Slack Separation Hopper With Filter Wall and Stationary Removal Body
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Solution Overview
Problem
Existing apparatuses and systems for removing excess slack from product packaging are complicated, require high energy input, and are inefficient in separating a significant proportion of slack, leading to issues such as machinery jamming, compromised seal quality, and health risks.
Innovation Solution
A hopper design with a stationary slack removal body and a moveable gate that separates slack from product using a filter wall, allowing slack to pass through while retaining product, and a vacuum system for collecting separated slack, which can be easily retrofitted to existing machinery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If existing apparatuses and systems are used to remove slack, then some slack is removed from product, but the devices are complicated, require large energy input, and can only remove a relatively small proportion of slack
Solution Approach 1:
The hopper is divided into distinct functional zones: a product receiving region at the top, a filter wall with varying aperture sizes in the middle, and a product discharge region at the bottom. This segmentation allows different parts of the hopper to perform specific functions - receiving mixture, filtering slack by size, and discharging cleaned product - thereby achieving efficient slack removal through simple structural division rather than complex machinery
Solution Approach 2:
The filter wall acts as an intermediary element between the product receiving region and the discharge region. It mediates the separation process by allowing smaller slack particles to pass through its apertures while retaining larger product pieces, enabling efficient slack removal through a passive intermediate structure rather than active mechanical separation systems
2Loss of substance
If existing apparatuses and systems are used to remove slack, then some slack is removed from product, but they require large energy input
Solution Approach 1:
The gate is operated periodically - closed during the slack separation phase to allow filtering to occur, and then opened to discharge the cleaned product. This periodic operation rhythm enables continuous processing through simple cyclic actions rather than continuous energy-consuming mechanical separation, maintaining high slack removal efficiency with minimal energy input
Solution Approach 2:
The filter wall performs the separation function passively based on the inherent size difference between product and slack particles. The structure uses gravity and natural particle flow to achieve separation without requiring external energy input for active sorting mechanisms, thereby achieving efficient slack removal through self-service physical principles rather than energy-intensive mechanical systems
3Reliability
If the sealing step is delayed to allow slack to settle, then seal quality is improved, but processing speed is reduced and output is reduced
Solution Approach 1:
The filter wall performs slack removal in advance, before the product reaches the sealing stage. By pre-separating slack particles through the filter apertures while product is still in the hopper, the system ensures that only cleaned product with minimal slack proceeds to sealing, thereby guaranteeing seal quality without requiring additional settling time and maintaining high processing speed
4Device complexity
If excess slack is allowed to float freely in packaging, then packaging is simpler, but product degradation occurs and safety issues arise
Solution Approach 1:
The filter wall extracts and removes excess slack particles from the product mixture before packaging. By taking out the harmful slack component through passive filtration based on particle size differences, the system prevents product degradation and safety issues that would otherwise require complex packaging solutions, thereby achieving both packaging simplicity and product protection
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
The hopper efficiently removes a high percentage of slack without delaying product throughput, improving machinery reliability, reducing waste, and minimizing slack in packaged products, while being simple to manufacture and maintain.
Implementation Method 1
the slack removal body comprises an internal chamber for receiving slack and a filter wall that separates the internal chamber from the product receiving volume, the filter wall being configured to prevent the passage of product therethrough, but to allow the passage of slack therethrough
Implementation Method 2
a vacuum system for collecting separated slack
Data Source
AI summary
Disclosed are a hopper, method and system comprising the hopper for separating slack from a mixture of product and slack, the hopper comprising a first gate that is moveable between respective open and closed positions; and a slack removal body the first gate and the slack removal body being arranged such that, when the first gate is in its closed position, they define a first product receiving volume therebetween wherein the slack removal body comprises a first internal chamber for receiving slack and a first filter wall that separates the first internal chamber from the first product receiving volume, the first filter wall being configured to prevent the passage of product therethrough, but to allow the passage of slack therethrough wherein the first gate is configured such that: when the first gate is in its open position a first path is provided for product to exit the first product receiving volume and when the first gate is in its closed position the first path is closed and product may be retained in the first product receiving volume and wherein the slack removal body is configured to remain substantially stationary as the first gate is moved between its respective open and closed positions.