Flexible Disc Container Emptying for High-Speed Reclamation

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Solution Overview

Problem

Existing systems fail to efficiently separate rigid open-ended containers from their content, such as smokeless tobacco, at high speeds and in an automated manner, hindering the reclamation of non-conforming products.

Innovation Solution

An apparatus using a pair of rotating flexible discs with a stabilizer disc to grip and rotate the container, expelling the content along an arcuate path while maintaining the container's orientation, followed by an ejector to remove the emptied container, and a cleaning station to prepare it for reuse.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional separation methods are used, then the separation process can be performed, but the separation speed is low and cannot keep up with high-speed loading output

Engineering Contradiction:

Improveseparation speedVSAvoidreclamation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The reclamation system operates continuously with the loading apparatus, processing rejected containers without interruption. The rotating flexible discs maintain constant motion to grip and empty containers as they pass through, eliminating idle time between separation operations and enabling the system to keep up with high-speed loading output.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system is positioned to receive rejected containers directly from the loading apparatus output, and the flexible discs are pre-positioned to immediately grip containers upon receipt. This preliminary positioning ensures no time is lost in transitioning from loading to separation, maintaining continuous high-speed operation.

Inventive Principle:

Principle #10Preliminary action

2Extent of automation

If manual separation processes are used, then detailed inspection can be performed, but the process cannot be performed at high speeds and requires significant labor

Engineering Contradiction:

Improveautomated separationVSAvoidseparation accuracy

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The flexible discs automatically grip containers by their open ends and perform the emptying action through rotation without requiring external manipulation or inspection. The system serves itself by using the container's own geometry (open end) as the gripping point, eliminating the need for complex sensing or manual verification while maintaining high-speed automated operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical handling with an automated rotating flexible disc mechanism that uses controlled friction and rotation to grip and empty containers. This mechanical substitution enables high-speed automated separation while maintaining reliable container-emptying action through the inherent friction between the flexible disc surface and container walls.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If the reclamation system processes all loader output at start-up, then complete reclamation is achieved, but the system must handle varying rates from zero to maximum output

Engineering Contradiction:

Improvevariable processing rateVSAvoidrate control mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The reclamation system is designed with dynamic capabilities where the flexible discs can operate at variable speeds to match the loading apparatus output rate. The system transitions smoothly from processing zero containers (when loading is normal) to maximum capacity (when all output is rejected), with the rotation speed and feed rate adjusting dynamically to handle the full range of operational conditions without requiring complex control mechanisms.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates the high-speed, automated separation and reclamation of containers and content, enabling efficient reuse of rejected containers and content, even at varying production rates.

Implementation Method 1

opposing portions of the rotating flexible discs mutually converge into contact with side portions of a rigid body positioned at the first location to hold the rigid body between the rotating flexible discs

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

the rotating flexible discs rotate the rigid body in the orientation beyond the first location and content from the rigid body is expelled along a first arcuate path portion downstream of the first location

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS12552574B2System adapted to promote re-utilization of a rejected container loaded with content

Publication Date: 2026.02.17 ALTRIA CLIENT SERVICES LLC

AI summary

A high-speed automated separation apparatus includes a pair of flexible discs, a driver to rotate the flexible discs, a feeder to position a rigid body at a first location between the flexible discs, a spreader and a converger operable upon the flexible discs such that opposing portions of the flexible disc converge upon the positioned rigid body. The rotating flexible discs rotate the rigid body beyond the first location, and content from the rigid body is expelled. The rigid body and the expelled content are then available for reuse.