Apparatus for and method of distributing and compacting low density materials

Abstract

 The present invention relates to the processing of low density materials, in particular, to the processing of low density waste paper, such as shredded paper. There is described a method of distributing and compacting a material within a container (13) the method comprising providing a flow of air to distribute a flow of the material into the container (13) and a providing a compactor element (20) above the floor (14) of the container (13) the compactor element (20) being adapted to move generally vertically between an un-extended position and an extended position in which the compactor element (20) is closer to the floor (14) of the container (13). Also describe is an apparatus (10) to implement this method with a container (13) for a material, and a collection system for collecting waste material using the method and apparatus (10).

Description

[0001] The present invention relates to improvements in or relating to the processing of low density materials, in particular, to the processing of low density waste paper, such as shredded paper.

[0002] Our earlier application EP 1 120 363 describes, inter alia, a waste collection system in which a waste material, typically waste paper from a newspaper print room, is collected in lorry trailers through an aperture in the roof of the trailer. It has been found that often paper is shredded prior to disposal. This is particularly the case where whole print runs are to be destroyed if errors in content or poor print quality are discovered. Shredded paper forms a low density mass within the trailer which results in less than optimal filling of the trailer.

[0003] The present invention has been devised with a view to overcoming this problem and providing a solution which is also applicable more generally to other systems of collection of finely divided or low density materials in containers.

[0004] In one aspect, according to the present invention, there is provided a method of distributing and compacting a material within a container the method comprising providing a flow of air to distribute a flow of the material into the container and a providing a compactor element above the floor of the container the compactor element being adapted to move generally vertically between an un-extended position and an extended position in which the compactor element is closer to the floor of the container.

[0005] In a second aspect, the present invention also provides an apparatus adapted for use with a container for a material, the apparatus comprising means to provide a flow of air towards, in use, a flow of the material into the container; and a compactor element adapted for positioning above the floor of the container and being adapted to move generally vertically between an un-extended position and an extended position in which the compactor element is closer to the floor of the container.

[0006] In one embodiment, the compactor element is in the form of a frame. Suitably, the frame is generally rectilinear, most suitably square, or circular in plan view. Suitably, the frame is circular, square or rectangular in cross-section.

[0007] In a third aspect, there is provided a collection system for collecting waste material. The system comprises a waste material passage and a container, the passage defining a pathway along which waste material is transferable and having an inlet for receipt of waste material and an outlet from which outlet waste material is dischargable into the container by means of an aperture provided in a surface of the container.

[0008] The system further comprises an extendible compactor element positionable within the container and being adapted to be reciprocatable between a first position in which the compactor element is spaced from a floor of the container by a first distance and second position in which the compactor element is spaced from the floor of the container by a second distance, the first distance being greater than the second.

[0009] In a preferred embodiment, the aperture of the container is provided in the upper surface of the container. Preferably, the compactor element is mounted adjacent the outlet of the waste material passage, suitably by being mounted upon the outlet of the passage. In a modified embodiment, the aperture of the container is provided in the upper surface of the container but the compactor element is mounted within the container adjacent the aperture.

[0010] Alternatively, the aperture may be provided in a side surface, typically a rear side surface of the container. In this embodiment, the container is provided with a second aperture in the upper surface of the container through which the compactor element is positioned or the compactor element is mounted within the container adjacent the first aperture.

[0011] Preferably, the container is the trailer of a lorry, more preferably, the trailer of an articulated lorry.

[0012] Suitably, the waste material will be a finely divided waste material, such as waste paper. Preferably, the passage includes air-flow means to provide or maintain a flow of air in which said waste paper material is entrainable for transfer between the inlet and the outlet of the passage. Preferably, the system includes further air-flow means positioned with respect to the outlet of the passage so as to agitate the flow of waste paper material upon discharge into the container.

[0013] In one embodiment, the compactor element is in the form of a frame, suitably rectilinear or circular in plan view. More suitably, the frame is circular or rectilinear in cross section.

[0014] Suitably, the frame is hollow and includes a plurality of inwardly directed apertures in operative connection with a supply of air under increased pressure, thereby providing the further air-flow means.

[0015] Preferably, the compactor element is adapted to reciprocate between the first and second positions by means of a piston or ram assembly. Suitably, the ram assembly is hydraulically or pneumatically actuated.

[0016] Preferably, the compactor element is adapted to move between said extended and unextended positions by means of one or more hydraulic piston ram assemblies.

[0017] In a second, and preferred, embodiment, the compactor element is in the form of a plurality of individual compactor feet. Preferably each compactor foot is driven by a respective piston ram arrangement.

[0018] In one embodiment, the flow of air is provided through apertures within the compactor element frame.

[0019] In an alternative embodiment, the flow of air is provided by means of a air-flow element, separate from the compactor element. Suitably, the air-flow element is in the form of a frame having apertures formed therewithin through which apertures air is caused to flow.

[0020] Preferably, the apertures are formed in the inner surface of the frame. More preferably, the apertures direct the flow of air in a direction substantially orthogonally to the flow of material into the container.

[0021] In a preferred embodiment, the container is formed by a trailer unit for an articulated lorry and material flows into said trailer by means of an aperture formed in the roof of the vehicle. In this embodiment in use with an apparatus having a separate air-flow element, the air-flow element is preferably adapted to be positionable adjacent the aperture of the roof of the trailer. Whilst the air-flow element may be positionable internally or externally of the trailer, preferably, it is positionable externally. Advantageously, a cowling is provided

[0022] The above and other aspects of the present invention will now be described in further detail, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic cross-sectional view of a first embodiment of an apparatus in accordance with the present invention in use with a container containing a material;

Figure 2 is a schematic perspective view of the embodiment of Figure 1; and

Figure 3 is a schematic cross-sectional view of a second embodiment of an apparatus in accordance with the present invention in use with a container containing a material.

[0023] With reference to Figures 1 and 2, there is illustrated a first exemplary embodiment of an apparatus 10 in accordance with the present invention mounted upon the outlet chute 11 of a material flow path 12 above a container 13. Container 13 includes a floor 14, four side walls 15 and a roof 16. In the arrangement shown, the roof 16 has an opening 17 therein for receipt of the outlet chute 11. However, the present invention is equally suitable for use with open or roofless containers in which the outlet chute 11 is simply positioned generally centrally over the open container.

[0024] Suitably, but not essentially, the container 13 is in the form of a trailer of the type used with a tractor unit and referred to as an articulated lorry. An example of such a trailer, having an aperture formed in the roof thereof, is described in my earlier patent application EP-A-1 120 363, to which further reference should be made.

[0025] The apparatus includes a compactor element in the form of a generally rectangular frame 20 mounted upon the rams of a number of pistons 21 each mounted, for convenience, upon the outlet chute 11 by means of brackets 22. The pistons may be pneumatically or hydraulically actuated. Alternatively, the rams may be part of an electrically operated ram assembly. By actuation of the pistons, the frame 20 is moveable between an unextended position illustrated in Figure 1 by solid line I in which the frame is generally adjacent the outlet chute 11, and an extended or deployed position, illustrated by dotted line II, in which the frame contacts a pile of material 23 in the container 13, thereby compressing the material. Typically, the extended position is set to be between about 150cm below the roof of the trailer. As shown, suitably, the frame 20 is mounted upon two pistons 21, but any number of pistons may be appropriate depending upon the general situation of the apparatus. Although shown as rectangular, the frame may generally be of any rectilinear or curvilinear shape.

[0026] In the embodiment shown, the frame 20 is of hollow construction and is generally square or rectilinear in cross-section. Curvilinear cross-sectional frames are equally suitable and frames having diamond-shaped cross-section have been found to be particularly suitable. The frame 20 includes a plurality of outlets or nozzles 30 disposed about the inner surface thereof. Frame 20 is operatively coupled through a duct 31 to an air supply, such as a fan blower 32, such that a flow of air (arrows A in Figure 2) is emitted from nozzles 30.

[0027] Preferably, the compactor element frame is mounted at the end of the rams 21 by means of universal joint arrangements, such as a ball and socket joint, to allow flexing of the orientation of the frame during impacting against the material 23 in the container 13.

[0028] In use, in a typical print room situation, shredded paper passes along chute 11 and falls vertically into container 13. Typically, the paper is caused to pass along chute 11 by an airblowing system. Such systems are well known in the art. The flows (A) of air from frame 20 ensure that the finely divided paper is more evenly distributed about the container 13 than would otherwise be the case. Finely divided paper does not naturally form a dense mass. As the paper mounts up in the container, the pistons 21 are actuated to extend the frame 20 downwardly onto the paper thereby compressing it. Typically, the apparatus includes a control assembly 33 to actuate the frame extension on a periodic basis, suitably every 10 seconds or so. In the preferred arrangement, the control assembly 33 also includes a manual actuation facility, such that an operator can actuate the frame extension on a manual basis.

[0029] In known arrangements for filling containers with shredded paper from print rooms and other sources, the outlet chute 11 is provided at its outlet end with a bellows arrangement in which a frame is adjustably mounted below the outlet of the chute upon a bellows assembly. In an alternative embodiment to that described above, the frame 20 of the embodiment of the apparatus of the present invention is mounted upon the frame of the bellows arrangement or, alternatively, directly replaces the frame of the bellows arrangement.

[0030] In the alternative embodiment illustrated in Figure 3, the flow of air is provided by a separate air-flow element 40. A compactor element 41 is mounted substantially as described above by means of rams 21 to an outlet chute 11. In the arrangement shown, the air-flow element 40 is mounted such that it can be position above the aperture 17 in the roof 16 of the container 13. Equally, the air-flow element may be mounted such that it can be positioned just inside the roof aperture 17. Indeed, the air-flow element may be mounted within the container 13.

[0031] The rams are typically pneumatically driven, but hydraulic or electrical operation is equally suitable.

[0032] Preferably, a cowling or similar enclosure (not shown) is provided around the chute 11 and enclosing the compactor element 20,41 mounting arrangement and the air-flow element 40 where provided as a separate component. As typically the apparatus will be operated outdoors, a cowling helps to ensure that the flow of material 23 along chute 11 is not affected by external forces such as flows of wind.

[0033] In a further alternative embodiment, the air flow element is positionable within the cavity of container 13.

[0034] A preferred embodiment is illustrated in Figures 4 and 5. In this embodiment, frame 20,41 is replaced by a matrix of discrete compactor feet 50, typically in a generally square or rectangular 3x2 matrix of two feet in each of three rows, although other arrangements are equally suitable. In the embodiment shown, each foot 50 is generally pyramidal in shape with a square base. Each foot is mounted on the lower end of a ram 51, driven hydraulically, pneumatically or by other suitable means 52.

[0035] In a preferred embodiment, the container is a trailer including a walking floor as described in my earlier patent application EP-A-1 120 363. Briefly, the trailer described there includes a closeable roof aperature for receipt of waste materials such as paper. The trailer also includes a headboard moveable from the front of the trailer to the rear thereof and useable to divide the front of the trailer immediately below the aperture into a generally cuboid cavity. The cavity is filled with waste materials whereupon a "walking floor" which is provided within the trailer is activated to cause the block of waste materials to advance towards the rear of the trailer, thereby forming a "new" cavity for receipt of further waste materials. The operation is repeated until the whole trailer has been filled.

[0036] In each embodiment, preferably the pistons 21 or rams 51 are in operative connection with a force-feedback system comprising sensors to monitor the "back-force" exerted by the material within the container 13 upon the frame 20 or feet 50. When the back-force exceeds a predetermined level, indicating that the capacity of the filling area has been met, the feedback system alters the user that the capacity has been met so that they may operate the walking floor, or, in the preferred embodiment using a trailer having a walking-floor and headboard arrangement as described in our European application EP-A-01 120 363, causes unattended advancement of the walking-floor to form a "new" cavity.

Claims

1. An apparatus adapted for use with a container for a material, the apparatus comprising means to provide a flow of air towards, in use, a flow of the material into the container; and a compactor element adapted for positioning above the floor of the container and being adapted to move generally vertically between an un-extended position and an extended position in which the compactor element is closer to the floor of the container.

2. An apparatus as claimed in Claim 1 wherein the compactor element is in the form of a frame.

3. An apparatus as claimed in Claim 2 wherein the frame is generally rectilinear, preferably square in plan view.

4. A collection system for collecting waste material, the system comprising a waste material passage and a container, the passage defining a pathway along which waste material is transferable and having an inlet for receipt of waste material and an outlet from which outlet waste material is dischargable into the container by means of an aperture provided in a surface of the container, wherein the system further comprises an extendible compactor element positionable within the container and being adapted to be reciprocatable between a first position in which the compactor element is spaced from a floor of the container by a first distance and second position in which the compactor element is spaced from the floor of the container by a second distance, the first distance being greater than the second.

5. A system as claimed in Claim 4, wherein the aperture of the container is provided in the upper surface of the container.

6. A system as claimed in Claim 5 wherein the compactor element is mounted adjacent the outlet of the waste material passage, suitably by being mounted upon the outlet of the passage.

7. A system as claimed in Claim 5 wherein the aperture of the container is provided in the upper surface of the container and the compactor element is mounted within the container adjacent the aperture.

8. A system as claimed in Claim 4 wherein the aperture is provided in a side surface, preferably a rear side surface, of the container and the container is provided with a second aperture in the upper surface of the container through which the compactor element is positioned or the compactor element is mounted within the container adjacent the first aperture.

9. A system as claimed in any one of claims 4 to 8 wherein the container is the trailer of a lorry, preferably, the trailer of an articulated lorry.

10. A system as claimed in any one of Claims 4 to 9 wherein the passage includes air-flow means to provide or maintain a flow of air in which said waste material is entrainable for transfer between the inlet and the outlet of the passage.

11. A system as claimed in Claim 10 wherein the system includes further air-flow means positioned with respect to the outlet of the passage so as to agitate the flow of waste paper material upon discharge into the container.

12. A system as claimed in any one of claims 4 to 11 wherein the compactor element is in the form of a frame.

13. A system as claimed in Claim 12 wherein the frame is hollow and includes a plurality of inwardly directed apertures in operative connection with a supply of air under increased pressure, thereby providing the further air-flow means.

14. A system as claimed in any one of Claims 4 to 11 wherein the compactor element is in the form of a plurality of individual compactor feet.

15. A system as claimed in Claim 14 wherein said plurality of compactor feet are arranged in an array of compactor feet.

16. A system as claimed in Claim 15 wherein 6 or 8 compactor feet are arranged in a 3 x 2 or 4 x 2 matrix.

17. A system as claimed in any one of Claims 4 to 16 wherein the compactor element is adapted to reciprocate between the first and second positions by means of a piston or ram assembly.

18. A system as claimed in Claim 17 wherein the ram assembly is hydraulically or pneumatically actuated.

19. A system as claimed in any one of Claims 4 to 12 or 14 to 18 wherein the flow of air is provided by means of an air-flow element, separate from the compactor element.

20. A system as claimed in Claim 19 wherein the air-flow element is in the form of a frame having apertures formed therewithin through which apertures air is caused to flow.

21. A system as claimed in Claim 20 wherein the apertures are formed in the inner surface of the frame.

22. A system as claimed in any one of claims 11 to 21 wherein the air-flow means directs the flow of air in a direction substantially orthogonally to the flow of material into the container.

23. A system as claimed in any one of claims 4 to 22 wherein the container is formed by a trailer unit for an articulated lorry and material flows into said trailer by means of an aperture formed in the roof of the vehicle.

24. A system as claimed in Claim 23 wherein the air-flow element is positionable adjacent the aperture of the roof of the trailer.

25. A system as claimed in Claim 24 wherein the air-flow element is positionable externally of the trailer.

26. A method of distributing and compacting a material within a container, the method comprising providing a flow of air to distribute a flow of the material into the container and providing a compactor element above the floor of the container, the compactor element being adapted to move generally vertically between an un-extended position and an extended position in which the compactor element is closer to the floor of the container.

Drawing