SYSTEMS AND METHODS FOR PREPARING AND PACKAGING WAX, SUCH AS SCENTED WAX FOR USE WITH WICKLESS CANDLES, AND OTHER SIMILAR PRODUCTS

Abstract

Systems and methods for preparing and packaging scented wax for use with wickless candles, and for preparing and packaging other types of wax and non-wax products, are disclosed herein. A wax product manufacturing machine configured in accordance with an embodiment of the disclosure can include a container loading assembly that loads a plurality of empty product containers onto a conveyor for transfer to container filling assembly. The container filling assembly can simultaneously fill the plurality of empty product containers with colored and/or scented wax. The manufacturing machine can further include a cooling assembly through which the filled wax containers move for cooling and hardening of the wax therein. The manufacturing machine can additionally include a discharge assembly that closes the product containers to encapsulate the wax product therein, and transfers the closed product containers to a labeling machine for automatic application of a suitable label.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/119,707, entitled “SYSTEMS AND METHODS FOR PREPARING AND PACKAGING WAX, SUCH AS SCENTED WAX FOR USE WITH WICKLESS CANDLES, AND OTHER SIMILAR PRODUCTS” and filed on Dec. 3, 2008, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The following disclosure is directed generally to systems and methods for preparing and packaging wax and other similar products and, more particularly, to systems and methods for preparing and packaging scented wax products for use with wickless candles.

BACKGROUND

Conventional candles have been used for centuries, and typically include a central wick encased in a wax body. As the wick burns, the wax slowly melts. In scented candles, fragrant oils or other additives are mixed with the wax so that it gives off a pleasant aroma as it melts.

Flameless or wickless candles are relatively new. They typically include a decorative ceramic or stoneware vessel (e.g., a “warmer”) that holds scented wax. Rather than use a flame, the warmer melts the wax with an electrical heating element (e.g., a 25-Watt bulb) positioned beneath the wax. Wax for use with wickless candles often comes in the form of segmented bars or “bricks” that enable the user to break off the amount they wish to use. Users can combine different types of wax in the warmer to create a desired scent. As the wax melts and forms a pool, it gives off a pleasant fragrance that fills the room as would a conventional scented candle. In contrast to conventional candles, however, wickless candles do not produce a flame, soot, or smoke. Moreover, the warming vessel typically melts the wax at a relatively low temperature.

One method of manufacturing wax for wickless candles includes manually filling individual packaging containers with hot wax from a storage tank. In this method, a hand-operated nozzle is connected to a flexible hose that leads to the storage tank. The operator can position the nozzle over an empty packaging container, and then squeeze a handle on the nozzle to dispense wax from the storage tank into the container. When one container is full, the operator proceeds to fill the next container in a similar manner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevation view of a wax product manufacturing machine configured in accordance with an embodiment of the disclosure.

FIG. 2A is an enlarged, rear isometric view of a product infeed portion of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure, and FIG. 2B is further enlarged view of a portion of FIG. 2A.

FIG. 3 is an enlarged, rear isometric view of a container loader configured in accordance with an embodiment of the disclosure.

FIG. 4 is an enlarged, side elevation view of the infeed portion of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure.

FIGS. 5A and 5B are enlarged, rear isometric views illustrating various stages of a method for loading wax product containers on a product conveyor in accordance with an embodiment of the disclosure.

FIGS. 6A and 6B are enlarged, rear and front isometric views, respectively, of a drive assembly configured in accordance with an embodiment of the disclosure.

FIG. 7 is an enlarged, front isometric view of a product container filling assembly of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure.

FIG. 8 is a rear isometric view of the container filling assembly of FIG. 7.

FIG. 9 is an enlarged, partially exploded isometric view of a wax dispenser configured in accordance with an embodiment of the disclosure.

FIG. 10 is an enlarged isometric view illustrating operation of the container filling assembly of FIGS. 7 and 8, in accordance with an embodiment of the disclosure.

FIG. 11 is a schematic diagram of some of the pneumatic systems of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure.

FIG. 12 is a rear isometric view of a cooling assembly of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure.

FIG. 13 is a front isometric view of a discharge assembly of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure.

FIGS. 14A and 14B are enlarged isometric views of a portion of the discharge assembly of FIG. 13, illustrating various stages of a method of closing lids on wax product containers in accordance with an embodiment of the disclosure.

FIGS. 15A and 15B are enlarged, rear and front isometric views, respectively, of another portion of the discharge assembly of FIG. 13, illustrating various stages in a method of discharging packaged wax products onto a container labeling assembly in accordance with an embodiment of the disclosure.

FIG. 16 is a front isometric view of a container labeling assembly of the manufacturing machine of FIG. 1, configured in accordance with an embodiment of the disclosure.

DETAILED DESCRIPTION

The following disclosure describes systems and methods for preparing and packaging wax products, such as scented wax products for use with wickless candles. Certain specific details are set forth in the following description and in FIGS. 1-16 to provide a thorough understanding of various embodiments of the invention. Other details describing well-known structures and systems often associated with wax products, scented wax products, and manufacturing such products are not set forth in the following disclosure to avoid unnecessarily obscuring the description of the various embodiments of the invention.

Many of the details, dimensions, angles and other features shown in the Figures are merely illustrative of particular embodiments of the disclosure. Accordingly, other embodiments can have other details, dimensions and specifications without departing from the present disclosure. In addition, other embodiments may be practiced without several of the details described below.

FIG. 1 is a side elevation view of a wax product manufacturing machine 100 configured in accordance with an embodiment of the disclosure. In one aspect of this embodiment, the wax product manufacturing machine 100 (“manufacturing machine 100”) can be used to prepare and package wax products for use with wickless candles. Such products can include, for example, scented and/or colored wax bars, segmented wax bricks, etc. which are individually packaged in suitable containers for sale to consumers through retail and/or other distribution outlets. In other embodiments, the manufacturing machine 100 and various systems and methods thereof can be used as described herein to manufacture other products. Such products can include, for example, other wax products as well as other commercial and consumer products formed from flowable and/or moldable materials, such as flowable and/or moldable materials that demonstrate properties similar to those of wax.

The manufacturing machine 100 includes a product infeed portion 102 and a product discharge portion 104. As described in greater detail below, in the illustrated embodiment the product infeed portion 102 includes a container loading assembly 120 that can automatically load a plurality of open receptacles or product containers 132 (e.g., plastic “clam-shell” containers) onto a product moving assembly 160. The product moving assembly 160 includes a product conveyor 162 operably supported by an elevated support frame 180. In one embodiment, the product conveyor 162 can include a plurality of pockets that receive the open product containers 132 and move them to a container filling assembly 128. The container filling assembly 128 includes a wax hopper 110 that automatically dispenses hot, molten or liquid wax into the product containers 132 through a plurality of dispensing nozzle outlets 118.

After filling, the product conveyor 162 moves the product containers 132 through a cooling assembly 150. In the illustrated embodiment, the cooling assembly 150 includes a plurality of upper air movers or fans 152 (identified individually as upper fans 152a-152q) and a plurality of lower air movers or fans 154 (identified individually as lower fans 154a-154q). As the product conveyor 162 moves the filled product containers 132 through the cooling system 150, the fans 152 and 154 direct cooling air over and around the containers 132 to cool and harden the wax therein.

When the wax-filled containers 132 arrive at the end of the cooling assembly 150, a container discharge assembly 126 automatically closes the lids on the containers 132. The container discharge assembly 126 then displaces the containers 132 from the product conveyor 162 and transfers them onto an adjacent labeling assembly 140. The labeling assembly 140 can include one or more conveyor belts 144 that move the closed containers 132 past a labeling machine 142. As described in greater detail below, the number of labeling machines 142 in operation at any given time can vary depending on the number of different types of products coming off the manufacturing machine 100. For example, if two different types of wax products are being produced in parallel, two labeling machines 142 can be employed in parallel so that a first labeling machine 142 applies appropriate labels 146 to the first product, and a second labeling machine 142 applies appropriate labels to the second product. After labeling, an operator 103 can transfer the individually packaged wax products to a nearby rack 107 for temporary storage prior to bulk packaging.

Although the manufacturing machine 100 of the illustrated embodiment is arranged at least generally horizontally, in other embodiments the manufacturing machine 100 and variations thereof can have other orientations or arrangements without departing from the present disclosure. For example, in other embodiments the manufacturing machine 100 and/or portions thereof can be arranged vertically or on an incline to conserve floor space and/or for other reasons. For example, in one embodiment the cooling assembly 150 and the associated portion(s) of the product conveyor 162 can be arranged vertically so that the wax-filled containers 132 travel on a vertical or inclined path for cooling. In such an embodiment, the product discharge portion 104 of the manufacturing machine 100 can be positioned at a different elevation (e.g., higher) than the product infeed portion 102. Accordingly, the present disclosure is not limited to horizontal configurations of the manufacturing machine 100, but extends to other configurations in which the machine and/or portions thereof are arranged in curved paths, in vertical or inclined orientations, and/or other configurations.

Returning to the product infeed portion 102, base wax 101 (e.g., unscented and uncolored natural wax, paraffin, polymer additives and/or mixtures thereof, etc.) can be readied for use in a heated (e.g., an electrically heated) storage tank 106. The storage tank 106 can hold the base wax 101 in liquid form at approximately 130 to about 170 degrees F., or at approximately 140 to about 160 degrees F., e.g., about 150 degrees F. When needed, a pump or other suitable transfer system (not shown) flows the liquid base wax 101 from the storage tank 106 to one or more heated (e.g., electrically heated) mixing tanks 108 (identified individually as a first mixing tank 108a and a second mixing tank 108b) via corresponding conduits 112.

An operator 105 can combine one or more colorings or dyes 116, fragrant oils 117, and/or other additives with the base wax 101 in the mixing tanks 108 to prepare a different wax mixture 103 in each of the mixing tanks 108. The different wax mixtures 103 can have different colors and/or scent compositions, depending on the particular type of wax product or products being produced at that time. For example, the first mixing tank 108a can be holding a brown wax mixture 103 having a musk scent, and the second mixing tank 108b can be holding a green wax mixture 103 having a pine scent. Using two or more mixing tanks 108 enables two or more different types of wax products (having, for example, two different colors and/or scents) to be produced simultaneously by the manufacturing machine 100.

In operation, the mixing tanks 108 refill the wax hopper 110 as needed with the desired type or types of scented and colored wax 103 for dispensing into the product containers 132. The mixing tanks 108 maintain the wax 103 in a flowable or liquid form at about 140 to 160 degrees F., e.g., about 150 degrees F., as higher temperatures could melt some product container materials (e.g., some plastics). These and other features of the manufacturing machine 100 are described in greater detail below with reference to FIGS. 2-16.

FIG. 2A is an enlarged rear isometric view of the infeed portion 102 of the manufacturing machine 100 configured in accordance with an embodiment of the disclosure, and FIG. 2B is a further enlarged view taken from FIG. 2A. The mixing tanks 108, the product conveyor 162, the cooling assembly 150, and other selected structures have been omitted from FIGS. 2A and 2B for purposes of illustration. In one aspect of this embodiment, the container loading assembly 120 includes a container magazine 220 (sometimes referred to as a “denester” assembly) having a plurality of container loading chambers 227 (identified individually as container loading chambers 227a-227h). As shown in FIG. 2B, each container loading chamber 227 includes a plurality of alignment rods 224 extending upwardly from a corresponding container tray 222 (identified individually as container trays 222a-222h). The alignment rods 224 are positioned around corresponding openings 225 in each of the container trays 222 to align vertical stacks of open containers 132 above the openings 225. The lower-most containers 132 in each of the stacks is releasably supported at the opening 225 by a first adjustable clip 226a that extends inwardly from one side of the opening 225 and a second adjustable clip 226b that extends inwardly from the opposite side of the opening 225.

In another aspect of this embodiment, the container loading assembly 120 further includes a container loader 230 movably positioned beneath the container magazine 220. The container loader 230 includes a plurality of container extraction units 232 (identified individually as container extraction units 232a-232h) that reach up through the container tray openings 225 and pull the lower-most containers 132 free of the clips 226 and downwardly through the openings 225. For this purpose, each of the container extraction units 232 includes a first suction cup 236a and a plurality of second suction cups 236b-236g. In the illustrated embodiment, the first suction cup 236a is larger than each of the second suction cups 236b-236g. As explained in greater detail below, the relative sizes of the suction cups 236 facilitate attachment of the suction cups 236 to the bottom surfaces of the containers 132. In other embodiments, however, and especially in those other embodiments that may use different product container configurations, extraction units configured in accordance with the present disclosure can include more or fewer suction cups in other arrangements and having other relative sizes. In still further embodiments, suitable mechanisms other than suction cups can be used to extract the product containers from the container trays 222.

Although only two stacks of containers 132 are shown in FIGS. 2A and 2B for purposes of illustration, as described in greater detail below, in operation all or any portion of the container loading chambers 227 can be filled with empty containers 132 for loading onto the product conveyor 162, depending on the desired rate of production and/or the number of different products being produced at a particular time. Moreover, although in the illustrated embodiment the manufacturing machine 100 includes eight container loading chambers 227 and eight container extractions units 232 for simultaneously loading up to eight product containers 132 at a time onto the product conveyor 162, in other embodiments manufacturing machines configured in accordance with the present disclosure can include more or fewer container loading chambers 227, container extractions units 232, etc. depending on the needs and scale of the particular manufacturing operation.

FIG. 3 is an enlarged, rear isometric view of the container loader 230 configured in accordance with an embodiment of the disclosure. In the illustrated embodiment, the container extraction units 232 are mounted in parallel on a movable support structure 334. The support structure 334 includes a plurality of individual support members 345 extending outwardly from a base member 347. A vacuum manifold 342 is attached to the base member 347. Each of the suction cups 236 is coupled in fluid communication with the vacuum manifold 342 via a corresponding system of air hoses 344, a junction block 346, and a vacuum coupling 338. The vacuum manifold 342 is evacuated during operation of the manufacturing machine 100 via a first manifold coupling 340a and a second manifold coupling 340b. More particularly, as described in greater detail below the manifold 342 is evacuated at preset times which in turn evacuates the suction cups 236, causing them to attach to the lower-most container 132 in the overhead stack.

FIG. 4 is a partially cut-away, enlarged side elevation view of the product infeed portion 102 of the manufacturing machine 100. A first air hose 442a operably connects a first vacuum valve 440a to the first manifold coupling 340a (FIG. 3). Although not shown, a second air hose operably connects a second vacuum valve to the second manifold coupling 340b (FIG. 3) on the other side of the manufacturing machine 100. As described in more detail below, the vacuum valves 440 are controlled by signals from a machine controller 410 that opens and closes the valves 440 at appropriate times so that the suction cups 236 attach themselves to the lower-most product containers 132 at an appropriate time, and then release the containers 132 onto the product conveyor 162 at an appropriate time.

The machine controller 410 can include or be a programmable logic controller (PLC) or other microprocessor-based industrial control system that communicates with the process control components of the manufacturing machine 100 through data and/or signal links to control switching tasks, machine timing, process controls, data manipulation, etc. In this regard, the machine controller 100 can include one or more processors 412 that operate in accordance with computer-executable instructions stored or distributed on computer-readable media 414. The computer-readable media 414 can include magnetic and optically readable and removable computer discs, firmware such as chips (e.g., EEPROM chips), magnetic cassettes, tape drives, RAMs, ROMs, etc. Indeed, any medium for storing or transmitting computer-readable instructions and data may be employed. The machine controller 410 and embodiments thereof can be embodied in a special purpose computer or data processor that is specifically programmed, configured or constructed to perform one or more of the machine operations explained in detail below. Those of ordinary skill in the relevant art will appreciate, however, that the manufacturing machine 100 and embodiments thereof can be controlled with other types of processing devices including, for example, multi-processor systems, microprocessor-based or programmable consumer electronics, network computers, and the like. Data structures and transmission of data and/or signals particular to various aspects of the manufacturing machine 100 are also encompassed within the scope of the present disclosure.

Returning to FIG. 2A, in a further aspect of this embodiment the container loader 230 is operably coupled to a lift assembly 270. The lift assembly 270 includes a first link 276a and a corresponding second link 276b. The second link 276b has a first end 273 pivotally attached to a second guide block 279b that slides up and down on a corresponding second guide shaft 278b. The second link 276b also has a second end 275 pivotally attached to a distal end of a corresponding lifting arm 274b. Although not shown from the perspective of FIG. 2A, the first link 276a is operably coupled to a first guide block 279a and a first lifting arm 274a in the same manner that the second link 276b is coupled to the second guide block 279b and the second lifting arm 274b.

The first and second guide blocks 279 are fixedly attached to opposite ends of the container loader base member 347 (FIG. 3). The lifting arms 274 are fixedly attached to opposing ends of a lifting shaft 272. As a result, when the lifting shaft 272 rotates, the lifting arms 274 cause the links 276 to slide the container loader 230 up and down on the opposing guide shafts 278.

In another aspect of this embodiment, the product infeed portion 102 includes a drive assembly 250 that controls operation of the container loader 230 and movement of the product conveyor 162. The drive assembly 250 includes an electric motor 212 operably coupled to a drive shaft 214. The electric motor 250 can utilize standard AC power from a facility outlet. The drive shaft 214 is operably coupled to the lift shaft 272 by means of a sprocket and chain arrangement 216. Accordingly, operation of the electric motor 212 causes the drive shaft 214 to rotate which in turn causes the lift shaft 272 to rotate. In other embodiments, the drive shaft 214 can be operably coupled to the lift shaft 272 by other suitable means, such as by a gear train, belt, etc.

Referring to FIGS. 2A and 2B together, during operation of the container loading assembly 120 the electric motor 212 rotates the drive shaft 214 which in turn rotates the lifting shaft 272. The lifting shaft 272 in turn rotates the two lifting arms 274. As the lifting arms 274 rotate upwardly, the links 276 move the container extraction units 232 upwardly through openings or “pockets” in the temporarily stationary product conveyor 162 (FIG. 1). At the top of the stroke, the suction cups 236 contact the lower-most containers 132 in each of the container stacks. At this time, the machine controller 410 moves the vacuum valves 440 (FIG. 4) to a first position that evacuates the suction cups 236, causing them to attach to the lower-most containers 132. As the lifting arms 274 continue rotating downwardly, the suction cups 236 pull the lower-most containers 132 free from the container trays 222 and downwardly toward the product conveyor 162. As the containers 132 move downwardly toward the product conveyor 162, the machine controller 410 moves the vacuum valves 440 to a second position that releases the vacuum in the suction cups 236, thereby releasing the containers 132 in their respective pockets in the product conveyor 162. Once the containers 132 have been suitably loaded onto the product conveyor 162, the product conveyor 162 indexes forward to position the empty product containers 132 beneath the dispensing nozzle outlets 118 of the wax hopper 110. In other embodiments, other systems can be used to suitably load the product containers 132 onto the product conveyor 162 without departing from the spirit or scope of the present disclosure.

FIGS. 5A and 5B are enlarged rear isometric views illustrating various aspects of the product conveyor 162 and the container loading sequence described above in more detail. Referring first to FIG. 5A, in the illustrated embodiment the product containers 132 can be formed from plastic (e.g., clear polyethylene plastic) and/or other suitable package materials, and can include a mold portion 534 and a cover or lid portion 536. The mold portion 534 can include a plurality of cavities 538 (identified individually as cavities 538a-538f) that form the wax into a bar having separate sections of equal size that can be easily broken off as needed for use. The lid portion 536 can be configured to fold about a hinge line 537 and fit snugly over the mold portion 534 to close the product container 132 after filling, as described in more detail below. In one embodiment, the product containers 132 can be reusable, so that the user can pour molten wax back into the container to store the wax when the wickless candle is not in use, when the warmer is being cleaned, and/or when changing waxes.

The product conveyor 162 can include a plurality of conveyor sections 560 carried by a first conveyor chain 566a and a second conveyor chain 566b. In the illustrated embodiment, the conveyor sections 560 are positioned next to each other in a contiguous arrangement, and extend around the entire loops of the conveyor chains 566. The conveyor sections 560 can be formed from suitable sheet metals, such as stainless steel, mild steel, aluminum, etc. In other embodiments, however, the conveyor sections 560 can be fabricated from other suitable materials including, for example, other metals and non-metal materials such as plastics, composites, etc. Each of the conveyor sections 560 can include plurality of first pockets 562a configured to receive and hold the container mold portions 534, and a plurality of second pockets 562b configured to receive and hold the container lid portions 536. In other embodiments, the pockets 562 can be omitted and conveyor sections having other means of holding the product containers 132 can be used.

In the illustrated embodiment, the conveyor chains 566 can be standard, industrial grade roller chains, e.g., standard stainless steel roller chains having pinned links configured to engage teeth on drive sprockets. In other embodiments, other suitable chains, belts, gears, etc., and other drive mechanisms and the like, can be used with the product conveyor 162. A plurality of first mounting clips 568a having threaded fastener holes can be fixedly attached to the first conveyor chain 566b. Similarly, a plurality of second mounting clips 568b also having threaded fastener holes can be fixedly attached to the second conveyor chain 566b.

The individual conveyor sections 560 can be mounted to the conveyor chains 566 by means of a first fastener 569a (e.g., a first threaded fastener) that attaches a first side portion 561a of each conveyor section 560 to one of the first mounting clips 568a, and a second fastener 569b (e.g., a second threaded fastener) that attaches a second side portion 561b of each conveyor section 560 to one of the second mounting clips 568b. Attaching each of the side portions 561 to the corresponding conveyor chain 566 at a single point enables the conveyor chains 566 to curve smoothly around sprockets without derailing or damaging the conveyor sections 560. The side portions 561 of each of the conveyor sections 560 can also include a durable edge member 570 made out of ultrahigh molecular weight (UHMW) plastic, polyurethane, Teflon, or other suitably durable material that allows the conveyor section 560 to contact or rub on the conveyor chains 566 and/or other support surfaces without substantial wear or degradation.

During loading of the containers 132 onto the conveyor section 560, the product conveyor 162 is momentarily stationary and the container loader 230 moves (via the lift assembly 270) the suction cups 236 upwardly through the open pockets 562 in the conveyor section 560. The suction cups 236 continue moving upwardly until they contact the lower-most container 132 in the corresponding stack (FIGS. 2A and 2B). More particularly, the larger suction cup 236a contacts the bottom surface of the container lid portion 536, and the plurality of smaller suction cups 236b-g contact the bottom surfaces of the individual mold cavities 538 of the container mold portion 534. At this time, the suction cups 236 are being evacuated so that they attach to the container 132 when contact is made. The container loader 230 then moves downwardly, pulling the container 132 into the respective pockets 562 of the conveyor section 560. At this time, the vacuum in the suction cups 236 is released so that they release the container 132 in the pockets 562. The container loader 230 then continues moving downwardly and away from the conveyor section 560. As shown in FIG. 5B, the end result of this sequence is that a row of (e.g., eight) empty containers 132 are positioned in their respective pockets 562 of the conveyor section 560, and are ready to be advanced to the container filling assembly 128 (FIG. 1).

FIG. 6A is an enlarged, rear isometric view, and FIG. 6B is an enlarged, front isometric view of a portion of the drive assembly 250 described above with reference to FIG. 2A. As discussed above, the drive assembly 250 includes the electric motor 212 (e.g. a 1.5 HP electric motor) which is operably coupled to the drive shaft 214. A first drive sprocket 616 is releasably engaged with the drive shaft 214 by means of a clutch 650. A distal end portion of the drive shaft 214 carries a vacuum control cam 694 (FIG. 6A) having a first lobe surface 697, and a conveyor control cam 690 (FIG. 6B) having a second lobe surface 698.

A first proximity switch 696 (e.g., an optical sensor) is positioned to detect the presence of the first lobe surface 697 on the vacuum control cam 694 when the first lobe surface 697 is directly in front of the first proximity switch 696. The first proximity switch 696 is operably connected (via, e.g., an electrical link, wired connection, etc.) to the machine controller 410 (FIG. 4). As described in greater detail below, the machine controller 410 controls the vacuum pressure in the container extraction unit suction cups 236 (FIGS. 2A, 2B and 3) in response to the signal received from the first proximity switch 696.

A second proximity switch 692 (e.g., an optical sensor) is positioned to detect the presence of the second lobe surface 698 on the conveyor control cam 690 when the second lobe surface 698 is directly in front of the second proximity switch 692. The second proximity switch 692 is operably connected (via, e.g., an electrical link, wired connection, etc.) to an indexer 652. The indexer 652 transmits power from the electric motor 212 to a second drive sprocket 654 in response to the signal received from the second proximity switch 692.

As shown in FIGS. 2A and 4, the second drive sprocket 654 is operably coupled to a third drive sprocket 458 via a drive chain 456 (e.g., a roller chain). In other embodiments, the second drive sprocket 654 can be operably coupled to the third drive sprocket 458 with other suitable drive mechanisms including gears, belts, etc. The third drive sprocket 458 is fixedly attached to a distal end of a conveyor shaft 262 that extends transverse to the product conveyor 162. The conveyor shaft 262 carries a first conveyor sprocket 258a inboard of the third drive sprocket 458 toward one end of the conveyor shaft 262. The conveyor drive shaft 262 also carries a second conveyor sprocket 258b (not shown in FIG. 2A) toward the opposite end of the conveyor shaft 262. As shown in FIG. 4, the teeth on the first conveyor sprocket 258a operably engage the first conveyor chain 566a (FIG. 5A). Although not shown in FIG. 4, the teeth on the second conveyor sprocket 258b similarly engage the second conveyor chain 566b. Accordingly, when the electric motor 212 rotates the second drive sprocket 654 (counterclockwise as seen in FIG. 4), the drive chain 456 rotates the third drive sprocket 458 in the same direction, which in turn rotates the two conveyor sprockets 258 and drives the product conveyor 162 forward. As shown in FIG. 2A, the conveyor shaft 262 also carries a central support roller 260. Although the product conveyor 162 has been omitted from FIG. 2A for purposes of clarity, the central support roller 260 supports a mid-section of the product conveyor 162 as it turns around at the end of the manufacturing machine 100.

As discussed above, the movements of the product conveyor 162 and the container loader 230 are coordinated so that the product conveyor 162 momentarily stops when the open pockets 562 (FIG. 5) are properly aligned with the corresponding container extraction units 232. This coordinated movement enables the container extraction units 232 to reach up through the pockets 562, attach to product containers 132, and then pull the containers 132 down and into the proper pockets 562. This coordinated movement can be achieved in one embodiment as follows.

During normal operation, the electric motor 212 is continually rotating the drive shaft 214, which in turn continually raises and lowers the container loader 230 by means of the lift assembly 270. The second drive sprocket 654, however, only advances or indexes the product conveyor 162 forward periodically. More particularly, when the second proximity switch 692 (FIG. 6B) detects the immediate presence of the second lobe surface 698 of the conveyor control cam 690, the second proximity switch 692 sends a corresponding signal to the indexer 652. The indexer 652 responds to this signal by interrupting rotation of the second drive sprocket 654 and stopping movement of the product conveyor 162 where the container pockets 562 (FIG. 5A) are positioned directly above the corresponding container extraction units 232. In the illustrated embodiment, the size of the second lobe surface 698 causes the product conveyor 162 to remain stopped for 180 degrees of rotation, or at least approximately 180 degrees of rotation, of the drive shaft 214. As shown by the relative positions of the lift assembly 270 (e.g., at top-dead-center of the stroke) and the conveyor control cam 690 (e.g., at the mid-point of the second lobe surface 698) in FIG. 2, the 180 degrees of rotation of the drive shaft 214 during which the product conveyor 162 remains stopped corresponds to the period of time in which the container extraction units 232 move upwardly and downwardly through the container pockets 562. Once the second proximity switch 692 no longer detects the presence of the second lobe surface 698, the indexer 652 provides power to the second drive sprocket 654, causing the product conveyor 162 to advance forward until the next row of empty product pockets 562 are positioned directly above the container extraction units 232.

Returning to FIG. 6A, the vacuum control cam 694 controls the vacuum in the extraction unit suction cups 236. More particularly, as the suction cups 236 approach the uppermost position and contact the bottom surfaces of the lower-most product containers 132, the leading edge of the first lobe surface 697 is directly adjacent to the first proximity switch 696 as shown in FIG. 6A. This causes the first proximity switch 696 to transmit a corresponding signal to the machine controller 410 (FIG. 4). The machine controller 410 responds to the signal by opening the vacuum valve 440 and evacuating the manifold 342 on the container loader 230 (FIG. 3). The resulting vacuum causes the suction cups 236 to attach to the bottom surfaces of the product containers 132, which are then pulled downwardly toward the product conveyor 162. As the suction cups 236 move downwardly through the container pockets 562, the first lobe surface 697 of the vacuum control cam 694 moves away from the first proximity switch 696. This causes the first proximity switch 696 to transmit a corresponding signal to the machine controller 410, which responds by closing the vacuum valve 440 and releasing the vacuum in the suction cups 236. This causes the suction cups 236 to release the containers 132 in the container pockets 562. At this time, the conveyor control cam 690 causes the indexer 652 to reengage the second drive sprocket 654 (FIG. 4), causing the second drive sprocket 654 to start rotating and drive the product conveyor 162 forward toward the container filling assembly 128 (FIG. 1). The foregoing describes one system and method of coordinating or indexing movements of the product conveyor 162 and the container loader 230 in accordance with the present disclosure. In other embodiments, other suitable systems and methods of coordinating this movement can be used. Such systems can include, for example, software controls, optical targets on the product conveyor, digital sequencing devices, etc.

Referring back to FIGS. 2A and 4, a first row of proximity sensors 264 (e.g., optical sensors; identified individually as proximity sensors 264a-264h), is positioned above the product conveyor 162 just downstream of the container magazine 220. Each of the proximity sensors 264 is positioned directly above a corresponding row of container pockets 562, and is operably coupled to the machine controller 410. As the product containers 132 move forward from the container loading assembly 120, the proximity sensors 264 detect their presence in the corresponding pockets 562 of the product conveyor 162, and send corresponding signals to the machine controller 410. As described in greater detail below, the machine controller 410 uses these signals as confirmation of empty containers 132 in the corresponding rows, and then commands the container filling assembly 128 to dispense wax into the containers 132 through corresponding dispensing nozzles 480a-480h accordingly.

FIG. 7 is an enlarged, front isometric view of the container filling assembly 128 configured in accordance with an embodiment of the disclosure. As this view illustrates, the each of the wax mixing tanks 108 provides the wax 103 to the hopper 110 via a corresponding outlet 714 (identified individually as a first outlet 714a and a second outlet 714b). In the illustrated embodiment, each of the outlets 714 can include an electrical heater 756 (e.g., a band-type heating element) to maintain wax temperature and reduce clogging as the wax 103 flows through the outlet 714. Each of the heaters 756 can receive power from a corresponding user-operable mixing tank heat controller 758. Wax flow through the outlets 714 is controlled by corresponding valves 715 (identified individually as a first valve 715a and a second valve 715b). As explained in more detail below, in the illustrated embodiment the valves 715 are pneumatically controlled to allow wax to flow from the mixing tanks 108 into the hopper 110 via corresponding ducts or conduits 720 (identified individually as a first conduit 720a and a second conduit 720b). In other embodiments, electrically controlled valves and/or other devices can be used to control wax flow from the mixing tanks 108 to the hopper 110.

A first junction box 710a and a second junction box 710b are mounted toward the front portion of the wax hopper 110. Each junction box 710 includes a plurality of heater connectors 712 and a plurality of corresponding thermocouple connectors 714. The heater connectors 712 are electrically coupled to individual heaters 716 (e.g., Watlow thinband, 120 volt, 125 watt heating elements) which are mounted to individual dispensing nozzles 480. The adjacent thermocouple connectors 714 are electrically coupled to individual thermocouples 718 mounted to the dispensing nozzles 480 adjacent to the electrical heaters 716. In operation, the heater connectors 712 provide electrical power to the heaters 716 to heat the dispensing nozzles 480 to a suitable operating temperature (e.g., from about 140 degrees F. to about 160 degrees F., or about 150 degrees F.), and the thermocouples 718 determine whether or not the wax 103 is being dispensed at a suitable temperature (e.g., about 140-150 degrees F.) to avoid or reduce clogging without melting the receiving product container 132. If temperature is too low, the junction box 710 increases the electrical power to the appropriate nozzle heaters 716 as required to increase the temperature of the corresponding dispensing nozzles 480.

Returning to FIG. 2, a main control box 210 includes operator controls 211 for controlling operation of the container loading assembly 120, the container filling assembly 128, and the product conveyor 162. A dispensing nozzle heat control box 206 includes individual operator controls 207 for controlling the power applied to the corresponding wax dispensing nozzle heaters 716 (FIG. 7) via the junction boxes 710 for heating the dispensing nozzles 480.

FIG. 8 is a rear isometric view of the container filling assembly 128 configured in accordance with an embodiment of the disclosure. The mixing tanks 108, the container loading assembly 120, and other portions of the manufacturing machine 100 have been omitted from this view for purposes of illustration. Similarly, an outer portion of the wax hopper 110 has been removed in FIG. 8 to better illustrate some of the operative components positioned within the wax hopper 110. In one aspect of this embodiment, the wax hopper 110 includes a plurality of planer side panels 811 (identified individually as side panels 811a-811d), and a semi-circular sump or bottom portion 813. The semi-circular shape of the bottom portion 813 causes the wax 103 (FIG. 7) to collect near the dispensing nozzles 480 in the lower-most region of the hopper 110 as the wax level in the hopper 110 drops. In other embodiments, the bottom portion 813 can have other curved and/or tapered shapes that act to funnel the wax 103 toward the dispensing nozzles 480. In the illustrated embodiment, the wax hopper 110 and the associated side panels 811 and bottom portion 813 can be formed from a suitable sheet metal, such as stainless steel, using fabrication methods known in the art. In other embodiments, these structures can be made from other suitable materials known in the art.

In the illustrated embodiment, the wax hopper 110 can include one or more dividers or partitions 812 that separate the wax hopper 110 into a plurality of separate hopper portions 810 (identified individually as a first hopper portion 810a and a second hopper portion 810b). Each of the hopper portions 810 receives the wax 103 from the corresponding mixing tank 108 via the corresponding inlet conduit 720. Dividing the wax hopper 110 into two or more hopper portions 810 as illustrated in FIG. 8 enables the wax hopper 110 to simultaneously dispense two or more different types of wax (e.g., waxes having different colors and/or scents, etc.) into product containers 132 as they proceed forward through the manufacturing machine 110 (FIG. 1). Although the illustrated embodiment includes two separate hopper portions 810, in other embodiments, more or fewer separate hopper portions can be used. For example, in another embodiment, a wax hopper 110 having three or more separate hopper portions can be used to enable the manufacturing machine 100 to produce three or more different types of wax products simultaneously. Alternatively, in another embodiment, a manufacturing machine configured in accordance with the present disclosure can include a wax hopper 110 having only a single hopper portion. This could be accomplished in the present embodiment by simply removing the partition 812 from the wax hopper 110.

In the illustrated embodiment, each hopper portion 810 includes a wax mixer 852 and a wax level controller 850 (identified individually as a first wax mixer 852a and a first wax level controller 850a associated with the first hopper portion 810a, and a second wax mixer 852b and a second wax level controller 850b associated with the second hopper portion 810b). Each of the wax mixers 852 can include a mixing device 853 (e.g., a mixing blade or blades, a mixing drum, a cage-type mixer, a Squirrel Mixer®, or other type of mixing apparatus) driven by an electric motor 854. For example, in the illustrated embodiment a cage type Squirrel Mixer® is shown. In operation, the motor 854 rotates the mixing device 853 to keep the wax (not shown) in the respective hopper portion 810 suitably mixed prior to dispensing into the product containers 132. In one embodiment, this mixing can ensure wax products with consistent colors, scents, and/or other qualities. In other embodiments, other suitable apparatuses and systems can be used to mix the wax in the hopper portions 810 without departing from the spirit or scope of the present disclosure.

Each of the wax level controllers 850 can include a plurality of visual markers 857 that move up or down relative to a proximity sensor 855 (e.g., an optical sensor) in response to vertical movement of a float 851 positioned in a tube 858. As incoming wax raises the float 851, the sensor 855 detects which of the markers 857 is directly in front of the sensor 855, and sends a corresponding signal to the machine controller 410. As shown in FIG. 4, the machine controller 410 is operably connected to two air control valves 451 (e.g., two-position, electrically actuated solenoid air valves; identified individually as a first air control valve 451a on one side of the manufacturing machine 100 and a second air control valve 451b (not shown) on the other side of the machine 100). Each air control valve 451 is operably coupled to a corresponding one of the valves 715 by means of a first air hose 453a and a second air hose 453b. When the signal from the sensor 855 indicates that the corresponding wax hopper portion 810 is full, the machine controller 410 sends a corresponding signal to the appropriate air control valve 451. The signal causes the air control valve 451 to open a first passage that allows pressurized air to flow through the first air hose 453a and into the valve 715, thereby closing the valve 715 and stopping the flow of wax from the mixing tank 108 into the hopper portion 810. When the level of wax in the hopper portion 810 drops, the sensor 855 sends a corresponding signal to the machine controller 410, which in turns sends another signal to the air control valve 451. The air control valve 451 responds to the signal by closing the first passage and opening a second passage, allowing pressurized air to flow through the second air hose 453b and into the valve 715, thereby opening the valve 715 and letting more wax flow into the hopper portion 810 from the mixing tank 108.

Although the valves 715 of the illustrated embodiment are pneumatically controlled, in other embodiments, other types of valves, including various types of manually and electrically actuated valves, can be employed. In other embodiments, other suitable apparatuses and systems can be used to control the level of wax in the hopper portions 810 without departing from the spirit or scope of the present disclosure. Such wax level control systems and apparatuses can include, for example, simple float-type shut-off valves that are mechanically and/or electrically actuated. In yet other embodiments, these automated systems can be omitted and wax level control and/or wax mixing can be performed manually.

In the illustrated embodiment, each hopper portion 810 further includes a plurality of wax dispensers 840 (e.g., eight wax dispensers; identified individually as wax dispensers 840a-840d associated with the first hopper portion 810a, and wax dispensers 840e-840h associated with the second hopper portion 810b) extending in a series or row above and across the product conveyor 162 in a direction transverse to the product feed direction. In this embodiment, the wax dispensers 840 extend vertically through the wax hopper 110, terminating in the dispensing nozzle outlets 118 which are positioned directly above respective longitudinal rows of product container pockets 562 in the product conveyor 162. As described in greater detail below with reference to FIG. 9, the wax dispensers 840 are configured to dispense wax into the open containers 132 through the dispensing nozzle outlets 118.

In a further aspect of this embodiment, the container filling assembly 128 includes a hold-down member 830 and a row of filling sensors 864 (identified individually as filling sensors 864a-864h) positioned above the product conveyor 162. The hold-down member 830 can include a plate or other structure that extends across the product conveyor 162 and ensures that the product containers 132 are properly seated in the conveyor pockets 562 as they move under the wax hopper 110. The filling sensors 864 (e.g., ultrasonic proximity sensors) are positioned just downstream of the hold-down member 830 adjacent to individual dispensing nozzles 480. The filling sensors 864 detect the upper surface of the wax as it flows into the product containers 132 from the dispensing nozzles 480, and can send corresponding signals to the machine controller 410 (FIG. 4) when the containers 132 have been filled to the desired level. The machine controller 410 responds to the signals by shutting off the corresponding wax dispensers 840, as described in greater detail below with reference to FIG. 9.

FIG. 9 is an enlarged, partially exploded isometric view of one of the wax dispensers 840 configured in accordance with an embodiment of the disclosure. In the illustrated embodiment, all of the wax dispensers 840 are at least generally similar in structure and function. In one aspect of this embodiment, the wax dispenser 840 includes a cylindrical, two-way piston 946 operably coupled to an elongate rod 948. The piston 946 slides fore and aft in a cylinder 942. A first flow control valve 944a is operably coupled to the cylinder 942 on one side of the piston 946, and a second flow control valve 944b is operably coupled to the cylinder 942 on the opposite side of the piston 946.

A distal end of the rod 948 includes a plunger portion 950 that carries one or more seals or O-rings 952 (e.g., rubber O-rings). The O-rings 952 form a seal between the plunger portion 950 and a nozzle bore 984 as the plunger portion 950 moves into, and out of, the wax dispensing nozzle 480 through an opening 982 during operation of the wax dispenser 840. The wax dispensing nozzle 480 includes a circular flange 985 that is sealably mated to a corresponding outlet flange (not shown) on the bottom of the wax hopper 110 with a tube clamp 954 and a gasket 956. The electrical heater 716 (e.g., a Watlow thinband, 120 volt, 125 watt heating element) is clamped around the wax dispensing nozzle 480, and the thermocouple 718 is operably coupled to the nozzle 480 with a collar 958 positioned below the heating element 716.

The wax dispenser 840 can operate in one embodiment as follows: Pressurized fluid (e.g., air) flows into the cylinder 942 through the second flow control valve 944b to drive the piston 946 upwardly toward the first flow control valve 944a. As the piston 946 moves upwardly, back pressure in the cylinder 942 escapes through the first flow control valve 944a. Moreover, as the piston 946 moves upwardly, the plunger 950 retracts from the nozzle bore 984. This permits wax from the hopper 110 to flow into the nozzle bore 984 through the opening 982, and then into the waiting product container 132 (not shown) through the nozzle outlet 118. When the product container 132 is full, pressurized air flows into the cylinder 942 through the first flow control valve 944a, driving the piston 946 downwardly toward the opposite end of the cylinder 942. As the piston 946 moves downwardly, back pressure in the cylinder 942 escapes through the second flow control valve 944b. Moreover, downward movement of the piston 946 drives the plunger 950 back into the nozzle bore 984 to close off the opening 982 and stop the flow of wax through the outlet 118. The cycle repeats as the next product container 132 moves into position beneath the nozzle outlet 118.

FIG. 10 is an enlarged isometric view illustrating a portion of the container filling assembly 128 (FIG. 1) simultaneously filling a plurality of product containers 132 with wax 103. Referring to FIGS. 10 and 4 together, as the product conveyor 162 advances the empty product containers 132 forward from the container loading assembly 120, the product containers 132 pass beneath the row of proximity sensors 264. When the proximity sensors 264 detect an empty product container 132 passing beneath them, they send a corresponding signal to the machine controller 410. The machine controller 410 is operably connected to a plurality of air control valves 450 (e.g., two-position, electrically actuated solenoid air valves; identified individually as air control valves 450a-450d on one side of the manufacturing machine 100, and air control valves 450e-450h (not shown) on the other side of the machine 100). Each air control valve 450 is operably coupled to a corresponding one of the wax dispensers 840 by means of a first air hose 452a and a second air hose 452b. As shown in FIG. 9, the first air hose 452a is operably connected to the first flow control valve 944a on the dispenser cylinder 942, and the second air hose 452b is operably connected to the second flow control valve 944b.

When the machine controller 410 receives a signal from one of the proximity sensors 264 indicating that an empty product container 132 is in position on the product conveyor 162, the machine controller 410 responds by sending a corresponding signal to the appropriate air control valve 450 when the product container 132 is momentarily stopped beneath the associated wax dispensing nozzle 480. The signal causes the air control valve 450 to open a first passage allowing pressurized air to flow through the second air hose 452b and into the wax dispenser cylinder 942 (FIG. 9) through the second flow control valve 944b. The air pressure drives the piston 946 upwardly in the cylinder 942. As the piston 946 moves upwardly, the plunger 950 retracts from the nozzle bore 984. This permits wax from the hopper 110 to flow into the product container mold portion 534 through the nozzle outlet 118, as shown in FIG. 10.

When the adjacent filling sensor 864 detects that the mold portion 534 is sufficiently full of wax, the filling sensor 864 sends a corresponding signal to the machine controller 410. The machine controller 410 responds by sending another signal to the air control valve 450. The air control valve 450 responds to the signal from the machine controller 410 by closing the first passage and opening a second passage, allowing pressurized air to flow through the first air hose 452a and into the dispenser cylinder 942 (FIG. 9) through the first flow control valve 944a. The pressurized air drives the piston 946 downwardly toward the opposite end of the cylinder 942. Downward movement of the piston 946 drives the plunger 950 back into the nozzle bore 984 to stop the flow of wax through the nozzle outlet 118, thereby metering the amount of wax dispensed into the product container 132. Once the container mold portion 534 has been filled as shown in FIG. 10, the product conveyor 162 indexes forward (by means of the drive assembly 250 described above with reference to, e.g., FIGS. 6A and 6B) and places a new row of empty product containers 132 beneath the wax dispensing nozzles 480, and the cycle repeats.

In one embodiment, the drive assembly 250 described above with reference to FIGS. 6A and 6B can be operated at a rate of from about five to about 15 indexes of the product conveyor 162 per minute. For example, in one embodiment the drive assembly 250 can be operated at a rate of about four indexes per minute, corresponding to filling about 48 product containers per minute. In another embodiment, the drive assembly 250 can be operated at a rate of about 10 indexes per minute, corresponding to filling about 80 product containers per minute. In further embodiments, the manufacturing machine 100 can be configured to fill more or fewer product containers 132 at different rates. Filling rates can depend on various factors including, for example, the number of product containers 132 in a given row or rows of the product conveyor 162 and the corresponding number of dispensing nozzles 480, the conveyor indexing rate, etc.

FIG. 11 is a schematic diagram illustrating aspects of the pneumatic systems and components described above with reference to FIGS. 1-10. For example, FIG. 11 illustrates the pneumatic connections between the vacuum control valves 440 and the vacuum manifold 342 of the container loading assembly 120. FIG. 11 also illustrates the pneumatic connections between the air control valves 450 and the corresponding wax dispenser cylinders 942 of container filling assembly 128.

FIG. 12 is a rear isometric view of the cooling assembly 150 configured in accordance with an embodiment of the disclosure. Certain portions of the manufacturing machine 100 (e.g., the container loading assembly 120, the container filling assembly 128, the container labeling assembly 140, etc.) have been omitted from FIG. 12 for purposes of illustration. In one aspect of this embodiment, the cooling assembly 150 includes a plurality of side panels 1222 (identified individually as side panels 1222a-1222η) and top panels 1223 (identified individually as top panels 1223a-1223η) that form an enclosure 1220 around the upper air movers 152. The enclosure panels 1222 and 1223 can be manufactured from a suitable sheet metal, such as stainless steel, aluminum, etc. In the illustrated embodiment, the fan enclosure 1220 extends between the container filling assembly 128 and the container discharge assembly 126 (FIG. 1). In this regard, the fan enclosure can be from about 10 feet long to about 35 feet long, such as from about 15 feet long to about 30 feet long, or about 25 feet long. The fan enclosure 1220 can be supported by a series of legs 1224 that elevate the fan enclosure 1220 a given distance (e.g., from about five inches to about two feet, or from about eight inches to about one foot) above the product conveyor 162.

As the filled product containers 132 move forward underneath the fan enclosure 1220, the upper air movers 152 and the lower air movers 154 direct cooling air over the wax-filled containers 132 from above and below, respectively, to cool and harden the wax therein. In one embodiment, the air movers 152 and 154 can include electric motor-driven axial or propeller fans. In other embodiments, other types of suitable air movers (e.g., centrifugal (radial) fans, mixed flow fans, cross flow fans, etc.) can be used with the cooling assembly 150. In further embodiments, chilled air from one or more air conditioning units (either remote or local) utilizing refrigerants, water, and/or other coolants etc., can be directed over the wax-filled product containers 132 via ducting or other suitable means to cool the wax therein.

FIG. 13 is an enlarged front isometric view of the container discharge assembly 126 configured in accordance with an embodiment of the disclosure. Certain portions of the manufacturing machine 100 (e.g., the container labeling assembly 140) have been omitted from FIG. 13 for purposes of clarity. In one aspect of this embodiment, the container discharge assembly 126 includes a hold-down plate 1350 and a skid plate assembly 1352. The hold-down plate 1350 extends transversely across and slightly above the product conveyor 162. The skid plate 1352 is positioned downstream of the hold-down plate 1350, and also extends across and slightly above the product conveyor 162. As described in greater detail below with reference to FIG. 14A, the skid plate assembly 1352 causes the lid portions 536 (FIG. 5A) of the oncoming product containers 132 to rotate up and aft for container closure. The closed product containers 132 then proceed forward under the skid plate assembly 1352 to a lift ramp 1354 where they are moved off of the product conveyor 162 and onto the container labeling assembly 140 (FIG. 1).

At the discharge portion 104 of the manufacturing machine 100, the conveyor chains 566 (FIG. 5A) of the product conveyor 162 wrap around and operably engage a first conveyor sprocket 1358a and a second conveyor sprocket 1358b. The conveyor sprockets 1358 can be at least generally similar in structure and function to the conveyor sprockets 258 located at the infeed portion 102 of the manufacturing machine 100 and described above with reference to FIG. 4. The conveyor sprockets 1358 are carried on an idler shaft 1364 which extends transversely beneath the product conveyor 162. A support roller 1360 is mounted to the idler shaft 1264 toward the center thereof to provide support for the center portion of the product conveyor 162 as it reverses direction. In addition to the support roller 1360, the idler shaft 1264 also carries a plurality of product lifters 1362 (identified individually as product lifters 1362a-1362h) which are fixedly attached thereto and aligned with respective rows of the product conveyor 162. As described in greater detail below with reference to FIG. 15A, the product lifters 1362 rotate with the idler shaft 1364 to sequentially knock the oncoming product containers 132 off of the product conveyor 162 and onto the lift ramp 1354.

A first drive sprocket 1366 is fixedly coupled to an outer end of the idler shaft 1364, and is operably coupled to a second drive sprocket 1370 by means of a drive chain 1368 (e.g., a conventional steel roller chain). The second drive sprocket 1370 is fixedly attached to an outer end of a lid-lifter shaft 1374 which extends transversely beneath the product conveyor 162. A plurality of lid lifters 1372 (identified individually as lid lifters 1372a-1372h) which are generally similar in structure and function to the product lifters 1362, are fixedly attached to the lid-lifter shaft 1374 in alignment with respective rows of the product conveyor 162. As described in greater detail below with reference to FIG. 14A, the lid lifters 1372 rotate with the lid-lifter shaft 1374 to sequentially push the lid portions 536 of the oncoming product containers 132 upwardly and onto an upwardly facing surface of the skid plate assembly 1352 as the product containers 132 move forward from underneath the hold-down plate 1350.

FIGS. 14A and 14B are enlarged isometric views illustrating how the lid lifters 1372 cooperate with the skid plate assembly 1352 and the hold-down plate 1350 to close the product container lid portions 536, in accordance with one embodiment of the disclosure. As shown in FIG. 14A, in this embodiment each of the lid lifters 1372 includes four arms 1420 extending outwardly from a central hub 1422 at right angles to each other. Each of the arms 1420 carries a pusher 1424 on a distal end thereof. The pushers 1424 can have cylindrical or other suitable shapes, and can be made from plastic, Teflon, rubber, metals, and/or other suitable materials known in the art. The arms 1420 can be fabricated from metal rods and/or other suitable materials known in the art. The product lifters 1362 can be at least generally similar in structure and function to the lid lifters 1372.

As the product conveyor 162 moves forward, the drive chain 1368 rotates the lid-lifter shaft 1374, which in turn rotates the lid lifters 1372. The movement of the lid lifters 1372 is coordinated with the movement of the product conveyor 162, so that the pushers 1424 rotate upwardly through the lid pockets 562b (FIG. 5A) and raise the container lid portions 536 as they move out from under the hold-down plate 1350. As the product containers 132 proceed forward, the lid portions 536 slide over a leading edge portion 1460 of the skid plate assembly 1352. As shown in FIG. 14B, continued forward movement of the product containers 132 causes the lid portions 536 to fold backwardly about the hinge lines 537 (FIG. 5A) and sealably engage a rim or lip on the container mold portions 534 in a press-fit relationship, thereby closing the product containers 132 around the scented wax product therein.

FIGS. 15A and 15B are enlarged isometric views illustrating how the product lifters 1362 move the closed product containers 132 off of the product conveyor 162 and onto the lift ramp 1354, in accordance with an embodiment of the disclosure. Referring first to FIG. 15A, as the closed product containers 132 emerge from under a trailing edge portion 1562 of the skid plate assembly 1352, pushers 1524 on the product lifters 1362 rotate upwardly through the container pockets 562a to dislodge the product containers 132 and move them onto parallel support rails 1572 of the lift ramp 1354. As the product containers 132 continue sliding forward on the support rails 1572, a plurality of rollers 1570 (e.g., rubber rollers) on a transverse, rotating shaft 1574 propel the product containers 132 forward and over a ridge in the lift ramp 1354. As shown in FIG. 15B, the product containers 132 slide down the backside of the lift ramp 1354 and onto the awaiting conveyor belt 144 for delivery to the labeling assembly 140.

FIG. 16 is a front isometric view of the container labeling assembly 140 configured in accordance with an embodiment of the disclosure. In the illustrated embodiment, the conveyor belt 144 can direct the product containers 132 onto two or more separate conveyor belts 1644 (identified individually as conveyor belts 1644a and 1644b) associated with two or more corresponding labeling machines 142 (identified individually as labeling machines 142a and 142b). In the illustrated embodiment, the container labeling assemblies 140 are commercially available labeling machines. In other embodiments, however, other types of suitable labeling machines known in the art can also be used. The use of multiple labeling machines 142 enables the container labeling assembly 140 to apply different labels 146 to different product lines when two or more different types of product are being produced simultaneously by the manufacturing machine 100. Even when only a single type of product is being manufactured, the use of multiple labeling machines 142 can enable faster labeling by labeling the product containers 132 coming off the manufacturing machine 100 in parallel rather than in series. The product labels 146 can include conventional paper or plastic labels having an adhesive back for adherence to the product containers 132.

From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the spirit and scope of the various embodiments of the invention. Further, while various advantages associated with certain embodiments of the invention have been described above in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the invention. Accordingly, the invention is not limited, except as by the appended claims.

Claims

1. A system for manufacturing wax for use with wickless candles, the system comprising:

a product conveyor;

a plurality of product containers moveably supported by the product conveyor;

a filling assembly having a plurality of wax dispensing outlets in fluid communication with a wax hopper, wherein the filling assembly automatically dispenses molten wax from the wax hopper into the product containers through the dispensing outlets; and

a cooling assembly having a plurality of air movers, wherein the product conveyor automatically moves the wax-filled product containers away from the filling assembly and through the cooling assembly, and wherein the air movers are operable to move cooling air over the product containers.

2. The system of claim 1 wherein each of the wax dispensing outlets includes a heater.

3. The system of claim 1 wherein the filling assembly automatically dispenses a metered portion of molten wax from the wax hopper into the product containers through the dispensing outlets.

4. The system of claim 1 wherein the wax hopper includes at least one partition dividing the wax hopper into a first hopper portion and a second hopper portion, wherein the first hopper portion can hold a first wax mixture having a first composition and the second hopper portion can hold a second wax mixture having a second composition different from the first composition.

5. The system of claim 1 wherein the product conveyor moves the product containers in a product feed direction, and wherein the plurality of wax dispensing outlets are arranged in a row above the product conveyor and transverse to the product feed direction.

6. The system of claim 1 wherein the product conveyor includes a plurality of container pockets therein, and wherein each of the product containers is releasably supported in one or more of the container pockets.

7. The system of claim 6, further comprising a container loading assembly, wherein the container loading assembly includes a plurality of container extraction units that simultaneously load the plurality of product containers into a row of the container pockets on the product conveyor.

8. A system for manufacturing wax products, the system comprising:

at least one product container;

a product conveyor that movably supports the product container;

a filling assembly having at least one wax dispensing outlet in fluid communication with a wax hopper, wherein the filling assembly automatically dispenses molten wax from the wax hopper into the product container through the dispensing outlet; and

a cooling assembly having at least one air mover, wherein the product conveyor automatically moves the product container away from the filling assembly and through the cooling assembly, and wherein the at least one air mover is operable to move cooling air over the product container and harden the wax therein.

9. The system of claim 8:

wherein the product container includes a lid portion;

wherein the filling assembly automatically dispenses molten wax from the wax hopper into the product container when the lid portion is in an open position;

wherein the product conveyor automatically moves the product container through the cooling assembly when the lid portion is in the open position; and

wherein the product conveyor automatically moves the product container away from the cooling assembly and through a product discharge assembly that automatically moves the lid portion from the open position to a closed position to enclose the hardened wax in the product container.

10. The system of claim 8 wherein the filling assembly includes a plurality of wax dispensers, and wherein each of the wax dispensers includes a corresponding wax dispensing outlet in fluid communication with the wax hopper.

11. An automated method for producing wax products for use with wickless candles, the method comprising:

releasably engaging a product container with a conveyor of a wax product manufacturing machine;

automatically moving the product container to a filling assembly with the conveyor;

automatically dispensing molten wax into the product container from the filling assembly; and

automatically moving the filled product container from the filling assembly through a cooling assembly to cool and harden the wax in the product container.

12. The method of claim 11, further comprising automatically closing a lid on the filled product container and discharging the filled product container from the conveyor.

13. The method of claim 11 wherein the product container is a first product container, and wherein the method further includes:

while releasably engaging the first product container with the conveyor, simultaneously releasably engaging a second product container with the conveyor;

while automatically moving the first product container to the filling assembly with the conveyor, simultaneously moving the second product container to the filling assembly with the conveyor; and

while automatically dispensing molten wax into the first product container from the filling assembly, simultaneously dispensing molten wax into the second product container from the filling assembly.

14. The method of claim 11 wherein the product container includes a lid, and wherein the method further comprises automatically closing the lid on the product container before discharging the product container from the conveyor.