CA1048948A - Stackable containers with mixing bar - Google Patents

Abstract

Abstract of the Disclosure The specification describes a method and an apparatus for storing material as well as conducting required batch pro-cessing operations on the material within a container. The container has an opening for passage of material, and groove means located on at least two sides thereof for quick engagement by sliding movement with corresponding projection means located on two arms of a device of a docking station for retaining the container. The device interlocks with containers of different size in a positive self-positioning manner. Blending, mixing, chemical reaction, and reconstituting of liquid and/or solid material in the container or inverting of the container itself can then be accomplished without having to transfer the material to additional process equipment. In addition to the significant materials handling advantages obtained, the apparatus and system virtually eliminate pollution and contamination problems for batch processing operations.

Description

104~3~8 The present invention relates to process container apparatus and system and, more particularly, to apparatus and a system for obtaining improved materials handling by storing and transporting material as well as conducting required batch processing operations on the material within the same container.
This application is a divisional application of Canadian patent application Serial No. 200,699, filed May 23, 1974.
Conventionally, industrial mixing devices have been permanently located. Utilization of such equipment has accord-ingly required that material to be mixed or blended be trans-ported to the mixing devices, removed from one or more storage containers, inserted into the mixing devices, mixed or blended, removed from the mixing devices and placed inside new storage or shipping containers. Of course, the mixing devices must be cleaned at least periodically and normally after every batch operation. These various operations obviously require consider-able time and labor in addition to creating storage problems for containers. Completely automated systems for batch type operations can be devised but tend to be somewhat rare. ~ot only are automated systems costly, but such automation tends to defeat flexibility - an inherent advantage of batch operations.
In addition to the time and expense involved with materials handling aspects of batch type operations, the problem of contamination and pollution control are very significant. In industries such as the pharmaceutical industry and food industry, product purity is synonymous with product quality. The very real and serious hazards which can occur by cross contamination of pharmaceutical ingredients have led the Food and Drug Administration of the U. S. Government to require very rigid housekeeping efforts to eliminate contamination problems. This has meant that equipment such as mixing equipment which is used ~8948 to perform its function with a variety of product formulations must be cleaned laboriously between runs of different material.
The problem, however, involves more than simply the time-consuming effort required to clean previously used containers and mixing equipment. Part of the existing problem is the exposure of material to plant environment, including solid materials and vapors, and the effort required to prevent migra-tion of material either into the plant environment or of impurities into the material from the plant environment.
Enviromnent control is exceedingly difficult when material is being transferred back and forth between containers and process-ing equipment. The solutions which have been suggested for combating problems of contamination and environmental pollution, including such practices as segregation of different product operations, utilization of vacuum systems to combat dust pro-blems, and the like, all have recognized limitations.
Included among the various devices and procedures which have been proposed for handling both solid and liquid materials in an attempt to obtain improved handling procedures are those proposed by Schmitt and Wheeler, U. S. Letters Patent No. 3,315,945, granted on April 25, 1967 to Alfred Schmitt as well as U. S. Letters Patent No. 3,090,604, granted on May 21, 1963 to Delbert Wheeler, involve equipment designed to be used in conjunction with a standard 55 gallon metal drum for mixing the contents of the drum. According to the Schmitt patent, the metal drum must be clamped to a circular frame which is then rotated in order to accomplish some form of mixing. The Wheeler patent also involves means for securing a metal drum to a frame which is then moved to accomplish some form of mixing action.
The objective in both the Schmitt and Wheeler patents is to position a standard industrial drum at an angle which will promote efficient mixing of the container contents. Movement of 1t;)4~948 a 55 gallon industrial drum containing granular powder or liquid material, however, can be very difficult even with leverage applied to the drum. There is simply no convenient or quick way of mounting a 55 gallon industrial drum in the appara-tus taught by Schmitt and Wheeler or introduce variations in drum size.
Suppliers of specialized storage containers have also offered some improvement in the materials handling aspects of batch processing apparatus. Today, portable bins of various kinds are frequently employed for charging and discharging process machines, transferring materials between processing machines and storing materials, including the raw materials, intermediates and final product. In reality, such bins are simply glorified versions of the standard 55 gallon metal drum which has conventionally been used in industry for storing and shipping liquids and dry bulk material. For convenience, the portable bins are normally equipped with resealable openings, piping to facilitate removal of contents, and corner extensions which permit stacking the bins during shipment or storage.
~otwithstanding the use of specially designed storage containers, charging and discharging the containers remains time consuming, costly, dirty and troublesome, and it has been almost impossible in batch type operations to approximate the coordination of storage, movement and processing that is taken for granted in continuous operation.
Another approach which has been proposed in order to reduce capital equipment costs and improve overall efficiency has been to employ multiple cone blenders in conjunction with one drive unit. Use of cone type hoppers which can be bolted one at a time to a single drive unit has helped to reduce capital investment costs in some operations, but has not over-come contamination, storage, transfer, interplant shipment and 104~948 cleaning problems. Of course, the drive unit can only be used with a fixed hopper size.
Process container apparatus and a system have now been developed which provide clean, safe, economical and flexible materials handling for batch type operations. By improving the materials handling aspects of batch operations, the efficiency of an entire manufacturing operation can be improved.
In accordance with the present invention, the container apparatus comprises a container having at least one opening for transfer of material and having a frame member. The frame member has sides which join together to form a right angle and in which two adjoining sides of the frame member are equipped with fitting means which comprise parallel grooves designed for interconnection with other apparatus. A mixing bar is provided inside the container, wherein one end of said mixing bar extends through an opening in said frame member to permit the mixing bar to be turned by means external from the container.
In another aspect of the present invention, there is provided a multiwall container comprising a top member, bottom member, four side walls, and at least one opening for the trans-fer of material. Means are provided for connecting said top member to said bottom member other than with the four side walls to provide structural strength to the container. Parallel grooves are formed along at least two side walls of the con-tainer in a direction horizontal with the top and bottom members.
In accordance with an embodiment of this other aspect, an enclosed multiwall container comprises: an upper end wall member, a lower end wall member, side wall members, each side wall member connected to said upper end wall member and said lower end wall member, at least one vertical channel member con-nected to said upper end wall member and said lower end wall member, each said channel member separating adjacent side wall 1~48948 members and turned outwardly to form a recessed corner along adjacent side wall members, at least two adjacent side wall members having horizontal means extending along each side wall member from a recessed corner, said horizontal means being adapted for interconnection of the container with V-shaped arms of a retaining device, and said upper end wall member and lower end wall member each having two separate projecting hourglass shaped members positioned parallel to each other, each said hourglass shaped member being narrowest at the midsection of its hourglass shape, and the hourglass shapedmembersprojecting from the upper end wall member are of slightly different size than the hourglass shaped members projecting from the lower end wall member such that hourglass shaped members on different con-tainers will nest with each other when one container is stacked on another.
Other and further objects, advantages and features of the invention will be apparent to those skilled in the art from the following detailed description thereof, taken in conjunction with the accompanying drawings, in which:
Figure 1 is a perspective view of a container designed for use in connection with the present invention, having recessed fittings located - 4a -i -along at least two sides cf the container;
Figure 2 is a side view of a docking station in accordance with the present invention which is designed for quick and positive connection with a container, such as the container illustrated in Figure l;
Figure 3 is a side view in cross-section along line 3-3 of Figure 2, illustrating the rails on the angled arms of the docking station which connect with the recessed fittings of con-tainers used in the process of the invention;
Figure 4 is a side view of a rectangular frame holding a cylindrical cone-shaped container and illustrates another shape of container which can be utilized in accordance with the present invention;
Figure 5 is a side view of four containers which are shaped to fit inside an airplane fuselage and this Figure illustrates still further container shapes which can be utilized in the present invention;
Figure 6 is a top view in cross-section of an octagon-ally shaped container equipped with a square frame adapted for use in the present inven-tion and further illustrates a removable rotating bar present in the container which can be engaged when the container is placed in a docking station;
Figure 7 is a perspective view of a container designed for use in the present invention which illus-trates certain structural aspects which can be incorporated into the container, including a lifting hook, interlocking channels and the outside connection for an internal mixing bar, such as that illustrated in Figure 6, Figures 8 and 9 are diagrammatic drawings which illus-trate the preferred hour-glass shape of the channel members used for stacking and inter-locking containers in accordance with the present invention, the channel member illus-trated in Figure 9 being expressly designed to be attached to the top of the container and the channel member illustrated by Figure 8 being designed to be attached to the bottom of the container;
Figure 10 is a perspective drawing which illustrates the interlocking of multiple containers on a pallet; and Figure 11 is a side view of a docking station inter-locked with a container, in which the docking station has "U"-shaped movable arms for positioning the container to the optimum angle for mixing.
In accordance with the present invention, one container can be used for storage and transportation of material as well as the processing of the material, thereby providing clean, safe, economical and flexible materials handling. Utilization of one container for these different functions means that product contamination is virtually eliminated, pollution problems are minimized, there is a reduction in cost, time and handling problems, there is a reduction of required cleaning operations and a resulting improvement in safety. Safety in handling materials is of course of particular concern in dealing with explosives, corrosive materials, poisonous materials and also 1~4~948 materials which involve physiological hazards. While product contamination is perhaps of primary concern in connection with the pharmaceutical and food processing industry, the reduction in overall plant housekeeping activities as well as reduction in cost of plant equipment is of significance to every industry.
Referring to Figure 1, the containers which can be utilized in accordance with the present invention can be of almost any shape provided that at least two sides of the con-tainer are equipped with a frame having fittings adapted for connection with a docking station, as hereinafter described.
Container 10 illustrated in Figure 1 is a square container which is equipped with any desired number, shape and size of openings, such as opening 11, which will facilitate the transfer of materials to and from the container. Parallel grooves 13 and 14 are illustrated as recessed fittings on at least two of the sides of container 10, and these grooves are designed to inter-connect with rails projecting from an angled arm of the docking station illustrated in Figure 2. As seen in Figure 3, rails 16 and 17 pro]ecting from arm 20 of the angled docking station are spaced exactly the same distance apart as parallel grooves 13 and 14 of container 10. Accordingly, when container 10 is connected with docking station 18, two side walls of container 10 contact arms 20 and 21 of docking station 18.
Fittings such as grooves 13 and 14 are recessed in order to avoid any protrusions on the outside of container 10 which would interfere with the transportation, storage or other utilization of the container. In special cases, however, members could be welded onto the side of a container to provide fittings required for connection with corresponding fittings on the docking station. Obviously, the shape and number of rail members 16 and 17, which become engaged in grooves 13 and 14, is somewhat critical. Preferably, at least two rails are present and these ~4~8 rails are triangular in shape. Other rail shapes can obviously be used, including rails trapezoid in shape, half rounded in shape and even rectangular in shape. Provided a uniform dis-tance between container fittings is maintained, any number of containers can be used in conjunction with the same docking station. It will be seen that container 10 becomes firmly inter-connected with docking station 18. Once the container is in position, it can be securely locked in place by means of any suitable number of mechanically, electrically or hydraulically actuated wedges or other means, such as taper pins 22-22 shown in Figure 2. Taper pins 22 are retracted until a container has been positioned in the docking station and then said pins are actuated by suitable means to engage the container and lock it securely to the arms of the docking station. This locking assures positive engagement of the triangular rails 16 and 17 with the triangular grooves 13 and 14 of the container, and such locking normally is done if the container is to be rotated by the docking station. For extreme protection, a band or strap or retaining arms could be clamped on or around the container after it has been connected to the docking station. However, such precautionary measures are normally required only in instances where violent mixing or agitation is required.
Referring to Figure 2, docking station 18, which can be maintained in a fixed or movable position, consists of member 19 which is normally attached to the floor but which can be mounted on a wall or even supported from the ceiling. Side members 20 and 21 of docking station 18 are of equal length and positioned at right angles to each other in an L-shaped manner.
These side members or arms are equipped with projecting rails, such as rails 16 and 17, for connection with containers of the invention. Side members 20 and 21 are elevated from the floor sufficiently to permit container 10 (Fig. 1) to be completely rotated around bearing 23 when container 10 is interlocked to dccking station 18. Docking station 18 can be adapted for either rotating the container to invert it or to blend, mix or reconstitute materials inside container 10, depending on the type of mixing, blending or vibration desired. Thus, rails 16 and 17 effect positive positioning for quick connect-disconnect and rapid locking. In addition, the rails cause the driving torque to be distributed over a large area when the container is rotated. Thus, the present invention permits the docking sta-tion to be centrally located which results in a reduction ofcapital investment costs with respect to equipment.
Referring to Figure 4, frame 25 is placed around cylindrical cone-shaped container 26. Since frame 25 is equipped with grooved fittings 28 and 29, it can be inserted into the docking station illustrated in Figure 2. In comparison to container 26, frame or skirt 25 can be quite small. Instead of having the frame around the container, the frame can consist of two side walls joined together at one end in a right angle and open at the other end to accept a container, such as a drum, which can be connected to the frame between the two side walls.
Utilization of the cone-shaped container inside frame 25 permits all the advantages of fast, gentle, uniform blending inherent with mixing operations using that shape of container. A fork-lift device or other means, such as a device which will lift container 26 by lifting hook 30, can be utilized to bring con-tainer 26 inside frame 25 to a docking station.
Another container shape which can be utilized in con-nection with the present invention is illustrated in Figure 5.
In this embodiment, four sections of a six section container are illustrated which can be fitted together. These sections are adapted to fit inside an airplane fuselage. The illustrated container sections are equipped with grooved fittings which 1~489413 permit them to be connected with a docking station, such as docking station 18 in Figure 2.
Figure 6 illustrates yet another container shape, specifically an octagonal shaped container 33, inside square frame 34 which is equipped with fittings (not shown) necessary for connection with a docking station. It will thus be seen that as long as either the container itself or a frame surround-ing container is equipped with necessary fittings for quick connect-disconnect operations with a docking station, a variety of different shapes and types of containers as well as materials for construction of containers can be utilized. In fact, as long as the outside frame 34 is constructed of a rigid material, the internal container itself which is attached to the frame need not be constructed of metal as in Figure 6. Thus, if desired, the internal container can be made of plastic, rubber, fabric or a similar material. Provided the fittings on a con-tainer match the fittings on the arms or side walls of the docking station, the container frame can be either shorter, the same size or longer than the arms or side walls. This fact means that containers of varying sizes, configuration and material construction can be used with the same docking station.
In addition, to the mixing and blending operations which are possible by rotation and/or vibration using a docking station, containers of the present invention can be equipped with a mixing bar, such as mixing bar 35 illustrated in Figure 6. By equipping a docking station with means for engaging end 36 of mixing bar 35, the mixing bar can be rotated when con-tainer 33 and frame 34 are connected with the docking station.
With such a mixing bar, internal mixing can occur either independent of or simultaneous with the mixing or blending caused by rotation or vibration of the container by the docking station.

- 10 ~

~6~4~3948 Referring to Figure 7, container 40 is illustrated which in addition to recessed grooves 42 and 43, the fittings required for connection with a docking station, has vertical channels, such as channel 45, located along each corner edge of the container. As previously explained, grooves 42 and 43 pro-vide fittings necessary for connecting container 40 with a docking station. The buildup of metal necessitated by such grooves, as well as channel 45, improves the structural rigidity of the container compared to a perfectly flat side wall rect-angular storage bin. A further feature of vertical channel 45in connection with the elimination of container shifting using vertical tie bars will be referred to below in connection with Figure 10.
Figure 7 also illustrates a recessed opening 47 which permits a connection to be made between an internal mixing bar (not shown) and a docking station (not shown). While lifting eye 49 appears in the drawing, container 40 is preferably trans-ported by means of conventional fork lift truck. Lifting eye 49, which can be on the top and/or bottom of the container, is protected by channels, for example, 50 and 51 described below.
Hourglass-shaped channels 50, 51, 52 and 53 are prefer-ably attached to container 40 as shown in Figure 7. These channels facilitate the stacking and interlocking of containers.
Channels 50 and 51 have a closed hourglass-shaped configuration as illustrated in Figure 9. Channels 52 and 53, on the other hand, have an open hourglass-shaped configuration (Figure 8) which is adapted to fit into the corresponding closed channels.
The difference in size between the channels of Figures 8 and 9 is just sufficient to permit them to become easily intermeshed.
Because of the configurations of these interlocking channels, containers can be safely stacked one on the other. The channels can be positioned at any suitable angle, e.g., a 45-degree angle, 1~8948 and spaced apart at a distance equal to the width of the tongs on a conventional fork-lift truck, making it possible for the container to be picked up by inserting the tongs of the fork-lift truck into the ends of channels 52 and 53. Preferably, these channels are slightly wider even at the narrowest point in their hourglass configuration than the width of the tongs of a fork-lift truck. This not only facilitates picking up con-tainer 40 using a fork-lift truck, but facilitates the docking operation because the lateral variance provides for non-critical docking. As grooves 42 and 43 of container 40 (Figure 7) become engaged with the rails of a docking station, some shift-ing occurs because of the automatic alignment caused by the side wall configuration of the docking station. If channels 52 and 53 are wider even at their narrowest point than the tongs of the fork-lift truck, container 40 automatically turns without binding while being held by the fork-lift truck and connected with the docking station.
In Figure 10 several containers are stacked together on pallet 54. Vertical members, such as vertical members 55, 56, 57 and 58, attached to the pallet serve to guide and also retain the containers in their position on the pallet during movement of the pallet itself. While Figure 10 illustrates only four containers positioned on a pallet, it will be under-stood that any number of containers can be arranged to fit on a pallet and that the containers can, if desired, be stacked one on the other in layers.
In Figure 11, U-shaped arms (two L-shaped arms joined together) are attached to a docking station 60. U-shaped arms 62 are actually movable in U-shaped frame 63 to permit a con-tainer 65 to be tilted at an angle, e.g. 45 degrees, which is known to provide classic blending action. Suitable locking means such as pins 67 and 68 can be used to retain container 65 at the 1~4~394~3 desired angle while the container is being rotated by docking station 60. Although the U-shaped arms of docking station 60 establish the width of the container which can be used in the docking station, the arms do not limit the depth or height of the container.
From the foregoing, it will be seen that the present invention is well adapted to attain all of the ends and objects hereinabove set forth, together with other advantages which are obvious and which are inherent to the system. With the present invention, it is possible to control contamination of products in a plant environment, to reduce plant equipment cleaning costs, to save time required to charge and discharge processing equip-ment, to use plant space more efficiently, to cut shipping and container costs, and to prevent plant obsolescence when changes occur in products and processes. Accordingly, a significant and major improvement in materials handling procedures for batch operations has been developed which provides for clean, safe, economical and flexible operation.
In accordance with the present invention, a container can be connected to or disconnected from a drive station in less than one minute. Most blending and processing cycles require less than ten minutes. On the basis of 12 minute intervals per batch, it is thus possible to handle five containers in an hour or forty containers per eight hour shift. Using fifty cubic foot containers, the output capacity is 2000 cubic feet per shift. What can be accomplished is intermittent "continuous"
processing.
One of the advantages of the present invention is the fact that containers of varying size, shape and construction can be adapted for utilization with the docking station by simply attaching a frame to the container which will permit quick connect-disconnect operations with the docking station.

1~48948 Preferred containers have a triple wall construction, such as an exterior layer of aluminum, an intermediate layer of styro-foam and an interior layer of stainless steel. This triple wall construction has certain inherent advantages over a single walled container not only with respect to structural aspects and weight, but also with respect to temperature control. Triple wall construction permits impact resistant containers to be built from relatively thin wall layers. Obviously, any desired material can be used to fabricate the containers including aluminum, magnesium, carbon, stainless steel, plastic, fiber-glass and the like.
The strength of three wall construction makes this type of container ideally suited for interplant transportation by conventional means, such as rail, truck or air shipment. To provide even further structural strength, the containers in a preferred embodiment have means such as a cable or tie rod attached to each corner or fork-lift channel, thereby connecting the top and bottom of the container. This preferred construc-tion permits the containers to be picked up and suspended and, if desired, for the container to have a floating interior shell.
Due to the structural strength of the containers, they can be positioned in an upright position or in an inverted position.
Accordingly, an improved container design is provided which permits empty containers to be forwarded to suppliers for receiving materials sealed inside ready for processing, thereby making it possible to eliminate the need for discarding empty drums. The system of the present invention also permits a manu-facturer to ship containerized formulations to regional plants for further operations, such as tableting and packaging. The incorporation of a built-in impeller or agitator simplifies the stirring req~ired in connection with formulations which tend to settle after shipment or long storage periods.

1~48948 The apparatus and process of the present invention can be used in connection with almost any dry bulk or liquid material. The list of materials which can advantageously be handled is practically limitless and would include powders, colors, pigments, minerals, synthetic products, fine and heavy chemicals, dyes, intermediates, resins, molding powders, plastics, liquid adhesives, lacquers, thinners, paints, petrochemicals, food materials such as liquid chocolate, sugar, and the like.
For materials which tend to solidify in storage or transit, the apparatus of the present invention can be equipped with special heating devices, such as electrical tape or heating coils. For materials needing refrigeration, the cont-iners can be equipped with means for cooling the contents, such as refrigeration coils.
As previously mentioned, the containers can be equipped with rotating bars which will assist in blending materials, vibrating to assist discharge or for compacting, breaking up lumps, etc. Conveniently, these rotating bars are mounted in the container with an end arranged to automatically become engaged with a turning mechanism located on the docking station when the container is connected with the docking station.
If desired, a dispersion device can be incorporated into an agitator bar. Such a device would permit liquid mist to pass through narrow slots in the agitator bar into the material inside the container. This liquid mist could be enveloped in a cascade of tumbling solid particles such that wetting of the shell is prevented. Similar equipment can also be used to intro-duce a gas into the material being processed. Instead of being used to introduce material into the container, the equipment can also be used to withdraw air from the container to create a vacuum.
To provide for dust free charging and discharging of solid ingredients, containers can be provided with ports that 1~4~9~3 fit dust tight charging and discharging spouts such that ingredients can be added and withdrawn without contaminating either the product or the environment. An advantage of the docking station is that it permits a container to be precisely aligned. This means that a container can be charged from a floor above or discharged to a floor below while being held in precise alignment with a chute or floor opening.
While the illustrated containers are conveniently moved with a conventional lift fork, obviously the containers can be equipped with hoisting eyes, rollers, casters, or other common means for positioning and moving the containers.
Obviously, many other modifications and variations of the invention as hereinbefore set forth can be made without departing from the spirit and scope thereof.

Claims (5)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-

1. An enclosed multiwall container comprising: an upper end wall member; a lower end wall member; side wall members;
each side wall member connected to said upper end wall member and said lower end wall member; at least one vertical channel member connected to said upper end wall member and said lower end wall member, each said channel member separating adjacent side wall members and turned outwardly to form a recessed corner along adjacent side wall members; at least two adjacent side wall members having horizontal means extending along each side wall member from a recessed corner, said horizontal means being adapted for interconnection of the container with V-shaped arms of a retaining device; and said upper end wall member and lower end wall member each having two separate projecting hourglass shaped members positioned parallel to each other, each said hourglass shaped member being narrowest at the midsection of its hourglass shape, and the hourglass shaped member projecting from the upper end wall member are of slightly different size than the hourglass shaped members projecting from the lower end wall member such that hourglass shaped members on different con-tainers will nest with each other when one container is stacked on another.

2. The multiwall container of claim 1 in which the hour-glass shaped members are at an angle with respect to said side wall members.

3. The multiwall container of claim 1 in which the side wall members have three layers, the outer layer being metal, the middle layer being plastic and the inner layer being metal.

4. The multiwall container of claim 3 in which the outer layer is aluminum and the inner layer is stainless steel.

5. The multiwall container of claim 1 in which the side wall members have three layers, the outer layer being metal, the middle layer being plastic and the inner layer being plastic.