A variety of food processing systems have been
developed for slicing food items into helical or
spiral-shaped portions. For example, U.S. Patent
4,926,726, to Julian, issued ~ay 22, 1990, and U.S.
Patent 4,979,418 to Covert, et al., issued December
25, 1990, both disclose an apparatus for cutting food
items, such as potatoes, into helical portions. The
apparatus of each of these patents transports
potatoes between a set of top, bottom, and side
conveyors to a set of spring loaded feed rollers 150,
151, and 152. Each potato is then translated
horizontally between the feed rollers into contact
with a rotating knife assembly 12. The knife assembly
has two radially oriented rows of horizontally
protruding knife blades 180 for scoring the potato,
and a vertically oriented blade 182 for severing
helical slices from the scored potato.
The knife assembly of U.S. 4,979,418 (and of a
first embodiment disclosed in U.S. 4,926,726) is
driven by drive gear 188 which engages the knife
assembly's drive teeth 231 (shown in Figure 11 of
~ ~3 8 ~
U.S. 4,926,726). In a second embodiment disclosed in
U.S. 4,926,726, the knife assembly is driven by drive
belt 360 (shown in Figure 13), which engages teeth
320 of knife assembly member 316.
The present invention is an improved apparatus
for producing helical slices of an object, which
includes an improved knife assembly drive means
employing water to cool and clean its bearings, an
improved knife assembly having knife blades arranged
in a spiral pattern to reduce the torgue needed to
slice objects, and an improved, spring-biased,
vertically oriented feed assembly for translating
objects into contact with the knife assembly.
Summary of the Invention
The invention is an apparatus for slicing an
object with a rotatably mounted knife assembly.
Preferably, the knife assembly is designed to produce
helical slices from the object. Although the
invention is suitable for slicing a wide variety of
objects, potatoes are an important example of an
object that can be sliced in accordance with the
invention. For convenience, the specification will
describe the invention in the context of slicing
potatoes, although the claimed invention is not
limited to a method or apparatus for slicing
potatoes.
The apparatus of the invention includes a
rotatably mounted knife assembly, which preferably
includes one or more sets of knife blades arranged in
a spiral pattern. Each set of knife blades produces a
set of helically shaped potato slices. The spiral
arrangement of each blade set reduces the torgue
needed to slice a potato using the inventive knife
assembly. The arrangement of scoring and slicing
blades in the inventive apparatus produces helical
slices in a single, continuous cutting action, rather
than by a scoring cutting action followed by a
subsequent slicing action to produce helical slices,
as in conventional devices such as those described in
above-discussed U.S. Patents 4,926,726 and ~,979,418.
In a class of preferred embodiments, the objects
(e.g., potatoes) to be sliced are conveyed downward
toward the blade assembly between a gripper chain and
a feed chain. Two springs, each mounted on a
rotatable arm assembly, provide biasing force to urge
the chains together, thereby ensuring that the chains
feed potatoes positively and uniformly toward the
blade assembly. When a large potato passing between
the lower chain ends temporarily displaces the chains
(thus stretching the springs), the springs will
rotate the rotatable arm assemblies, thereby
increasing the gripping force exerted by the chains
on a potato between their upper ends tto prevent the
chains from losing their grip on the latter potato).
Two feed rolls having teeth are mounted between
the lower chain ends and the blade assembly (each
feed roll at the end of a rotating, slidable shaft).
The teeth of the rotating feed rolls grip each potato
conveyed against them by the chains, and force each
such potato downward against the rotating blade
assembly. Preferably, a support and retaining plate
is fixedly mounted to the feed mechanism to constrain
vertical movement (and limit horizontal movement) of
the feed rolls as they rotate with a potato gripped
between them.
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Brief Description of the Drawinqs
Figure 1 is a perspecl:ive view of a preferred
embodiment of the apparatus of the invention.
Figure 2 is a cross-sectional view of the Figure
1 apparatus, taken along line 2-2.
Figure 3 is a cross-sectional view of the Figure
2 apparatus, taken along line 3-3.
Figure 4 is a front cross-sectional view of the
product feed assembly of the Figure 1 apparatus.
Figure 5 is a cross-sectional view of a portion
of the Figure 4 apparatus, taken along line 5-5 of
Figure 4.
Figure 6 is a is a cross-sectional view of a
gear box portion of the Figure 2 apparatus, taken
along line 6-6 of Figure 2.
Figure 7 is a side cross-sectional view of a
portion of the Figure 1 apparatus.
Figure 8 is an exploded perspective view of gear
components of the Figure 1 apparatus.
Figure 9 is an exploded perspective view of the
knife assembly of the Figure 1 apparatus.
Figure lO is a cross-sectional view of the
assembled Figure 9 assembly, taken along line 10-10
of Figure 9.
Figure 11 is an exploded side view of a portion
of the knife assembly of Figure 9.
Figure 12 is a cross-sectional view of a knife
portion of the Figure 11 apparatus, taken along line
12-12 of Figu,re 11.
Figure 13 is a cross-sectional view of the knife
of Figure 12, taken along line 13-13 of Figure 12.
Figure 14 is a top view of a portion of the
Figure 11 apparatus.
Figure 15 is a side view of a portion of a knife
template, of a type which can be processed (by
bending and sharpening) to produce the knife
component shown in Figure 14.
Figure 16 is a top view of an alternative
preferred embodiment of a }cnife assembly, suitable
for mounting in the Figure 1 apparatus.
Figure 17 is a cross-sectional view of the
Figure 16 assembly, taken along line 17-17 of Figure
16.
Figure 18 is a cross-sectional view of a portion
of the Figure 16 assembly, taken along line 18-18 of
Figure 17.
Figure 19 is a cross-sectional view of a portion
of the Figure 16 assembly, taken along line 19-19 of
Figure 17.
Figure 20 is a perspective view of another
alternative preferred embodiment of a knife assembly,
suitable for mounting in the Figure 1 apparatus.
Figure 21 is a cross-sectional view of a portion
of Figure 20 assembly, engaged with a potato.
Figure 22 is a perspective view of a helical
slice of the type that can be produced using the
Figure 20 assembly.
Figure 23 is a top view of a portion of the
Figure 20 assembly.
Figure 24 is a cross-sectional view of a portion
of the Figure 23 assembly, taken along line 24-24 of
Figure 23.
Figure 25 is a simplified front elevational view
(partially cut away) of another preferred embodiment
of the inventive apparatus.
Figure 26 is a side cross-sectional view of a
portion of the apparatus of Figure 25 (with elements
200-202 and 204-206 additionally shown in side
elevational view).
Figure 27 i5 a side ellevational view of a
preferxed embodiment of a shaft extension member
employed in the Fig. 26 app,aratus.
Figure 28 i5 a side cross-sectional view of a
preferred embodiment of a spring mounting member
employed in the FigO 26 app,aratus.
Figure 29 is a front elevational view of a
preferred embodiment of a spring hook washer employed
in the Fig. 26 apparatus.
Figure 30 is a front elevational view of a
preferred embodiment of a gripper chain take-up arm
employed in the Fig. 26 apparatus.
Figure 31 is a side cross-sectional view of the
Fig. 30 apparatus.
Figure 32 is a front elevational view of a
preferred embodiment of a feed chain take-up arm
employed in the Fig. 26 apparatus.
Figure 33 is a side cross-sectional view of the
Fig. 32 apparatus.
Figure 34 is a top elevational view of a
preferred embodiment of support member 130 of the
Fig. 26 apparatus.
Figure 35 is a front elevational view of the
member of Fig. 34.
Figure 36 is a top elevational view of a
preferred embodiment of support member 230 of the
Fig. 26 apparatus.
Figure 37 is a front elevational view of the
member of Fig. 36.
Figure 38 is a front elevational view of a
preferred embodiment of cover plate assembly 160 of
the Fig. 26 apparatus.
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Detailed Description of the Preferred Embodiment
A first preferred embodiment of the inventive
apparatus will be described with reference to Figures
1 through 15.
As indicated in Figure 1, the apparatus produces
helical slices (such as slices 4) from objects (such
as potato 2 on shaker table 1, and potato 3 shown
falling between feed chain 5 and gripper chain 7). As
unsliced potatoes fall from shaker table 1 they are
guided into the space between feed chain 5 and
gripper chain 7 by spindles 11 and 13, each potato is
gripped by chains 5 and 7 and conveyed downward to
set of feed rolls 27. Feed chain 5 is mounted around
spindle 11 and drive sprocket 15, and gripper chain 7
is mounted around spindle 13 and drive sprocket 17.
As sprockets 15 and 17 rotate, chain 5 rotates
counterclockwise (forcing spindle 11 to rotate about
axle lla in the direction shown) and chain 7 rotates
clockwise (forcing spindle 13 to rotate about axle
13a in the direction shown). Spindle 13 preferably
has a smaller radius than spindle 11, and spindles 11
and 13 are both preferably composed of durable
plastic. The centerline of spindle 13 is offset
vertically above the centerline of spindle 11, so
that spindles 11 and 13 act together to divert
potatoes 2 from a generally horizontal path to a
vertical downward path between chains 5 and 7.
As each potato is conveyed downward between
chains 5 and 7, it is constrained by one of cleats 9
of gripper chain 7 and aligned by guides 6 of feed
chain 5, so that it reaches feed rolls 27 in a
generally vertical alignment (with its long axis
oriented generally vertically).
Feed rolls 27 are mounted at the ends of
rotatable shafts 23 and 25, sprocket 15 i5 mounted at
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the end of rotatable shaft 2~, and sprocket 17 is
mounted at the end of rotatable shaft 26 (shown in
Figure 3, but not in Figure 1). Each oE shafts 23,
25, 26, and 28 is mounted (in a manner to be
described below with reference to Figures 2, 3, and
6) with freedom to move horizontally. This freedom to
move horizontally permits sprockets 15 and 17 (and
rolls 27) to be displaced away from each other when
necessary to allow large potatoes to pass between
them.
As shafts 23 and 25 rotate feed rolls 27 in the
directions shown in Figure 1, the teeth of feed rolls
27 grip each potato and force the potato vertically
against knife 21. Knife 21 rotates in a horizontal
plane to slice each potato forced against it by feed
rolls 27. Preferably, the teeth of feed rolls 27 have
a triangular cross-section (as shown in Figure 4).
Such a triangular cross-section, in combination with
a clearance slot in the center portion of each feed
roll (best shown in Figure 2), allows feed rolls 27
to be positioned in very close proximity (i.e., one-
sixteenth of an inch or less) to slicing knife 21.
Knife 21 is mounted on knife carrier 29, which
is attached to bearing 31. The outer cylindrical
surface of bearing 31 has teeth, which engage
corresponding teeth of idler gear 35. Bearing 31,
gear 35, and the other components of the inventive
apparatus for driving knife 21, will be described in
detail below with reference to Figures 2, 3, 7, and
8.
Helical slices 4 produced by rotating knife 21
fall downward through chute 19. Chute 19 is rigidly
mounted to frame 36 and its inner diameter is such
that it adds a slight drag to the cut helical slices
as they disengage from rotating knife 22. This drag
against chute or tube 19 will stop the uncut end
portion from spinning and k,reaking off after
disengaging feed rolls 27. The result is a
completely cut potato. The falling slices can be
collected in a bin or conve!yor belt (not shown in
Figure 1). Housing 18 (which is shown in phantom view
in Figure 1) is removably mounted around the feed
assembly of the apparatus (chains 5 and 7 and feed
rolls 27) to prevent potato slices from escaping from
the knife area, and to prevent contaminants from
reaching the knife area during slicing operations.
Water line 8 directs a stream of water to the
area of sprockets 15 and 17, and feed rolls 27, and
water line 9' directs a stream of water to the area
of knife 21, to rinse the components in these
respective areas when desired. As best shown in
Figure 4, housing 18 has a channel extending through
its sidewall through which water line 8 can be
inserted. Additional water lines 10 and lOa, shown in
Figures 2 and 7 but not in Figure 1, supply water to
cool and flush gear idler 35 and knife bearing 31 (in
a manner to be explained in greater detail below with
reference to Figures 2 and 7).
The means for driving sprockets 15 and 17, and
feed rolls 27, will next be described with reference
to Figures 2, 3, and 6. Vertically oriented shaft 47
within gear box 49 is rotated about its vertical axis
by drive belt 45, which is looped around drive shaft
39. Gear box 49 (best shown in Fig. 6) includes worm
gears for translating the vertical rotation of shaft
47 into counterclockwise rotation of shafts 63a and
clockwise rotation of shafts 65a. Lubricating oil
flows downward through gear box 49, and is forced by
pumping screw 49b to recirculate back to the top of
gear box 49 through oil line 49a.
Upper and lower shaf s 65a are connect~d to
upper and lower universal jloint couplers 65 (shown in
Figure 2), and upper and lower shafts 63a are
connected to upper and lower universal joint couplers
63 (upper coupler 63 is shown in Figure 3).
Upper and lower couple.rs 65 are connected,
respectively, to shafts 28 and 25. Upper and lower
couplers 63 are connected, respectively, to shafts 26
and 23. Shafts 28 and 25 are supported by adjustable
upper and lower slide blocks 79. Shafts 26 and 23 are
supported by upper and lower slide blocks 77.
Each of couplers 63 and 65 transmits rotational
motion from one shaft connected thereto to the other
shaft connected thereto. The inventive apparatus is
designed so that shafts 23, 25, 26, and 28 are
mounted with freedom to pivot toward each other ~r
away from each other in a horizontal plane (i.e., in
the direction of the arrows shown adjacent shafts 26
and 28 in Figure 3, and in the direction of the
arrows shown adjacent shafts 23 and 25 in Figure 1)
while they rotate.
With reference to Figure 3, mounting member 69
is rigidly connected to shaft 28 and to one end of
rigid member 75, and mounting member 71 is rigidly
connected to shaft 26 and to one end of rigid member
73. Members 69 and 71 are connected together by pivot
67, so that the assembly comprising shaft 26 and
members 71 and 73 is free to pivot in a horizontal
plane about pivot 67, with respect to the assembly
comprising shaft 28 and members 69 and 75.
A second end of member 73 is attached to slide
block 77, and a second end of member 75 is attached
to adjustable slide block 79. An adjustable screw 78
is attached to each block 79 to limit the minimum
distance between that block 79 and the adjacent slide
block 77. Each pair of adjacent slide blocks 77 and
79 is free to slide toward (and away from) each other
along the axis of screw 78 as shafts 26 and 28 pivot,
while at the same time shafts 26 and 28 rotate about
their respective axes relative to the slide blocks 77
and 79.
Vertically oriented slide plate 81 (shown in
Figures 1, 2, and 3) separates the knife and feed
assemblies from the drive assembly. Slide plate 81
(which is preferably made of durable plastic) has
four horizontally oriented linear openings 81a fone
for each of the upper and lower slide blocks 77 and
the upper and lower slide blocks 79). Shafts 23, 25,
26, and 28 extend through the openings 81a, and slide
blocks 77 and 79 slide along the openings 81a.
Openings 81a thus function as linear tracks which
constrain the slide blocks to translate along
horizontal linear paths. Slide plate 81 also prevents
product fragments from the knife area from
contaminating the drive assembly.
One end of rigid shaft 41 is connected to member
73, and spring 43 is compressed between member 75 and
the other end of shaft 41. Spring 43 thus biases
members 73 and 75 together. When shafts 26 and 28 are
forced apart (for example, by a potato passing
between them), the outward force exerted on members
73 and 75 by the outward sliding slide blocks 77 and
79 will further compress spring 43. Then, after the
potato has moved out from between shafts 26 and 28,
spring 43 will relax back to its original length. As
spring 43 relaxes to its original length, it causes
members 73 and 75 to push slide blocks 77 and 79
together and to rotate members 69 and 71 about pivot
67 back to their original positions.
)"~?~S`
Couplers 63 and 65 are capable of flexing in a
horizontal plane to accommodat pivoting motion of
shafts 25 and 28 with respect to fixedly mounted gear
~ox 49.
Adjustable screws 80 limit the pi~oting motion
of member 71. Screws 80 can be independently advanced
or retracted to control the angular range through
which member 71 is free to pivot.
The apparatus includes two identical shaft drive
assemblies, but only the upper assembly (for driving
shafts 26 and 28) is visible in Figure 3. The lower
assembly (for driving shafts 23 and 25) includes a
lower adjustable slide block 79 (shown in Figure 2),
a lower slide block 77 (positioned below upper slide
block 77 of Fig. 3), shafts 25 and 23 (positioned,
respectively, below shaft 28 and shaft 26 of Fig. 3),
and a second assembly comprising couplers 69 and 71,
slide blocks 77 and 79, members 73 and 75, shaft 41,
spring 43, and screws 80 (positioned below the
corresponding assembly shown in Figure 3, and
partially visible in Figure 2). The lower assembly
operates in the same way as does the upper assembly
described with reference to Figure 3, so that a
potato passing between shafts 23 and 25 will
temporarily displace the shafts (thereby compressing
spring 43), and then (after the potato has been
sliced by knife 21) spring 43 will urge shafts 23 and
25 back to their original positions as spring 43
relaxes back to its original length.
The means for driving the knife assembly of the
invention will next be described with reference to
Figures 2, 3, 7, and 8. As shown in Figures 7 and 8,
wear shim 34 (preferably made of stainless steel),
bearing housing 33, and idler gear mount 35a, are
fixedly attached to frame 36. Knife 21 is fixedly
12
~IJ~JJ~
attached to kniEe carri~r 29, and knife carrier 29 is
Ei~edly attached to knife bearing 31. Th asss~bly
comprising kni~e 21, carrie~r 29, and bearing 31 is
rotatably mounted within be!aring housing 33, so that
it ~s fre~ to xotate as a unit with rPspect to
fi~edly mounted housing 33. Bearing 31 is preferably
made of clurable plastic (such as UHMW plastic), and
housing 33 is preferably made of bronze.
Idler gear 35 is rotatably attached to idler
gear moun-t 35a. Teeth protrude from the outer,
generally cylindrical, surface of knife bearing 31.
These teeth engage corresponding teeth which protrude
from the outer, generally cylindrical, surface of
idler gear 35.
As shown in Figure 2, drive gear mount 37a is
fixedly attached to drive shaft 39, and drive gear 37
is fixedly mounted to member 37a. Gear teeth
dimensioned to engage the teeth of idler gear 35
protrude from the outer surface of drive gear 37.
Drive shaft 39 extends between motor 39a and drive
gear 37, and is rotatably mounted to frame 36. When
motor 39a rotates shaft 39, shaft 39 not only rotates
belt 45 (to cause shaft 47 to rotate) but also
rotates drive gear 37. The rotational motion of gear
37 is transmitted through gear 35 to bearing 31 (to
cause knife 21 to rotate).
A user of the inventive apparatus can control
the thickness of the helical slices produced, by
varying the rate at which shaft 47 rotates (and hence
the rate at which potatoes are fed by feed rolls 27
to the knife assembly), or changing the rate at which
gear 35 drives the knife bearing 31 (for example, by
replacing gear 35 or gear 37 with a substitute gear~,
or both.
S~
With reference to Figure 7, channel 12 extends
through bearing housing 33, and channel 12a extends
through idler gear mount 35,a. Channel 12 has an inlet
for receiving water (or somle other flushing liquid)
from water line 10, and channel 12a has an inlet for
receiving water (or some ot,her flushing liquid) from
water line lOa (line lOa can be a branch line
connected to line 10).
Channel 12 has annular outlets 14a and 14b (or,
alternatively, a series of pinhole outlets arranged
along annulus 14a and along annulus 14b). Thus, a
flushing liquid can flow (in the direction of the
arrows shown in Figure 7 in channel 12) from water
line 10, through channel 12, and out from outlets 14a
and 14b into the space between stationary bearing
housing 33 and rotatable knife bearing 31.
A channel 14c also extends through bearing 31,
so that a flushing liquid (such as water) can flow
from outlet 14b, through channel 14c, into region 14e
between stationary bearing housing 33 and rotatable
bearing 31. The liquid flowing out from outlets 14a
and 14b (and the outlet of channel i4c) serves to
flush contaminants (such as starchy potato fragments)
from between bearing 31 and housing 33 and from
between bearing 31 and gear 35, and to cool and
reduce wear on bearing 31.
Channel 12a also has annular outlet 14d, so that
a flushing liquid (such as water) can flow (in the
direction of the arrows shown in channel 12a) from
water line lOa, through channel 12a, and out from
outlet 14d into the space between stationary gear
mount 35a and rotatable gear 35. The liquid flowing
out from outlet 14d serves to flush contaminants from
between mount 35a and gear 35 and from between
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bearing 31 and gear 35, ancl to cool and reduce wear
on beariny 31 and gear 35.
As indicated schematically in Figure 7, the flow
of liquid within lines 10 and lOa is preferably
monitored by a flow sensor. A motor control switch is
also provided. The motor control switch can be
manually operable. However, in a preferred
embodiment, the motor control switch can be switched
off au~omatically in response to a control signal
from the flow sensor. For example, when the flow
sensor detects inadequate flow of fluid through lines
10 and lOa, it sends a signal to the motor control
switch, to cause the motor control switch to shut off
motor 39a.
A preferred embodiment of the inventive knife
assembly will next be described with reference to
Figures 4, and 9 through 15. As shown in Figures 9
and 10, knife 21 comprises knife sections 21a and
21b. Rnife sections 21a and 21b are fixedly attached
to knife carrier 29, such as by screws inserted into
holes 29a (of sections 21a and 21b) and holes 29b of
carrier 29 (when holes 29b are aligned with holes
29a).
Knife section 21b includes central cylindrical
blade 20. Knife 21 and carrier 29 are mounted so that
the axis of blade 20 is aligned with vertical axis
20a (shown in Figure 4). As feed rolls 27 push potato
3 downward along axis 20a, blade 20 of the rotating
knife assembly impales the potato, and severs the
central cylindrical core portion from the remainder
of the potato.
Knife section 21a includes a set of blades,
which consists of vertical blades 22 and horizontal
blades 24. As the knife assembly rotates in a
counterclockwise direction (the direction indicated
by arrow 20b of ~igure 9) and rolls 27 feed a potato
against knife sections 21a and 21b, blades 22 and 24
sever helical slices from the potato in a single,
simultaneous cutting action. In conventional potato
slicinq devices, the end of the potato is scored by a
set of scoring blades during a first cutting action,
and then helical slices are cut away from the scored
potato by a separate slicing blade in a second,
subsequent cutting action.
As shown in Figure 9, the upper surface of knife
carrier 29 is not flat, but instead has a ramped
profile. Vertical shoulder 29d of carrier 29
separates the lowest and highest portions of carrier
29's ramped surface. As shown in Figure 11, knife
section 2lb has an upper portion (adjacent edge 2lb)
and a lower portion (opposite edge 21b), and knife
section 21a has an upper portion (including blades 22
and 24) and a lower portion (opposite blades 22 and
24). When sections 21a and 21b are mounted on carrier
29, section 21a occupies position 21a' (shown in
phantom view in Figure 11) in relation to section
21b. With sections 21a and 21b so mounted on carrier
29, the upper portion of section 21b meéts the lower
portion of section 21a (with beveled edge 21c of
section 21b protruding slightly below the adjacent
trailing edge of section 21a), but blades 24 (of the
upper portion of section 21a) are exposed above the
lower portion of section 21b.
Figure 10 is a view from below of assembled
knife sections 21a and 21b. With reference to Figures
9 and 10, it will be appreciated that as knife 21
rotates (in a clockwise direction in Fig. 10), knife
section 21a rotates above the potato slices that have
been severed by blades 22 and 24, while the unsliced
16
7 ~ -~
potato portion presses downward against ~he upper
surface of section 2la.
As shown in Figures 11, 12, and 13, each of the
four vertical blades 22 has a sharpened leading edge
22a. The first step in a preferred technique for
manufacturing blades 22 is to produce an
appropriately shaped flat template (a portion of
which is shown in Figure 15) for knife section 21a.
Then, in order to form each blade 22, a portion of
the template is bent along a hinge segment 22b (for
example, into the position of blade 22 shown in
phantom view in Figure 15). Finally, sharp edges 22a
and blades 24 are produced by sharpening desired
portions of the leading edge of knife section 21a.
As shown in Figure 14 (which is a top view of
knife section 21a) and Figure 9, blades 22 and
corresponding blades 24 are arranged in a spiral (or
"curvilinear") pattern. Thus, the innermost blade 24
coincides with a first radius of the knife assembly,
and each other blade 24 coincides with a different
knife assembly radius. The midpoint of each of
vertical edges 22a also coincides with a different
knife assembly radius.
Rotating knife 21 is capable of producing as
many as five helical potato slices, each having a
different radius, and each corresponding to one of
regions A, B,C, D, and E of Figure 14. Less than five
helical slices would be produced from a potato having
radius less than the radius of region D. Each of
blades 22. In addition to such helical slices,
central cylindrical blade 20 produces a cylindrical
slice (the potato core portion that is severed by,
and pushed through, central blade 20).
The spiral pattern of blades 22 (and the spiral
pattern of blades 24) reduces the torque that the
17
inventive apparatus must ge!nerate to slice each
potato. This can be understood by recognizing that
the outermost blade 22 and the outermost blade 24
(the two blades farthest from central knife 20) sever
the outermost helical portion of each potato before
the other blades engage the potato. Thus, the entire
force exerted by knife 21 on the potato (during the
initial phase of each helical slicing operation) is
exerted by the outermost pair of blades only; not
simultaneously by all blades 22 and 24. Indeed, no
pair of adjacent blades 22 and 24 engages the potato
until afte.r all blades 22 and 24 outside such pair
have severed portions of the potato.
Although the Figure 14 embodiment has four
vertical blades 22 and five horizontal blades 24, it
is contemplated that alternative embodiments of knife
section 21a may include more (or less) than four
curvilinearly arranged vertical blades 22, and more
(or less) than five curvilinearly arranged horizontal
blades 24.
Knife 51 of Figures 16-19 is a variation on
knife 21 of Figures 9-15, having two identical sets
of blades which produce two identical sets of helical
slices (unlike knife 21, which produces only one set
of helical slices). Knife 51 is dimensioned to be
mounted on knife carrier 29' and carrier 29' is
dimensioned to serve as a substitute for knife
carrier 29 of Figures 1-10.
Knife 51 consists of central coring blade 50,
and identical blade pieces 51a and 51b rigidly
connected to central blade 50. 81ade piece 51a is
attached to knife carrier 29' by screw 60, or the
like, and blade piece 51b is attached to knife
carrier 29' by screw 62, or the like.
~ ~ r) f,~ r~ ~ ~
Knife 51 and carrier 29' are mounted so that the
axis of blade 50 is aligned vertically (as is the
axis of blade 20 in Figure 4). As the feed rolls push
a potato downward against rotating knife 51, blade 50
impales the potato and severs the potato's central
cylindrical core portion from the remainder of the
potato.
~lade piece 51a includes three vertical blades
52 and four horizontal blades 54, and blade piece 51b
includes three vertical blades 53 and four horizontal
blades 55. As the knife assembly of Figure 16 rotates
in a counterclockwise direction and the feed rolls
feed a potato against pieces 51a and 51b, blades 52
and 54 sever a first set of up to four helical
(spiral-shaped) slices from the potato.
Each helical slice in the first set has a
different radius, with each radius corresponding to
the radial distance between the center of blade 50
the midpoint of the blade 54 which severed the slice.
Also while the knife assembly of Figure 16 rotates,
blades 53 and 55 sever a second set of up to four
helical slices from the potato. Each helical slice in
the second set has a radiuR matching that of one of
the helical slices in the first set. The first and
second sets of slices are intertwined, so that the
loops of each slice in the first set occupy the
spaces between the loops of a corresponding slice in
the second set.
The severed potato slices fall downward through
the volume beneath inner inclined surface 30' of
carrier 29' into a chute (such as chute 19 of Figure
1). Preferably, a means (not shown) is mounted within
(or below) the chute to disentangle the intertwined
loops of the first and second sets of helical slices
as they fall from the Figure 16 knife assembly.
19
f 3 , ~ _3 ~
As shown in Figure 17, the upper surface of
knife carrier 29' is inclined (its elevation
decreases with increasing radial distance from
central blade 50). Thus, each of the outermost blades
52, 53, 5~, and 55 is lower than the corresponding
innermost ones of blades 5:2, 53, 54, and 55 tas shown
in Figures 17-19). Blades 52 and 54 are curvilinearly
arranged, so that the outermost pair of adjacent
blades 52 and 54 of rotating knife 51 will engage the
potato before the innermost pair of adjacent blades
52 and 54, thus reducing the torque needed to slice
the potato. Similarly, blades 53 and 55 are
curvilinearly arranged, so that the outermost pair of
adjacent blades 53 and 55 of rotating knife 51 will
engage the potato before the innermost pair of
adjacent blades 53 and 55.
Knife 81 of Figures 20, 21, 23, and 24, is also
a variation on knife 21 of Figures 9-15, and also has
two identical sets of blades which produce two
identical sets of helical slices (unlike knife 21,
which produces only one set of helical slices). Knife
81 is dimensioned to be mounted on knife carrier 129
and carrier 129 is dimensioned to serve as a
substitute for knife carrier 29 of Figures l-10.
Knife 81 consists of central coring blade 80,
identical blade pieces 81a and 81b (rigidly connected
to coring blade 80), knife-edged support tube 86
(rigidly connected to blade pieces 81a and 81b), and
separator tube 100 (rigidly connected to coring blade
80). Blade piece 81a is attached to knife carrier 129
by screw 94, or the like, and blade piece 81b is
attached to knife carrier 129 by screw 92, or the
like.
Knife 81 and carrier 129 are mounted so that the
axis of blade 80 is aligned vertically (as is the
~ ~33 ~
axis of blade 20 in Figure 4). As the feed rolls push
a potato downward against rotating knife 81, blade 80
impales the potato and severs the potato's central
cylindrical core portion from the remainder of the
potato. As best shown in Figure 23, separator tube
100 is coaxially aligned with (and connected to)
blade 80. The potato's central cylindrical core
portion is pushed downward through the channel which
extends through blade 80 and tube 100, until the core
portion emerges from the lower end of tube 100.
As shown in Figure 2~, knife carrier 129 rotates
relative to fixed housing 133. Chute 119 is attached
to housing 133. Chute 119 confines the potato's core
portion, and helical slices of the potato (to be
described below), as these potato fragments fall away
from the rotating assembly comprising knife 81 and
carrier 129.
Blade piece 81a includes two vertical blades 82
and four horizontal blades 84, and blade piece 81b
includes two vertical blades 83 and four horizontal
blades 85. Support tube 86 has sharpened, vertically
oriented, knife blade portions 86a and 86b. As knife
81 rotates about the axis of blade 80, éach set of
blades 84 and 85 produces a helical potato slice from
a potato 90 (shown in Figure 21). At the same time,
blades 86a and 82 divide the helical slice produced
by blades 84 into a first set of four (or less)
helical portions (each having a different radius),
and blades 86b and 83 divide the helical slice
produced by blades 85 into a second set of four (or
less) helical portions (each having a different
radius).
The radius of each helical slice in the first
(or second) set corresponds to the radial distance
between the central axis of blade 80 the midpoint of
21
t~
the horizontal blade ~ (or 85) which severed the
slice.
~ach helical slice in the first set is
intertwined with a corresponding slice in the second
set, with the loops of each slice in the first set
occupying spaces between the loops of a corresponding
slice in the second set. For example, in Figure 21,
helical slice 95 (the slice having smallest radius
from the first set of slices of potato 90) is
initially intertwined with helical slice 96 (the
corresponding slice from the second set of slices of
potato 90), immediately after slices 95 and 96
disengage from rotating knife 81. In Figure 21,
intertwined slices 95 and 96 are shown in phantom
view (identified by reference numerals 95' and 96')
in the positions they would initially occupy just
after disengaging from knife 81.
As intertwined slices 95 and 96 fall away from
knife 81 generally along the axis of separator tube
100 (within the volume enclosed by chute 119, shown
in Figure 24), tube 100 disentangles the intertwined
loops of slices 95 and 96 (as a result of the
centrifugal force produced by its end portion 101
turning at high speed). The curved end portion 101 of
tube 100 is shown in Figure 24. A pin 104 protrudes
outward from end portion 101. As shown in Figure 21,
as knife assembly 81 rotates, pin 104 will
momentarily restrain one of the slices (i.e., slice
95) while the action of rotating curved end portion
101 on slices 95 and 96 disengages these two slices
from each other. Each of the resulting disengaged
helical slices will have spaces between its loops
(which spaces were formerly occupied by the slice
with which the disengaged slice had initially been
) r~J ~3 ~
intertwined). For example, disengaged slice 95 shown
in Figure 22 has spaces 95ZI between its loops.
In a preferred embodiment, tube 100 is formed by
bending an end portion of al length of straight metal
tubing. The end portion (end portion 101, best shown
in Figure 24) is bent into a curved shape. The end of
the straight tubing opposite the curved end is fitted
around an end of cylindrical blade 80 (as shown in
Figure 24). A small hole is machined partially
through the sidewall of the tubing's bent end
portion, and pin 104 is mounted (i.e., welded) in
such hole.
As shown in Figure 23, blades 82, 84, and 86a
are curvilinearly arranged, so that the outermost
pair of adjacent blades 82 and 84 of rotating knife
81 will engage a potato before the innermost pair of
adjacent blades 84 and 86a, thus reducing the torque
needed to slice the potato. Similarly, blades 83, 85,
and 86b are curvilinearly arranged, so that the
outermost pair of adjacent blades 83 and 85 of
rotating knife 81 will engage the potato before the
innermost pair of adjacent blades 85 and 86b.
The method of the invention can be implemented
using the above-described apparatus, and includes the
steps of: (a) rotating a set of curvilinearly
arranged knife blades in a substantially horizontal
plane, by driving the blades with a gear means
positioned below the blades (which can include knife
bearing 31 and idler gear 35); (b) while performing
step (a), forcing the object downward against the set
of curvilinearly arranged knife blades, so that the
knife blades sequentially engage the object; and (c)
while performing step (a), directing a stream of
flushing liquid (such as water) onto the gear means
to flush fragments of the object from the gear means
23
(for example, from be~ween the meshing teeth of
bearing 31 and g~ar 35, andl from between bearing 31
and housing 33 which surrounds it). Due to thP
curvilinear arrangement of the knife blades, for the
cylindrical object oriented with its longitudinal
axis a~igned with the axis of rotation of the blades,
during step (b) the blades will commence to sever a
largest diameter helical slice from the object before
commencing to sever smaller diameter helical slices
from the object. If the object has an elliptical
shape (the typical shape of a potato), a smaller
diameter portion of the object will engage the blades
before the largest diameter portion of the object. In
this case, the blades will commence to sever a small
diameter helical slice from the object before
commencing to sever a maximum diameter helical slice
from the object.
In one class of preferred embodiments, step (b)
includes the operations of: gripping the object
between a pair of chains and counter-rotating the
chains to translate the object downward into
engagement with a pair of feed rolls; and then
gripping the object between the feed rolls and
counter-rotating the feed rolls to force the object
gripped between them against the rotating set of
curvilinearly arranged knife blades.
Preferably, the pair of chains is mounted around
a pair of slidably mounted chain sprockets ~i.e.,
sprockets 15 and 17, which are mounted at the end of
slidably mounted shafts 26 and 28), and an inward
biasing force is applied to the chain sprockets
(i.e., by upper spring 43), so that as the object
advances downward past the chain sprockets the object
exerts an outward force against the chain sprockets
which temporarily overcomes the inward biasing force
24
~ S~31
and displaces the chain sprockets outward, and 80
that the inward biasing force restores the chain
sprockets to their origina:L position after the object
advances downward beyond the chain sprockets.
Preferably, the feed rolls are also slidably mounted
(as are the above-described rolls 27, which are
mounted at the end of slidably mounted shafts 23 and
25), and an inward biasing force is applied to the
feed rolls (i.e., by lower spring 43), so that as the
object advances downward between the feed rolls, the
object exerts an outward force against the feed rolls
which temporarily overcomes the inward biasing force
and displaces the feed rolls outward, and so that the
; inward biasing force restores the feed rolls to their
original position when the object has been sliced by
the rotating set of curvilinearly arranged knife
blades.
Another preferred embodiment of the invention,
which employs a spring-biased feed mechanism, will
next be described with reference to Figures 25 and
26. The apparatus of Figure 25 and 26 conveys objects
(such as potato 112) between feed chain 115 and
gripper chain 117. Chains 115 and 117 are represented
schematically in Fig. 25, but chain 117 can consist
of links ll9 having cleats ll9a (identical to those
comprising chain 7 of Fig. 1), and chain 115 can
consist of links 116 having guides 116a (identical to
those comprising chain 5 of Fig. l). As unsliced
objects (e.g., potato 112) fall generally downward or
toward the left (for example, from a shaker table not
shown in Fig. 25) they are guided into the space
between feed chain 115 and gripper chain 117 by
spindles 111 and 113. Chain 115 is looped around a
drive sprocket 115a (which is shown in Fig. 25, and
which can be identical to sprocket 15 of Fig. 1) and
~J ~ t;~ ~ t
spindle 111. Gripper chain 117 is looped around drive
sprocket 117a (which is shown in Fiy. 26, and which
can be identical to sprocket 115) and spindle 113. As
sprocket 115a rotates counterclockwise (in the plane
of Fig. 25), it causes chain 115 and spindle 111 to
rotate counterclockwise. Similarly, as sprocket 117a
rotates clockwise, it causes chain 117 and spindle
113 to rotate clockwise.
The centerline of axle 113a is offset vertically
above the centerline of axle llla (by a greater
distance than axle 13a is offset above axle lla in
the Fig. 1 embodiment) so that the portion of chain
117 which extends above spindle 111 will divert
objects (e.g., potato 112) from a generally
horizontal path to a vertical downward path between
chains 115 and 117. Each object gripped between
chains 115 and 117 is conveyed downward by the chains
to set of feed rolls 127. In the case that the
conveyed objects are elongated, each is constrained
by one of cleats 119 of gripper chain 117 and aligned
by guides 116 of feed chain 115, so as to reach feed
rolls 127 in a generally vertical alignment (with its
long axis oriented generally vertically).
Feed rolls 127 are fixedly mounted on rotatable
shafts 23 and 25, which can be identical to shafts 23
and 25 shown in Figure 1. Shaft 23 (shown in Figure
26) and shaft 25 have freedom to move horizontally.
As shafts 23 and 25 translate horizontally, extension
member 23' connected to the end of shaft 23 and
identical extension member 25' connected at the end
of shaft slide along the horizontal axis of slot 131
of shaft support member 130. At the same time, shafts
23 and 25 slide along slot 231 of rear shaft support
member 230 (to be discussed below wi~h reference to
Figures 36 and 37). Member 130 (which rests on frame
26
36) supports extension members 23' and 25' and
constrains their vertical and horizontal motion
(i.e., prevents them from moving v~rtically below
slot 131 and prevents them Erom translating
horizontally beyond the le~t or right end of slot
131). Member 230 (which also rests on frame 36)
supports shafts 23 and 25 and constrains their
vertical motion (i.e., prevents them from moving
vertically below slot 231).
Front and rear plates 162 of cover plate
assembly 160 (shown in Fig. 26, but not in Fig. 25)
can be fitted between front and rear support brackets
161, to enclose chains 115 and 117 during slicing
operations. Bolts 163 extend through rear bracket 161
and rear shaft support member 230, to connect bracket
161 and member 230 to plate 36. Bolt 182 connects the
front bracket 161 to the front shaft support member
130.
A front view of a preferred embodiment of
assembly 160 is shown in Fig. 38. Front and rear
plates 162 of the Fig. 38 embodiment of assembly 160
are connected together by side plates 162a. A support
pin 206 is fixedly attached to each of side plates
162a, and pins 206 extend through corresponding holes
in front plate 162. Each support pin 206 has a hole
extending through it for receiving a locking pin 205.
Each locking pin 205 has a spring-loaded protrusion
205a, so that protrusions 205a will lock pins 205 in
place when they extend through pins 206. A ring 204
is attached to the end of each locking pin 205
opposite protrusion 205a, and a flexible lanyard 202
is connected between each ring 204 and a
corresponding bracket 201. Each bracket 201 is
fixedly attached to front member lS1 by a bolt 200.
Guide slots 208 through member 161 are dimensioned
27
2J ~
and oriented for receiving the ends of shafts 26 and
2e (on which drive sprocket 115a and 117a are
mounte~) when assembly 160 is in place betwe~n front
and rear brackets 161.
To permit convenient access to chains 115 and
117, pins 205 can be removed from support pins 206,
and front plate 162 then lifted off pins 206 and
removed from the area of chains 115 and 117. Lanyards
202 and rings 204 keep pins 205 attached to brackets
201 when front plate 162 has been removed from pins
206.
It should be appreciated that Figure 26 is a
side cross-sectional view of a portion of the Figure
25 apparatus, with the exception that Figure 26
additionally shows elements 200-202 and 204-206 in
side elevational view. Elements 200-202 and 204-206
are not physically located in the cross-sectional
plane of Fig. 26, and indeed (as indicated in Fig.
38) they are located in vertical planes other than
the vertical plane through shaft 26's central axis
(which latter plane extends through one of guide
slots 208).
Sprockets 117a and 115a are mounted,
respectively, on shafts 26 and 28 (which can be
identical to shafts 26 and 28 of Fig. 1). Each of
shafts 26 and 28 has limited freedom to translate
horizontally, as well as to rotate about its axis.
The freedom of shafts 26 and 28 to translate
horizontally permits potatoes being conveyed by
chains 115 and 117 to displace sprockets 115a and
117a (and feed rolls 127) away from each other,
thereby allowing the potatoes to pass between the
feed rolls and the lower ends of the chains while the
chains (and feed rolls) exert a gripping force on
each potato.
28
'~ ~ 8 ~
As rotating shafts 23 and 25 rotate feed rolls
127 in the directions shown in Figure 25, the teeth
of feed rolls 127 grip each potato and force it
downward into engagement with knife 21. ~nife 21
rotates in a horizontal plane to slice each potato
forced against it by feed rolls 127.
Extension springs 132 and 134 provide biasing
forces which urge the lower ends of chains 115 and
117 together, to ensure that potatoes gripped between
translating chains 115 and 117 are fed positively and
uniformly downward to feed rolls 127 and knife 21.
Spring 132 is connected (at one end) to spring anchor
144 of take-up arm 136, and (at the other end) to
spring hook washer 148. Washer 148 is fitted in a
slot of spring mounting member 152, and member 152 is
mounted around shaft 28. Spring 134 extends betwçen
spring anchor 158 of take-up arm 140, and a spring
hook washer (shown in Fig. 26, but not Fig. 25, and
preferably having the same shape as washer 148 of
Fig. 25) fitted in one of slots 153 of spring
mounting member 151. Member 151 (shown in Fig. 26) is
mounted around shaft 26. As shaft 28 rotates within
member 152, and shaft 26 rotates within member 151,
springs 132 and 134 (and members 151 and 152 and
washers 148) remain stationary, and springs 132 and
134 exert a biasing force which urges the rotating
shafts 26 and 28 toward each other.
Arm 136 is fixedly attached to arm 136a, and arm
136a is fixedly attached to arm 136b. The assembly
comprising arms 136, 136a, and 136b will be denoted
as the "gripper chain take-up arm." Arm 136b is
pivotally attached to axle 113a, and arm 136a is
pivotally attached to frame 148 (shown in Fig. 26) by
pin 138. Arm 140 is fixedly attached to arm 140a, and
arm 140a has an end portion pivotally attached to
29
,f~ r~
axle llla and a central portion pivotally attached to
frame 148 by pin 142. The assembly comprising arms
140 and 140a will be denoted as the "feed chain take-
up arm."
As chains 115 and 117 convey a potato between
sprockets 115a and 117a, the potato overcomes a
spring force exerted by spring 132 to displace
sprocket 115a (and shaft 28) toward the right (in
Fig. 25), thus pivoting the feed chain take-up arm
counterclockwise about pivot 142, and causing axle
llla (and hence spindle 111) to translate
counterclockwise along an arc about pivot 142. At the
same time, the potato overcomes a spring force
exerted by spring 134 to displace sprocket 117a (and
shaft 26) to the left ~in Fig. 25), thus pivoting the
gripper chain take-up arm clockwise about pivot 138,
and causing axle 113a (and hence spindle 113) to
translate clockwise along an arc about pivot 138.
Thus, when a potato temporarily separates the
lower ends of chains 115 and 117, springs 132 and 134
cause the take-up arms to rotate. Because springs
132 and 134 are crossed, they cause the rotating
take-up arms to move axles llla and 113a upward,
thereby stretching the chains. Thus, springs 132 and
134 and the take-up arms operate to increase
temporarily the gripping force exerted by chains 115
and 117 on a second potato between the upper ends of
the chains (to prevent the chains from losing their
grip on the second potato while a first potato
separates the lower ends of the chains).
Figure 27 is a side view of a preferred
embodiment of shaft extension member 23' (extension
member 25' is preferably identical to extension
member 23'). Extension member 23' can be connected to
feed roll shaft 23 by connecting its end portion 23a
within the portion of feed roll shaft 23 extending
through feed roll 127 and thus retaining fe~d roll
127 (as shown in Fig. 26)o
A pre~erred embodiment of spring mounting member
152 is shown in Fig. 28~ Channel 152a extending
through member 152 is dimensioned to receive shaft
28, so that member 152 can be mounted around shaft
28, and shaft 28 can rotate within channel 152a
relative to member 152. The outer surface o~ member
152 defines one or more annular slots 154.
The preferred embodiment of spring hook washer
148 shown in Fig. 29 is dimensioned so that it can be
slid along the outer surface of member 152 until it
fits within one of slots 154. In operation of the
apparatus of Figs. 25 and 26, a hooked end of
extension spring 132 is hooked through hole 150 of
washer 148, and washer 148 rides in one of slots 154
as shaft 28 rotates within channel 152a relative to
member 152 and washer 148 (washer 148 remains
stationary with respect to spring 132). The spring
force exerted on washer 148 by extension spring 132
(hooked through washer 148's hole 150) retains washer
148 in position within one of slots 154.
Preferably, mounting member 151 is identical to
member 152 (and has a channel identical to channel
152a, extending therethrough), and a second washer
148 is assembled in one of slots 153 of member 151
(as shown in Fig. 26) to couple spring 134 to shaft
26 in the same way that washer 148 couples spring 132
to shaft 28.
A preferred embodiment of the gripper chain
take-up arm is shown in Figures 30 and 31. A spring
anchor shaft 144 protrudes out from member 136. The
outer surface of shaft 144 defines a slot 144a, so
that a hooked end of spring 132 can be con~eniently
31
2r~
attached to sh~ft 144. As indicated in Fig. 31, arm
136 is thinnPr th~n ~ither of arms 136a and 136b.
Hol~ 138a through arm 136a is dimensioned to receive
pivot member 138 (which pivotally attaches arm 136a
to frame 148). Hole 113b through arm 136b i~
dimensioned to receive axle 113a (so as to pivotally
attach arm 136b to axle 113a).
A preferred embodiment of the feed chain take-
up arm is shown in Figures 32 and 33. A spring anchor
shaft 158 protrudes out ~rom member 140. The outer
surface of shaft 158 defines a slot 158a, so that a
hooked end of spring 134 can be conveniently attached
to shaft 158. As indicated in Fig. 33, arm 140 is
thinner than arm 140a. Hole 142a through arm 140a is
dimensioned to receive pivot member 142 (which
pivotally attaches arm 140a to frame 148). Hole lllb
through arm 140a is dimensioned to receive axle llla
(so as to pivotally attach arm 140a to axle llla).
A preferred embodiment of shaft support member
130 is shown in Figures 34 and 35, and a preferred
embodiment of shaft support member 230 is shown in
Figures 36 and 37.
When the embodiment of member 130 shown in Figs.
34 and 35 rests on frame member 36, and is attached
to front bracket 161 by bolts 182 (which extend
through bracket 161 as shown in Fig. 26, and into
holes 182a in member 130), extension members 23' and
25' are free to swing horizontally across thinner
central portion ("slot") 131 of member 130. Vertical
sidewalls 131a and 131b ~t the boundaries of portion
131 prevent members 23' ~nd 25' from translating
horizontally beyond portiDn 131. Support member 130
is preferably made of durable plastic (such as UHMW
plastic).
7 ~ 3
When the embodiment of member 230 shown in Figs.
36 and 37 rests on frame me~mber 36, and is attached
to rear bracket 161 and member 36 by bolts 163 (which
extend through rear bracket 161 as shown in Fig. 26,
and through holes 162a through member 130), shafts 26
and 28 are free to swing horizontally across thinner
central portion ("slot'l) 231 of member 230. Vertical
sidewalls 231a and 231b define the boundaries of slot
231. Support member 230 is preferably made of durable
plastic (such as UHMW plastic).
Various other modifications and alterations in
the described method and apparatus of the invention
will be apparent to those skilled in the art without
departing from the scope and spirit of this
invention. Although the invention has been described
in connection with specific preferred embodiments, it
should be understood that the invention as claimed
should not be unduly limited to such specific
embodiments.
