Automated packing apparatus, system, and method

Abstract

An automated apparatus ( 100 ), a system ( 1000 ), and method (M) for packing leafy produce ( 10 ) into a tray ( 20 ) involving a plunger ( 30 ), the plunger ( 30 ) having an actuator arm ( 40 ) and a footpad ( 50 ), the footpad ( 50 ) having an upper surface ( 50 a ) and a lower surface ( 50 b ), being in moveable relation to the actuator arm ( 40 ), for contacting the leafy produce ( 10 ).

1 . An automated apparatus for packing leafy produce into a tray, comprising: 
 at least one plunger, each at least one plunger having at least one actuator arm and at least one footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce.    
   
   
       2 . An apparatus, as recited in  claim 1 , wherein the moveable relation comprises means for articulating the at least one footpad about each respective at least one actuator arm.  
   
   
       3 . An apparatus, as recited in  claim 2 , wherein the articulating means is disposed at a location selected from a group consisting essentially of a periphery of the footpad at the upper surface, a centerline of the footpad at the upper surface, a location between a centerline and a periphery of the footpad.  
   
   
       4 . An apparatus, as recited in  claim 2 , wherein the articulating means comprises a feature selected from a group consisting essentially of a hinge, a pin, and a ball and socket combination.  
   
   
       5 . An apparatus, as recited in  claim 1 , wherein the at least one footpad comprises a corrugated surface at the lower surface for minimizing surface tension of the leafy produce.  
   
   
       6 . An apparatus, as recited in  claim 5 , wherein the corrugated surface comprises a configuration selected from a group consisting essentially of a sinusoidal profile and a square wave profile.  
   
   
       7 . An apparatus, as recited in  claim 1 , wherein the at least one actuator arm comprises means for adjusting stroke.  
   
   
       8 . An apparatus, as recited in  claim 1 , wherein the at least one footpad comprises means for adjusting size.  
   
   
       9 . An apparatus, as recited in  claim 1 , wherein the plunger is angularly disposed in relation to the tray.  
   
   
       10 . An apparatus, as recited in  claim 9 , comprising two opposing plungers being angularly disposed in relation to the tray, wherein the first opposing plunger conducts a first stroke, and wherein the second opposing plunger conducts a second stroke.  
   
   
       11 . An apparatus, as recited in  claim 9 , comprising two serial plungers being angularly disposed in relation to the tray, wherein the first serial plunger conducts a first stroke, and wherein the second serial plunger conducts a second stroke.  
   
   
       12 . An apparatus, as recited in  claim 1 , 
 wherein the moveable relation comprises means for articulating the at least one footpad about each respective at least one actuator arm,    wherein the articulating means is disposed at a location selected from a group consisting essentially of at a periphery of the footpad at the upper surface and at a centerline of the footpad at the upper surface,    wherein the articulating means comprises a feature selected from a group consisting essentially of a hinge, a pin, and a ball and socket combination,    wherein the at least one footpad comprises a corrugated surface at the lower surface for minimizing surface tension of the leafy produce,    wherein the at least one actuator arm comprises means for adjusting stroke, and    wherein the at least one footpad comprises means for adjusting size.    
   
   
       13 . An automated system for packing leafy produce into a tray, comprising: 
 a conveyor having a stepper for accommodating and moving at least one tray;    a hopper for channeling the leafy produce;    a feeder for receiving the channeled leafy produce and for filling the leafy produce into the at least one tray; and    at least one automated packing apparatus for packing the leafy produce into a tray, each at least one automated packing apparatus comprising at least one plunger, each at least one plunger having at least one actuator arm and at least footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce.    
   
   
       14 . A system, as recited in  claim 13 , further comprising a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce.  
   
   
       15 . A system, as recited in  claim 14 , wherein the feeder includes a funnel being disposed into the at least one tray upon receipt of the electronic signal from the sensor.  
   
   
       16 . A system, as recited in  claim 15 , wherein the plunger is disposed within the funnel.  
   
   
       17 . A system, as recited in  claim 13 , further comprising means for applying at least one lid to each respective at least one tray.  
   
   
       18 . A system, as recited in  claim 13 , further comprising means for labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray.  
   
   
       19 . A system, as recited in  claim 13 , further comprising means for vibrating the at least one tray to assist settling and packing of the leafy produce.  
   
   
       20 . A system, as recited in  claim 13 , further comprising means for security banding the at least one lid to each respective at least one tray.  
   
   
       21 . An automated system, as recited in  claim 13 , further comprising: 
 a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce;    means for vibrating the at least one tray to assist settling and packing of the leafy produce;    means for applying at least one lid to each respective at least one tray;    means for security banding the at least one lid to each respective at least one tray; and    means for labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray,    wherein the feeder includes a funnel being disposed into the at least one tray upon receipt of the electronic signal from the sensor, and    wherein the plunger is disposed within the funnel.    
   
   
       22 . An automated system, as recited in  claim 13 , wherein the at least one plunger is disposed outside the feeder.  
   
   
       23 . An automated system, as recited in  claim 13 , wherein the at least one plunger is disposed inside the feeder.  
   
   
       24 . An automated system, as recited in  claim 13 , 
 wherein the actuator arm comprises:    an actuating structure; and    an articulating arm,    wherein the articulating arm includes an articulating structure, and    wherein the articulating structure is disposed at a periphery of the footpad for facilitating pivoting of the footpad onto the leafy produce.    
   
   
       25 . An automated system, as recited in  claim 13 , 
 wherein at least one sidewall of the feeder, itself, acts as a footpad, and    wherein feeder comprises an articulating arm,    wherein the articulating arm includes an articulating structure, and    wherein the articulating structure is disposed at a periphery of the footpad for facilitating pivoting of the footpad onto the leafy produce.    
   
   
       26 . An automated system, as recited in  claim 13 , 
 wherein the at least one automated packing apparatus comprises a first automated packing apparatus and a second automated packing apparatus,    wherein the first automated packing apparatus and a second automated packing apparatus are serially disposed in an assembly line, and    wherein the second automated packing apparatus acts as a secondary set of plungers by plunging the leafy produce a second time.    
   
   
       27 . An automated system, as recited in  claim 13 , 
 wherein the hopper comprises: 
 a primary chute; and  
 a secondary chute,  
   wherein the primary chute comprises; 
 a flop gate for limiting the amount of leafy produce to be filled in two trays;  
 a flop gate actuator; and  
 a flop gate control device for controlling the flop gate actuator, and  
   wherein the secondary chute comprises two chute branches for facilitating filling of two trays simultaneously,    
   
   
       28 . An automated system, as recited in  claim 13 , further comprising: 
 an upper distribution bucket; and    a lower distribution bucket,    wherein the lower distribution bucket acts in at least one capacity selected from a group consisting essentially of a primary plunger and a secondary plunger, and    wherein the lower distribution bucket is deployed by a lower distribution bucket mechanism.    
   
   
       29 . A method of fabricating an automated packing apparatus for packing leafy produce into a tray, comprising: providing at least one plunger, the plunger providing step comprising providing each at least one plunger with at least one actuator arm and at least footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce.  
   
   
       30 . An automated method for packing leafy produce into a tray, comprising the steps of: 
 conveying and stepping at least one tray;    channeling the leafy produce through a hopper;    feeding the channeled leafy produce into the at least one tray, thereby filling the at least one tray;    providing an automated packing apparatus for packing the leafy produce into the at least one tray, the apparatus providing step comprising providing at least one plunger, the plunger providing step comprising providing each at least one plunger with at least one actuator arm and at least footpad, the at least one footpad having an upper surface and a lower surface, being in moveable relation to the at least one respective actuator arm, for contacting the leafy produce;    providing a sensor for detecting the presence of the at least one tray and for supplying an electronic signal to the feeder to effect its opening for filling the at least one tray with the leafy produce;    packing the at leafy produce into the at least one tray using the automated packing apparatus; and    applying at least one lid to each respective at least one tray.    
   
   
       31 . A method, as recited in  claim 30 , further comprising the step of security banding the at least one lid to each respective at least one tray.  
   
   
       32 . A method, as recited in  claim 30 , further comprising the step of vibrating the at least one tray to assist settling and packing of the leafy produce.  
   
   
       33 . A method, as recited in  claim 30 , further comprising the step of labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray.  
   
   
       34 . A method, as recited in  claim 30 , further comprising the steps of: 
 vibrating the at least one tray to assist settling and packing of the leafy produce;    labeling an upper surface of the at least one lid and a lower surface of each respective at least one tray; and    security banding the at least one lid to each respective at least one tray.