IES84951Y1 - A method for producing a component, and a container for use in the production method - Google Patents

Abstract

ABSTRACT The present invention relates to a method for producing a plurality of components in a batch production system, and the invention also relates to a container for use in the method for storing and transferring a batch of the components from one production area to another, and the invention also relates to a product comprising a component produced according to the method.

Description

A method for producing a component, and a container for use in the production method The present invention relates to a method for producing a plurality of components in a batch production system, and the invention also relates to a container for use in the method for storing and transferring a batch of the components from one production area to another, and the invention also relates to a product comprising a component produced according to the method.

Batch production methods for producing components and products in batches are know. Typically, the components in batches are subjected to a plurality of production steps in respective production areas, and may be transferred from one production area to the next production area by a conveyor or in containers. Where the components are transferred between production areas in containers, it is desirable that each batch of components be transferred in a single container. In other words, it is preferable that the containers for transferring components from one production area to the next is of size sufficient to accommodate a full batch of the components. This has two advantages, firstly, it provides an efficient system for transferring and tracking components from one production area to another, and secondly, and more importantly where a production step is fully automated, for example, in an injection moulding step in the production of component, the need for an operative to periodically replace a full container with an empty container during the automated step is avoided. In many cases, particularly in the case of injection moulding of components, it is desirable to produce batch sizes of components which correspond to one complete production shift, for example, an eight hour production shift. In general, a large quantity of components are produced by a single injection moulding machine operating for the duration of such an eight hour shift. Thus, it is desirable that containers for transferring batches of components from one production area to another should be of sufficient size to accommodate all the components of a batch produced during such an eight hour production shift, in order to avoid an operative having to periodically replace a full container of the components with an empty container throughout the shift. This, thus, necessitates the need for a relatively large container, and while such large containers are available, in general, such containers tend to be relatively large, typically having a floor area of 2m X 2m, < and a wall height of approximately 1.5m. Such containers may be carried on wheels or castors for facilitating wheeling of the containers from one production area to the next, or may be pallet mounted, suitable for transportation by a forklift or the like, from one production area to the next. in general, it is not feasible to tip such containers in order to tip the components from the containers due to the large size of the container, and also due to the possibility of injury to operatives in an adjacent area to that in which the container is being tipped, and also, tipping of such containers in order to discharge components therefrom can lead to damage to the components. Thus, once the level of components in the container has been reduced to a level beyond that to which an operative can gain access by reaching into the container, in general, the only feasible way of removing the remaining components from the container is by an operative gaining access to the container for removing the remaining components therefrom. This can lead to damage to the components as a result of an operative standing on the components when entering the container, and/or contamination or soiling of the components as a result of dirt on the shoes of the operative. A further problem which arises in the case of deep containers is damage to the components as the components are being delivered into the container. Due to the depth of such containers, when the container is empty, the initial lot of components being delivered into the container must fall through quite a distance from the production machine, for example, an injection moulding machine to the base of the container, which can result in damage to the components, and in particular to the components initially delivered into the container.

As well as the damage which can result to components during delivery of components into such containers or transfer from such containers, difficulties also arise in enabling an operative to gain access to such containers. In general, a step ladder is required in order to permit an operative to reach the top of a side wall of the container, and a further step ladder is required within the container for the operative.

There is therefore a need for a container for use in a production process which overcomes these problems, and furthermore, there is a need for a method for producing a component in a batch production system which overcomes the problems of known methods, and there is also a need for a product comprising a component produced by such a production method.

The present invention is directed towards providing a method for producing components in a batch production system, and the invention is also directed towards providing a containerfor use in the method, and the invention is directed towards providing a product comprising a component produced according to the method.

According to the invention there is provided a container comprising a pair of spaced apart side walls extending generally upwardly and between opposite ends of the container, an elongated flexible membrane coupled at spaced apart first and second locations to the side walls, and extending transversely therebetween, and being urgeable relative to the side walls between a container forming state forming with the side walls a hollow interior region, and a discharge state for facilitating removal of contents of the hollow interior region therefrom. in one embodiment of the invention the membrane is coupled to the side walls at the second location by a winch, and preferably, the winch defines a winch axis extending transversely between the side walls, and advantageously, the membrane is wound onto the winch, and ideally, the winch is operable for winding the membrane onto the winch for urging the membrane from the container forming state to the discharge state, and preferably, the winch is selectively reversible for facilitating paying out of the membrane from the winch for urging the membrane from the discharge state to the container forming state, and ideally, a locking means is provided for selectively preventing operation of the winch for paying out the membrane for retaining the membrane in a desired intermediate state between the container forming state and the discharge state.

In another embodiment of the invention the winch is located adjacent the top of the side walls, and advantageously, extends therebetween.

In another embodiment of the invention the membrane is secured at the first location at a level below the level of the top of the side walls, so that in the discharge state the membrane substantially inclines downwardly from the second location to the first location.

In one embodiment of the invention a door extends transversely between the side walls, and extends upwardly from the first location, and preferably, the door is hingedly coupled to the container along a hinge axis extending between the side walls, and preferably, substantially parallel to the winch axis.

Preferably, the door is hlngeable along the hinge axis from a first position extending upwardly of the hinge axis between the side walls, and a second position extending outwardly of the container.

In another embodiment of the invention the door is hlngeable to a third position extending substantially downwardly from the hinge axis. in another embodiment of the invention the container comprises a base wall from which the side walls extend upwardly, and a first end wall extending upwardly from the base wall between the side walls, and preferably, the first end wall extends upwardly to the first location. Preferably, a second end wall spaced apart from the first end wall extends upwardly from the base wall between the side walls, and advantageously, the second end wall extends upwardly to the second location.

Ideally, the base wall, the side walls and the first and second end walls together define a main hollow interior region, and ideally, the membrane is located within the main hollow interior region, and in the container forming state lines the base wall and the first and second end walls.

In one embodiment of the invention the container is adapted for storing components, and preferably, is adapted for transporting components within a manufacturing facility.

In another embodiment of the invention the container is mounted on ground engaging wheels for facilitating wheeling of the container.

Additionally the invention provides a method for producing a plurality of components in a batch production system, the method comprising the steps of carrying out a first production step in the production of the components in a first production area, delivering each component on completion of the first production step into a container according to the invention until a batch of the components has been delivered into the container, transferring the container with the components therein from the first production area to a second production area, transferring the components from the container to the second production area, and urging the flexible membrane of the container from the container forming state to the discharge state as the components are being transferred from the container for facilitating transfer of the components therefrom.

Preferably, the membrane is urged from the discharge state to the container forming state as components of the batch of components are being delivered into the container in the first production area.

In one embodiment of the invention the membrane is progressively urged from the discharge state to the container forming state in response to the components being delivered into the container.

Alternatively, the membrane is periodically urged from the discharge state to the container forming state in incremental steps in response to respective counts of the components being delivered into the container.

In one embodiment of the invention the first production step comprises a moulding step for forming the components, and preferably, a plastics injection moulding step for forming injection moulded plastics components.

In another embodiment of the invention the components are subjected to a second production step in the second production area, and in another embodiment of the invention the second production step is a packaging step whereby the components are packaged, and in one aspect of the invention the components are individually packaged, while in an alternative embodiment of the invention the components are packaged whereby at least two components are included in each package.

The advantages of the invention are many. By virtue of the fact that the flexible membrane of the container according to the invention is progressively urgeable from a container forming state to a discharge state for facilitating transfer of the components to the second production area, the components can readily be transferred from the container to the second production area without the need for an operative to gain access to the container. By urging the membrane of the container from the container forming state to the discharge state, components in the container are progressively urged to a level at which the components can be readily easily removed from the container by merely reaching into the container. Thus, damage, contamination and soiling of the components which would otherwise result from an operative having to gain access to the container is avoided.

Additionally, by urging the flexible membrane from the discharge state to the container forming state, either progressively or incrementally, as components are being progressively delivered into the container, the level of components in the container can be maintained substantially constant adjacent the level of the membrane when in the discharge state, and thus the distance components must fall from the machine carrying out a production step into the container is minimised, thereby avoiding damage to the components being delivered into the container.

The invention will be more clearly understood from the following description of a preferred embodiment thereof, which is given by way of example only, with reference to the accompanying drawings, in which: Fig. 1 is a block representation of a production method according to the invention for producing a plurality of components in a batch production system, Fig. 2 is a perspective view of a container also according to the invention for use in the production method of Fig. 1, Fig. 3 is a side elevational view of the container of Fig. 2, and Fig. 4 is a side elevational view of the container of Fig. 2 with a portion of the container illustrated in different states.

Referring to the drawings, there is illustrated a container according to the invention, indicated generally by the reference numeral 1, for use in transferring components (not shown) of a batch of components produced by a method also according to the invention for producing a plurality of the components in a batch production system.

Before describing the container 1 in detail, the production method according to the invention will first be described with reference to Fig. 1. In the method according to the invention, the components (not shown) of plastics material are produced by injection moulding. The components may be any components suitable for production in an injection moulding process. However, it will be readily apparent to those skilled in the art that the method according to the invention may be used for producing any type of components or products, whether of plastics material or otherwise, whereby the components or products are produced in batches and require at least two production steps in their production.

In the method according to the invention the components (not shown) of plastics material are produced in a first production step by injection moulding in an injection moulding machine 2 illustrated in block representation in a first production area 3, also indicated in block representation. in this embodiment of the invention the injection moulding machine 2 is capable of operating automatically without the intervention of an operative for lengthy periods, and in this embodiment of the invention is operated on an eight-hour shift basis without manual intervention.

Accordingly, during each eight-hour shift a batch of the components is produced by the injection moulding machine 2. As the components are produced by the injection moulding machine 2, the components are delivered into the container 1 for transfer to a second production area 4 where a second production step is carried out on the components. The container 1 is of sufficient size to hold one complete batch of the components, namely, for holding the output of the injection moulding machine 2 over an eight-hour shift. On completion of the eight-hour shift, the batch of components in the container 1 is transferred from the first production area 3 to the second production area 4 where a second production step is carried out on the components.

In this embodiment of the invention the second production step is a packaging step, whereby the components are individually packaged on a packaging bench 5 in the second production area 4 for subsequent delivery to a customer.

Referring now in particularto Figs. 2 to 4, the container 1 according to the invention will now be described. The container 1 comprises a base wall 12, a pair of spaced apart upstanding side walls 13 extending upwardly from the base wall 12, a first end wall 14 extending upwardly from the base wall 12 between the side walls 13, and a second end wall 15 extending upwardly from the base wall 12 between the side walls 13 and spaced apart from the first end wall 14. The base wall 12, the side walls 13 and the first and second end walls 14 and 15 together define a main hollow interior region 16 of the container 1. The side walls 13 and first and second end walls 14 and 15 define an open mouth 17 to the container 1. A door 18 hingedly coupled to the first end wall 14 along a horizontal hinge axis 19 is pivotal between a first position extending upwardly closing a portion of the open mouth 17 defined between the side walls 13 and the first end wall 14, a second position illustrated in Fig. 2 forming a counter 20, and a third position illustrated in Fig. 3 depending downwardly from the hinge axis 19, leaving the portion of the open mouth 17 formed between the side and front end walls 13 and 14 unimpeded, Clips 21 on the respective side walls 13 are provided for securing the door 18 in the first position extending upwardly from the hinge axis 19.

An elongated flexible membrane 22, in this embodiment of the invention provided by an elongated flexible sheet of plastics material extends transversely between the side walls 13, and is located within the main hollow interior region 16 and is secured to the container 1 at a first location 24 along the top of the first end wall 14 adjacent the hinge axis 19, and a second location 25 adjacent the top of the second end wall , The membrane 22 is fixedly secured to the first end wall 14 by suitable fixings, for example, tacks, adhesive or the like (not shown). A winch 27 secures the membrane 22 at the second location 25 adjacent the top of the second end wall 15.

The winch 27 is rotatably mounted in bearings (not shown) mounted on the side walls 13 adjacent the second end wall 15, and defines a winch axis (not shown) which extends parallel to the hinge axis 19.

The membrane 22 is urgeable by the winch 27 between a container forming state illustrated by the broken lines 29a in Fig. 3 to a discharge state illustrated by the broken lines 29b in Fig. 4. In the container forming state illustrated by the broken lines 29a of Fig. 3, the membrane 22 essentially lines the first end wall 14, the base wall 12 and the second end wall 15, and defines with the side walls 13 a hollow interior region 30 within the main hollow interior region 16 for storing components therein. Winding the membrane 22 onto the winch 27 urges the membrane 22 from the container forming state to the discharge state illustrated in Fig. 4 by the broken lines 29b with the membrane 22 substantially inclined from the winch 27 to the hinge axis 19, for facilitating removal or discharge of components from the hollow interior region 30. As the membrane 22 is wound onto the winch 27, it takes up an infinite number of intermediate states, two of which are illustrated by broken lines 29c and d in Fig. 4.

A locking means for selectively preventing unwinding of the winch 27 for paying out the membrane 22 from the discharge state to the container forming state is provided by any suitable locking means, for example, a selectively releasable ratchet and pawl mechanism (not shown), or the like, mounted on the winch 27 in order to selectively retain the membrane 22 in the discharge state, or any intennediate state between the discharge state and the container forming state.

A handle 31 is provided for winding the winch 27.

The base wall 12, side walls 13, first and second end walls 14 and 15 and the door may be of any suitable material, for example, metal, wood or plastics material Although not illustrated, the container 1 may be mounted on castors or suitable ground engaging wheels for facilitating wheeling of the container 1.

In use, the container 1 is placed in the first production area 3 in order to receive components from the injection moulding machine 2. The door 18 of the container 1 is secured in the upwardly extending first position, and the winch 27 is operated for urging the membrane 22 into the discharge state. With the membrane 22 in the discharge state, the container 1 is ready to receive the components from the moulding machine 2. Periodically as the components are being delivered from the injection moulding machine 2 into the container 1, the handle 31 of the winch 27 is operated for urging the membrane 22 in incremental steps from the discharge state to the container forming state for maintaining the level of components in the container 1 within predetermined upper and lower levels, so that the distance the components have to fall from the moulding machine 2 into the container 1 is maintained reasonably constant. At the end of the shift the container 1 is transferred from the first production area 3 to the second production area 4 by wheeling or by a forklift truck, and an operative or operatives in the second production area 4 manually remove the components and pack the components in the second production area 4. initially, the components are removed from the container with the door 18 in the upwardly extending first position and the membrane 22 in the container forming state by an operative reaching over the side walls 13 or the door 18. Once the level of components has been reduced to the top of the first end wall 14, the door 18 is pivoted downwardly into either the second position to form a counter 20 or into the third position illustrated in Fig. 3, and further components are removed from the container 1 by reaching into the container over the top of the first end wall 14. As the level of components is further progressively reduced, the winch 27 is periodically operated for urging the membrane 22 upwardly in incremental steps for maintaining the level of components in the container 1 at a reasonably constant level at which they can be readily removed, until the membrane 22 is in the discharge state, and the last remaining components are then removed.

While the winch has been described as being manually operable, it is envisaged that in many cases the winch may be powered by an electrically powered motor, and in which case, a control system may be provided whereby the electrically powered motor would be operated to operate the winch for urging the membrane from the discharge state to the container forming state in incremental steps in response to a predetermined number of components being delivered from the moulding machine into the container for maintaining the level of components in the container reasonably constant. The control system could be responsive to a counter on the moulding machine, which would count the number of components being produced by the moulding machine. Alternatively, the control system could be responsive to the level of components or the weight of components in the container for operating the motor for in turn urging the membrane between the discharge state and the container forming state in incremental steps as the container is being loaded or unloaded.

While the container has been described as comprising a base wall and first and second end walls, these, in certain cases, may be dispensed with, since the essential components of the container are the side walls and the membrane.

While the method according to the invention has been described for use in the production of injection moulded plastics components, the method may be used in the production of any other components, whether of plastics material or otherwise, and when of plastics material, may be produced by any other suitable plastics forming method besides injection moulding, for example, blow moulding extrusion or the like.

Additionally, while the method has been described for use in the production of a component which merely requires two production steps, namely, the injection moulding step and a packaging step, it will be readily apparent to those skilled in the art that the method may be used for any production process, irrespective of the number of production steps in the production process, and it will also be appreciated that the production method according to the invention may be used in an assembly production process whereby a plurality of components are assembled at respective different steps of the production process to produce a product, and it will also be appreciated that the production method may be used in a production process where the components are only part completed in the production process.

Claims (5)

Claims

1. A container comprising a pair of spaced apart side walls extending generally upwardly and between opposite ends of the container, an elongated flexible membrane coupled at spaced apart first and second locations to the side walls, and extending transversely therebetween, and being urgeable relative to the side walls between a container forming state forming with the side walls a hollow interior region, and a discharge state for facilitating removal of contents of the hollow interior region therefrom.

2. A container as claimed in Claim 1 in which the membrane is coupled to the side walls at the second location by a winch, the winch defining a winch axis extending transversely between the side walls, and the winch being adapted for winding the membrane onto the winch for urging the membrane between the container forming state and the discharge state.

3. A container as claimed in Claim 1 or 2 in which the membrane is secured at the first location at a level below the level of the top of the side walls, so that in the discharge state the membrane substantially inclines downwardly from the second location to the first location.

4. A container substantially as described herein with reference to and as illustrated in the accompanying drawings.

5. A method for producing a plurality of components in a batch production IO system, the method comprising the steps of carrying out a first production step in the production of the components in a first production area, delivering each component on completion of the first production step into a container as claimed in any of Claims 1 to 3 until a batch of the components has been delivered into the container, transferring the container with the components therein from the first production area to a second production area, transferring the components from the container to the second production area, and urging the flexible membrane of the container from the container forming state to the discharge state as the components are being transferred from the container for facilitating transfer of the components therefrom.