IES86565Y1 - Under bar counter bottle crusher - Google Patents

Abstract

ABSTRACT My invention relates to a method of crushing bottles under a standard bar counter to reduce the volume of waste produced and to increase space behind the bar. The under bar counter bottle crusher is designed to fit under a standard bar counter and is of a similar size to a standard bar fridge. Bottles are fed into a flap (22) on the front of the machine. The bottles then fall through a plastic shoot (18) which brings the bottles to a crushing chamber. The bottles are crushed by rotating hammers (10). The crushed cullet then falls into a plastic bin (7) which is on a hinged plate (6). When this plate reaches a set weight the plate will compress a set of springs to press a switch which looks the inlet flap (22) of the machine. Another feature is that the inlet flap (22) of the machine when opened. If the flap of the machine is not opened for period of time the machine will automatically go into stand-by, saving energy. If the machine door (20) is opened the machine will shut down.

Description

Under Bar Counter Glass Bottle Breaker.

Field of the Invention The present invention relates to a method of reducing glass bottle waste by the invention of a machine to break the bottle and reduce glass waste volume by a ratio of 5:1.

Background to the Invention The present invention relates to a machine used to reduce the volume of empty bottles returned and stored behind a busy private or public establishment which serves drinks from glass bottles. The machine is capable of receiving the bottle from the operator, breaking it and depositing the broken glass cullet into a plastic tote box, where the material is stored securely until the operator has time to dispose of the material for recycling.

Storage of empty glass bottle behind bars in public houses, restaurants, night clubs, private clubs and hotels is a problem. These modern day establishments use large quantities of products supplied in glass bottles, from still water to alcoholic beverages. All these establishments face the same problem at the end of the day; the bottles must be disposed of in a responsible manner to allow fridges and shelves behind the bar to be fully stocked for the customer.

In many of the aforementioned establishments, space is at premium and the storage of empty glass bottles can prove difficult and uneconomical. Large air filled bottles take up the same amount of space as the equivalent bottle full of a drink ready to be purchased for consumption. In reaction to this, this invention provides a machine that can break the bottles into a recyclable cullet format. This allows for a space reduction ratio of 5:1 and is far more efficient in terms of space usage behind the bar.

The next obstacle the owner of the aforementioned establishment meets is many of their bars have been designed and built in times where space was not given up for this type of equipment. This creates a problem owner as to where to locate the machine. There are devices in the market place for reducing glass waste, however due to their design are not , 886565 seen commonly behind a bar, the source of our empty glass bottle collection. For example there are machines out there that are designed for behind the bar counter but are quite cumbersome and awkward, adding to the problem of space utilisation and optimisation. The situation present with prior art machines is that there is no convenience from installing such machines. The machines take up more space than the bottle storage crates would have, thus not alleviating the storage issue.

Another problem the owner would have is the noise created from the clanging of the bottles when they are being stored. For example there is a device known for use behind a bar, which can take multiple bottles into its crusher unit in a single use, however the noise created from loading the machine can be a likened to the placing of glass bottles into a standard bottle bin. At times of high pressure behind a public bar, operators of such machine may not be able to afford the time for due diligence to allow for loading as quietly as possible. There have also been objections for such machines being placed at the back of pubs in waste areas, as these machines have been known to disrupt neighbouring residents.

Other machines in the market place often compromise safety to ensure the machine is compact in dimension to fit neatly in the tight area behind a bar. In this instance machines provide direct access from the bottle shoot into the crusher unit. In order to protect the operator the unit power must be isolated during loading. After loading is complete, the unit is switched on and a strong force is required to get the crusher unit up to speed. The increased force required will eventually put unnecessary wear on the machine. Dealing with bottle jams can also be uncomfortable and tedious as the bottle shoot must be removed, to alleviate the jam.

Another problem associated with such machines is the purpose for which they built for. The combination of corrosive ingredients, i.e. alcohol and the abrasive nature of cullet glass can cause premature wearing and failure of components. This increases the need for extensive servicing. A final problem with prior art machines is the economy of using the machine. As some machines use a hopper fed system, it has been noted that the programmed cycle is the same length of time no matter how many bottles are in the hopper, i.e. a cycle to crush one bottle lasts as long as a cycle to crush several.

Statement of Invention The presented under counter bottle breaker seeks to provide a more durable sustainable bottle crusher machine. As previously mentioned, the bottle breaking machine is designed to fit under a standard bar counter. Its purpose is to reduce the volume of waste glass bottles and increase the amount of storage space. The footprint of the machine is based around a footprint of standard fridges or glass washing equipment. It can be easily slotted underneath the majority of bars, with seamless installation.

The machine includes a bottle flap, a bottle shoot, a bottle breaking chamber and receptacle tote box for holding the bottle cullet. The bottle flap is in constant communication with the crusher chamber and the receptacle tote box. When the bottle flap is engaged the bottle crusher chamber is activated, while the bottle is in transit down the bottle shoot. By the time the bottle arrives at the crusher chamber the bottle breaking rotor and hammers are at optimum speed for crushing. When the bottle flap goes through a period of inactivity the signal is sent back to the control box to power off the bottle breaking chamber, this helps to optimise the efficiency of the power usage, as the machine will only stay active for the length of time it is needed. Another advantage of this system is that the machine is automated, meaning the operator doesn’t have to worry about turning on and off and waiting for cycle times to run their course. The next feature of the machine is that the receptacle tote box is also is also in communication with the bottle flap. When the tote box reaches its maximum weight a signal is sent to a limit switch which will lock the bottle flap and power a red warning light to alert the operator that the tote box must now be emptied. During this process when the tote box door is open the machine cannot operate, no controls are active and a buzzer will sound to keep the operator alert to any dangers. Once the tote box is replaced in the machine and door closed, the machine automatically resets itself and it is ready for further U89.

As previously mentioned the working of the machine consists of a bottle flap, bottle shoot, crusher chamber and enclosed receptacle tote box cabinet. The outer structure of the machine is constructed from mild steel and designed to be as ethically pleasing behind the bar counter. No corrosive liquid or abrasive glass will ever be in contact with this sheet metal, thus the aesthetics and construction of the machine should never be compromised.

The bottle shoot is manufactured from hard wearing PVC plastic piping and has a 90 degree bend at the entrance to the crusher chamber to stop any human misuse of the machine and protect them from serious injury. This pipe again will never be in contact with abrasive glass cullet and the hard wearing properties of the PVC make it an equal match for the corrosive liquid contained within alcohol. The crusher shaft and hammers are the only mechanical parts to contact the glass bottle and cullet, and these parts are constructed from hardened steal. Hardened steal is heated to make it extremely durable and long lasting. This makes the material more chemically inert or substantially inert and more resistant to degradation.

The mode of operation of the machine allows the operator to continuously feed the machine with bottles. As the bottles are collected and fed into the machine. There is no down time, as one bottle is crushed the next one can be in transit to the crusher chamber behind it. The mode selected in the control box, means that the signal sent to the crusher chamber is reset and resent every time the bottle flap is activated. This ensures the crusher chamber will not get backed up and jam the shattering mechanism. The only break in the continuous use of the machine will be when the control panel alerts the operator that the tote box is full. The length of the bottle shoot has been determined by the time it takes the motor speed to be fully operational before the bottle reaches the rotor. This means the motor has reached full momentum before the bottle falls into the crushing zone and is adequately smashed. As result no undue stress should be put on the glass mechanism and motor windings.

The motor can be also activated when the bottle flap is not engaged by the user. This can be done at peak times to get the motor up to speed quickly. This can be done by pressing the green button on the control panel. In case of an emergency, there is also an emergency stop button. Once the emergency stop button is pressed in, all power will be stopped instantly tp prevent misuse or failure.

The crushing rotor cannot be activated when any of the following criteria are activated . The receptacle tote box is full and the bottle flap is locked.

. The receptacle tote box door is open . The emergency stop circuit is broken.

Should any of the following criteria need attention the operator is alerted to this by a signal warning light or a buzzer sounds.

Acoustics are of upmost importance to the success of bottle breaking machines behind a counter. There are machines in the market that are volume fed into a container. This can be quite loud with the bottles clinking of each other during loading and with shear volume being fed into the crusher chamber at once, noise is substantial during the crushing process. With the under counter bottle breaker single feed, the bottle slides down the PVC pipe, and into the crusher with ease and minimal sound, as there is no resistance created from the smooth surface of the PVC pipe. The inside of the main structure is also lined with dense flexible melamine foam which stops sound penetrating from the crushing chamber during a cycle.

Brief Description of the drawings The invention will be more clearly understood from the following description of an embodiment thereof, given by way of an example only with reference to the accompanying drawing in which: Figure 1 is an exploded cross-sectional view, detail all the parts of the under counter bottle breaker.

Figure 1-1 is an exploded view of the assembly of the shaft and hammer and rotor section inside the bottle crusher chamber.

Table 1 Part number and description of part in relation to Figure 1 and Figure 1-1. (01) Front Panel (02) Bottle Flap (03) PVC Bottle Shoot (04) Motor (05) Control Box (06) Hammers (07) Back Panel (08) Bin Full Tray (09) Solenoid Limit Switch (10) Crusher Chamber (11) Right Side Panel (12) Left Side Panel (13) Top Lid (14) Receptacle Tote Box (15) Tote Box Door (16) Drive Pulley (17) V-Belt Detailed Description Figure 1 is an exploded cross-sectional view, detail all the parts of the under counter glass bottle crusher. When the parts are assembled they form a stand-alone machine which can be installed or positioned under a drinks bar for a client to reduce their volume of glass by breaking the glass.

With reference to Figure 1, the process will be outlined of the cycle and operation on the machine detailing how all parts are linked and a brief discussion on their integrity within the machine.

Figure 1 show the main feature of the under counter bottle crusher broke down into seventeen main piece.

Front panel (01) is a flat panel with punched recesses to allow for the mounting of the electrical control box (05) and bottle flap (02). This panel (01) is secured in position by bolting to right side panel (11) and left side panel (12). When panels (01), (11) and (12) are linked together the machine is structural solid, however full structural stability and vibration will not be eliminated until the lid (13) is secured down around these panels (01), (11) and (12). All structural panel (01),(11),(12) and (13) are padded with melamine foam (07). This foam (07) stops any noise from penetrating through covers. The foam (07) is rendered to the inside of each panel and the outside is finished with the colour the customer requires. Panel (O1),(11),(12) and (13) never come into contact with corrosive alcohol or abrasive glass cullet, so there main purpose is to house the control box (05), the electric motor (04) and pulleys (16), the PVC bottle shoot (03) and the crusher chamber (10).

The bottle flap (02) can be pushed open to insert a bottle. It then springs closed behind.

When bottle flap (O2) is opened it sends an instant signal to control box (05), this in turn instantly activates the motor (04) and hammers (06) in the crusher chamber (10). This all happens as the bottle slides down the bottle shoot (03). The product left behind after the bottle has gone through the crusher chamber (10) is called cullet. This cullet is then funnelled from the crusher chamber (10) in the receptacle tote box (14). Figure 1-1 shows the shaft and hammers (06) in more detail. The hammers (06) are used to smash the glass bottles. There are, at least, two hammers (06) in each machine. They are held in place preferably using high tensile zinc plated bolts and nylon lock nuts. The hammers (06) cut to a certain length and depth. This is important as it determines the different size of glass cullet produced. This sizing is at the customer’s discretion.

When the bottle has been crushed in the chamber (10) and after a short period of in activity, the bottle flap (02) will signal the control box (05) to power down the motor (04) and the machine will go into sleep mode until required again.

When the receptacle tote box (14) reaches its glass cullet capacity the bin full tray (08) will press against a weight limit switch. This will then in turn send a signal to the control box (05) which in turn will send a signal to the solenoid limit switch (09) to lock the bottle flap (02).

The machine is now in shut down and a red light will illuminate off the control box (05). This will shine out through a recessed hole on front panel (01). The operator must now empty or replace the receptacle tote box (14) with an empty one. It must be noted that the bin full tray (08) is set to alert the operator when there is a approximately twenty kilograms of glass cullet in the box. This can be adjusted to suit differing manual handling regulations. However, it can be no more than thirty kilograms.

When the operator goes to empty the receptacle tote box (14), the door (15) is opened and the tote box (14) can be removed. During this period an alarm from the control box (05) beeps, this is to make the operator aware that they need to take care when handling the tote box (14) and also to alert them that the machine will not operate when the door (15) is open.

When the alarm from control box (05) stops, the machine is reset and ready for use again.

This same alarm will also sound if the emergency stop button on the control box (05) is pushed or engaged. This is also a safety mechanism to alert the operator that there is a problem or to release the emergency stop button.

The motor (04) has a small diameter pulley installed on the shaft of the motor, this is connected to a larger diameter pulley (16) by using a V-belt (17). The belt is tapered and slots neatly into both pulleys. The motor (04), v-belt (17) and both pulleys (16) drives the shaft which mounts the hammers (06). It must be noted at this point that motor (04) is set up to rotate anti—clockwise. When the hammers (06) rotate anti-clockwise and a bottle slides down bottle shoot (03) the glass bottle is immediately sucked into the crusher chamber (10).

If the hammers rotated clockwise it would have the opposite effect and there could be a chance the bottle will be rejected from the crusher chamber (10).

The invention is not limited to the embodiment described herein but can be amended or modified without departing from the scope of the present invention

Claims (1)

Claims

1. A glass bottle breaking machine which fits under any standard bar counter, for crushing glass bottles to a cullet state comprising: a front panel (01), right side panel (11), left side panel (12) and lid (13) for structural stability, wherein the stated panels are internally insulated with melamine foam to reduce noise levels; a bottle flap (02) positioned on the front panel (01) which can be pushed open to insert a bottle and will spring back once the bottle has been inserted; a bottle shoot (03) to allow passage of the bottle to a crusher chamber (10); a control box (05) positioned on the front panel (01) which controls a motor (04) and at least two hammers (O6) in the crusher chamber (10); a receptacle tote box (14) for containing the bottle cullet; a bin full tray (08) and weight limit switch which alert the control box (05) when the receptacle tote box (14) is full; a tote box access door (15) to allow the tote box (14) to be removed easily and a V-belt (17) for connecting a large diameter pulley (16) and the motor (04) to the shaft which mounts the hammers (06) in the crusher chamber (10). A method for crushing glass bottles to a cullet state, using the glass bottle breaking machine as claimed in claim 1, wherein: the bottle flap (02) positioned on the front panel (01) is pushed open to insert a bottle and will spring back once the bottle has been inserted; this opening of the bottle flap activates the motor (04) and hammers (06) in the crusher chamber (10) to instigate crushing; the inserted bottle is passed through a bottle shoot (03) which is of a curved nature to prevent users hands reaching the crusher chamber; the bottle is transformed into cullet by the hammers (06) of the crusher chamber, wherein the hammers curt to a certain length and depth according to the customers settings; the cullet is funnelled from the crusher chamber (10) into a receptacle tote box (14); when the tote box (14) has reached its maximum capacity the bin full tray (08) will press against a weight limit switch, sending a signal to the control box (05) to lock the bottle flap (02) and shut down the machine; the cullet is removed by opening the tote box access door (15), removing the full tote box and replacing with an empty one; wherein the action of opening the tote box door (15) will cause an audible alarm to be activated, this alarm being deactivated when the door is shut again; after a period of activity, the bottle flap (02) will signal the motor (04) to power down and the machine will enter a sleep mode until the bottle flap is activated again. . A glass bottle breaking machine which fits under any standard bar counter, for crushing glass bottles to a cullet state substantially as herein described with reference to the accompanying drawings. . A method for crushing glass battles to a cullet state substantially as herein described with reference to the accompanying drawings.