METHOD AND SYSTEM FOR PACKAGING BITUMEN (ASPHALT) AND PRODUCTS PRODUCED THEREFROM

Abstract

A system provided by an assembly for packaging bitumen (asphalt) comprises a loading and bagging station, a support mounting station, a curing station and a separating station. The loading and bagging station provides for loading bitumen into a bag and sealing the bag once the bag has been filled with bitumen thereby providing a package. The support mounting station is downstream the bagging station and provides for positioning the package on a movable support. The curing station is downstream the support mounting station and provides for curing the bitumen within the bag on the movable support. The separating station is downstream the curing station for separating the package after curing from the movable support. Associated methods and products are also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority on U.S. Provisional Patent Application No. 61/486,587 filed on May 16, 2011 and incorporated herein in its entirety.

TECHNICAL FIELD

The present disclosure relates to bitumen or asphalt. More particularly, but not exclusively, the present disclosure relates to methods and systems including assemblies and apparatuses for packaging bitumen (asphalt) as well as to the packaged products produced from these methods and systems.

BACKGROUND

Bitumen (or asphalt) is a mixture of organic liquids that are highly viscous, black, sticky, entirely soluble in carbon disulfide, and composed primarily of highly condensed polycyclic aromatic hydrocarbons. Naturally occurring or crude bitumen is a sticky, tar-like form of petroleum that is so thick and heavy that it must be heated or diluted before it will flow. At room temperature, it has a consistency much like cold molasses. Refined bitumen is the residual (bottom) fraction obtained by fractional distillation of crude oil. Bitumen (or asphalt) is primarily used, when mixed with mineral aggregates, to produce paving materials. Its other main uses are for bituminous waterproofing products, including production of roofing felt and for sealing flat roofs. Most natural bitumens contain sulfur and several heavy metals such as nickel, vanadium, lead, chromium, mercury and also arsenic, selenium, and other toxic elements. Bitumens can provide good preservation of plants and animal fossils.

Bitumen (or asphalt) is transported by way of tanks and large containers onto sights for usage. It is a very costly, labour intensive and long procedure to handle bitumen from its compartmentalization stage into shipment units within containers to its usage stage. There is the added burden of controlling the amount of bitumen. Much of this tar-like sticky substance is lost as it is difficult to control the amounts that will be used as the bitumen is kept in large containers. Moreover, handling bitumen during compartmentalization into shipping units is also challenging as the bitumen may cool down quickly and solidify make it difficult to pour and manipulate.

There thus remains a need for improvements in transporting bitumen and controlling the amounts that are used all the while reducing loss of the product. There is also a need to provide a more convenient way of handling bitumen in order to prepare it for shipment in view of ultimate use.

OBJECTS

An object of the present disclosure is to provide a method for packaging bitumen (asphalt) into bags. An object of the present disclosure is to provide a system for packaging bitumen (asphalt) into bags. An object of the present disclosure is to provide an assembly for packaging bitumen (asphalt) into bags. An object of the present disclosure is to provide apparatuses for packaging bitumen (asphalt) into bags.

An object of the present disclosure is to provide a product comprising bag with bitumen product ready for use by melting the product.

An object of the present disclosure is to provide an assembly for handling a bag filled with bitumen prior to curing so as to stack the bitumen bag packages. An object of the present disclosure is to provide a method for handling a bag filled with bitumen prior to curing so as to stack the bitumen bag packages. An object of the present disclosure is to provide apparatuses for handling a bag filled with bitumen prior to curing so as to stack the bitumen bag packages.

More particularly, but not exclusively, the present disclosure relates to methods and systems including assemblies and apparatuses for packaging bitumen (asphalt) as well as to the packaged products produced from these methods and systems.

SUMMARY

In accordance with an aspect of the disclosure, there is provided an assembly for packaging bitumen comprising: a loading and bagging station for loading bitumen into a bag and sealing the bag once the bag has been filled with bitumen thereby providing a package; a support mounting station downstream the bagging station for positioning the package on a movable support; a curing station downstream the support mounting station for curing the bitumen within the bag on the movable support; and a separating station downstream the curing station for separating the package after curing from the movable support.

In an embodiment, the assembly urther comprising a conveying assembly for: conveying the package between the bagging station and the support mounting station; conveying movable support carrying the package between the support mounting station said curing station; and conveying the movable support carrying the package between the curing station and the separating station.

In an embodiment, the support mounting station comprises a movable support discharge station comprising a platform for holding a stack of movable supports and having an opening positioned above a lower conveyor, a higher conveyor positioned downstream the platform and above the lower conveyor provides for carrying the package and selectively conveying the package, the discharge station providing for selectively allowing a movable support to be discharged via the opening onto the lower conveyor, the lower conveyor providing for conveying the package under the higher conveyor downstream thereof, the higher conveyor providing for conveying the package onto the movable support. In an embodiment, the higher conveyor comprises a font edge, the higher conveyor providing for causing the package to fall off the front edge onto the movable support being conveyed thereunder and downstream thereof. In an embodiment, the movable support discharge station further comprises movable supporting elements being positioned beneath the platform for holding the bottom movable support of the stack, the movable holding elements being retractable so as to allow the bottom movable support to fall through the opening onto the lower conveyor. In an embodiment, the movable support discharge station further comprises lateral grips for gripping the stack so as not to fall though the opening when discharging the bottom movable support.

In an embodiment, the movable support comprises a tray.

In an embodiment, the assembly further comprising a separation station downstream the curing station for separating the package from the movable support. In an embodiment, the separating station comprises: a conveyor for conveying the movable support carrying the package in a downstream direction; a first sub conveyor downstream from and contiguous to the conveyor for engaging the package only and conveying the package in the downstream direction; and a second sub conveyor for receiving the movable support once the package is engaged by the first sub conveyor for conveying the movable support separately from the package. In an embodiment, the second sub conveyor is a ramp. In an embodiment, the separating station further comprises a split floor structure defining an upper floor portion providing for the package to be conveyed thereon and a lower floor portion providing for receiving the movable support thereon and being contiguous with the second sub conveyor. In an embodiment, the separating station comprises a conveyor for conveying the movable support carrying the package in a downstream direction and a clamp for clamping and lifting the package from the tray. In an embodiment, the separating station further comprises a movable platform continuous with the conveyor providing for moving upwardly relative the conveyor thereby providing a space for the movable support to be conveyed therein. In an embodiment, the separating station comprises a conveyor for conveying the movable support carrying the package in a downstream direction and movable platform continuous with the conveyor providing for moving upwardly relative the conveyor thereby blocking the package from moving downstream and providing a space for the movable support to be conveyed therein.

In an embodiment, the loading and bagging station comprises a reservoir with bitumen having a discharge outlet, a first arm with a suction for suctionally engaging the bag at one side thereof and positioning the bag to the discharge outlet, a second arm with a suction for suctionally engaging the bag at another opposite side thereof, the arms providing for being moved away from each other thereby opening the top edge of the bag so as to receive bitumen therein from the discharge outlet. In an embodiment, the loading and bagging station further comprises clamp members for holding the bag at opposite longitudinal ends of the top edge thereof and spreading members for being positioned within the open top edge to maintain the top edge in an open position.

In an embodiment, the assembly further comprising a pair of oppositely disposed carriages mounted on respective rails and comprising top arm members for engaging the bag therebetween when the bitumen has been discharged within the bag so as to move the bag along the rails to a sealing station.

In an embodiment, the assembly further comprising a rack positioning and loading station for loading the packages on the movable supports on a rack having a plurality of shelves, the rack positioning and loading station comprising: a ramp conveyor for conveying the packages on the movable supports to a top conveyor; an elevator for carrying the rack thereon providing for lifting the rack so that each shelf is positioned adjacent the top conveyor; and a pusher for pushing the packages on the top conveyor unto the adjacent shelf.

In an embodiment, the assembly further comprising a rack unloading station for uloading the packages on the movable supports from the rack, the rack unloading station comprising: an out-feed conveyor providing for receiving the packages on the trays from the rack; an elevator for carrying the rack thereon providing for lifting the rack so that each shelf is positioned adjacent the out-feed conveyor; and a pusher for pushing the packages from each shelf adjacent the out-feed conveyor onto the out-feed conveyor.

In an embodiment, the assembly further comprising a pallet loading station for loading the separated packages onto a pallet thereby building a bundle, the pallet loading station comprising: a top platform comprising an opening and a floor adjacent the opening; an elevator platform for carrying the pallet and lifting the pallet or the top most packages of the bundle mounted thereon to the opening so as to be adjacent to the floor; a pusher for pushing the packages on the floor onto the pallet or the top most packages of the bundle mounted thereon when the pallet or the top most package is adjacent the floor; and a top pusher for exerting a top pressure on the bundle. In an embodiment, the platform is rotatable so as to provide for wrapping the bundle in a wrapping material from a dispenser during rotation thereof.

In accordance with an aspect of the present disclosure, there is provided a bitumen package as provided by the assembly herein.

In accordance with an aspect of the present disclosure, there is provided a method for packaging bitumen comprising: positioning a bag at the discharge outlet of bitumen reservoir; suctionally opening the bag; pouring the bitumen within a bag; sealing the bag thereby providing a package; positioning the package on a tray; positioning a plurality of trays with packeges thereon on a rack with shelves for curing; curing the bitumen; separating the packages from the trays; and stacking the packages on a pallet.

In accordance with an aspect of the disclosure, there is provided an a method for packaging bitumen comprising: pouring the bitumen within a bag; sealing the bag; positioning the bag on a tray; curing the bitumen within the bag on the tray; separating the bag with the bitumen from the tray. In an embodiment, the method further comprises stacking a plurality of bags with bitumen after separation from their respective trays. In accordance with an aspect of the disclosure, there is provided a product comprising bitumen within a sealed bag.

In accordance with an aspect of the present disclosure, there is provided a bitumen package as provided by the methods herein.

Other objects, advantages and features of the present disclosure will become more apparent upon reading of the following non-restrictive description of non-limiting illustrative embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the appended drawings, where like reference numerals denote like elements throughout and in where:

FIG. 1 is a schematic perspective view of a bitumen reservoir assembly in fluid communication via in-feed and return conduits with a bitumen container reservoir for discharging the bitumen within a housing structure in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 2 is a schematic perspective view of a bitumen loading and bagging station for packaging bitumen in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 3 is a schematic front view of the bitumen loading and bagging station of FIG. 2 when positioning a bag at a bitumen discharge outlet for bitumen loading in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 4 is a schematic front view the bitumen loading and bagging station of FIG. 2 when opening the bag for loading bitumen therein in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 5 is a schematic front view the bitumen loading and bagging station of FIG. 2 when engaging the bag so as to close its top end after loading bitumen therein in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 6 is a schematic front view the bitumen loading and bagging station of FIG. 2 when sealing the engaged bag with bitumen thereby providing a package in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 7 is perspective view of a support mounting station for mounting the package to a movable support in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 8 is a schematic front elevational view of the movable support discharging station of the support mounting station of FIG. 7 in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 9 is a perspective view of a rack positioning and loading station in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 10 is a perspective top view of a ramp conveyor of the leading to the rack positioning and loading station of FIG. 9 in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 11 is a perspective side view of the top area of the rack positioning and loading station of FIG. 9 when pushing packages on movable supports onto the rack in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 12 is a perspective view of a rack loaded with packages on movable supports being conveyed from the rack positioning and loading station in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 13 is a partial perspective view of a rack unloading station for unloading the movable supports carrying the packages in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 14 is a perspective view of a separating station for separating the package from the movable support in accordance with a non-limiting illustrative embodiment of the present disclosure;

FIG. 14A is a side elevational schematic view of the separating station of FIG. 14;

FIG. 14B is a side elevational schematic view of a separating station for separating the package from the movable support in accordance with another non-limiting illustrative embodiment of the present disclosure;

FIG. 14C is a side elevational schematic view of a separating station for separating the package from the movable support in accordance with a further non-limiting illustrative embodiment of the present disclosure;

FIG. 14A is a side elevational schematic view of a separating station for separating the package from the movable support in accordance with yet another non-limiting illustrative embodiment of the present disclosure;

FIG. 15 is perspective top view of a conveyor downstream the separating station in accordance with another non-limiting illustrative embodiment of the present disclosure;

FIG. 16 is top perspective view of a pallet loading station in accordance with a non-limiting illustrative embodiment of the present disclosure; and

FIG. 17 is a front perspective view of bundle wrapping station in accordance with a non-limiting illustrative embodiment of the present disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Generally stated and in accordance with an embodiment of the present disclosure, there is provided a method and a system including assemblies and apparatuses for packaging bitumen as well as the products produced therefrom. Hot bitumen is discharged from a silo into a container. Polymeric bags are provided for being filled by this container. The bags are sealed thereby providing separate bitumen packages and placed on movable supports such as trays which are conveyed to a rack with shelves so as to be set aside for curing. Once the curing operation is completed, the trays and the packages are removed from the rack and the packages are subsequently separated from their tray to be stacked in a bundle on a pallet for shipment thereof. The bundle is conveniently wrapped. Also provided is a package comprising a polymeric bag filled with bitumen that is ready for use by melting the package so as to access the bitumen.

With reference, to the appended Figures, non-restrictive illustrative embodiments will be herein described so as to further exemplify the disclosure only and by no means limit the scope thereof.

With respect to FIG. 1, the present system S includes a reservoir assembly R including three reservoirs. Two reservoirs 10 and 12 are insulated and contain therein heated bitumen; the third reservoir 14 is not insulated and provides for cooling down the bitumen received therein. A discharge pump 16 provides for receiving bitumen within the reservoir assembly R. As is known in the art, each top side T of each reservoir 10, 12 and 14 includes sampling valves and thermometers for temperature control, hot oil tanks 15 for heating the bitumen therein, interrupter switches for shutting down in feed when a content indicator signals that the reservoirs are over capacity. Temperature indicators are also mounted to the reservoirs as is known in the art. Each reservoir 10, 12, and 14 is in fluid communication with a respective discharge conduit 18, 20 and 22.

A discharge conduit line 24 runs from the reservoir assembly R to the housing structure 25 and a return conduit line 26 runs from the housing structure 25 back to the reservoir assembly R. In this way there is flow of the bitumen from the reservoir assembly R to the housing structure 25 and back again, if the bitumen is not used as described herein. The narrower conduits 28 provide for heating the conduit lines 24 and 26. It is convenient for the bitumen to flow within this circuit daily. The bitumen is kept at a very stable temperature.

A monitor 30 with indicators provides for indicating the temperature of the hot oil as well as the bitumen and for control thereof. A conduit circuit network 32 provides for heating the bitumen discharge conduits 18, 20 and 22 during both the flow of bitumen from the reservoir assembly R to the housing structure 25 and its return.

The discharge conduit line 24 acts as an in-feed conduit line within the housing structure 25 as it runs therein and towards an actuator 34 which controls the in-feed of bitumen from the in-feed line 24 into the discharge tube 36 and from there into the dispensing reservoir 38 which is a large rectangular container. The dispensing reservoir 38 is insulated and kept at high temperature so as not to allow the received bitumen to cool down. The actuator 34 provides for returning the unused bitumen back to the reservoir assembly via the return conduit line 26.

An actuator 40 is interposed between the discharge tube 36 and the dispensing reservoir 38 for stopping bitumen fluid in case of an emergency. A temperature indicator 42 is connected to the actuator 34 for confirming the temperature of the bitumen before it is discharged into reservoir 38 via tube 36. A temperature indicator 44 is also positioned at the in-feed opening of the reservoir 38 in order to monitor the temperature of the dispensed bitumen as well as the temperature of the bitumen within the reservoir 38. Of course, the reservoir 38 also includes a plunger to indicate the level of bitumen therein, thereby avoiding over feeding the reservoir 38 beyond capacity. A heating element provides for maintaining the bitumen therein at the desirable constant temperature.

Once sufficient bitumen has been discharged within the reservoir 38, the actuator 44 is shut down and discharge is arrested. The remaining bitumen within the tube 36 and in-feed conduit 24 is returned to the reservoir assembly R via the action of actuator 34 by way of conduit 26.

It should be noted that the temperature of the bitumen is monitored and controlled by a controller in order to be maintained at suitable levels throughout its flow.

With reference to FIGS. 2-6, the bitumen loading and bagging station 48 as well as the related process of packaging bitumen will now be described.

The bitumen loading station 48 includes a discharge outlet 50 for discharging the bitumen within the reservoir 38. A controller provides for controlling pumps that modulate the amount of bitumen that is discharged at each loading operation.

A plurality bags 52 are provided on a support table 54. The bags 52 are made of a pair of interposed sheets and include unsealed edge to be opened for filing. The bags 52 that are engaged by a first movable robotic arm 56 having suction elements 57 for suctioning a portion of the bags 52 on one side 53 (see FIG. 3) thereof thereby lifting the bags 52 towards the discharge outlet 50.

Once the bag 52 is positioned at the discharge outlet 50, an opposite second arm 58 having suction elements 60 engages the bag 52 on the other side 55 thereof and suctions a portion thereof as shown in FIG. 3. Top clamp members 62 engage opposite longitudinal ends of the top unsealed edge of the bag 52 to keep it in place. The arms 56 and 58 are moved away from each other such that the opposite sheets (at each side 53 and 55) of the bag 52 are pulled away from each other, by the action of suction elements 57 and 60 spreading the bag 52 and opening the bag 52 as shown in FIG. 4. Spreader elements 64 are pivoted away from each other engaging the inside of the open top portion of the bag 52 to maintain the top end of the bag open. The suctions 57 and 60 are disengaged from the bag 52.

With the bag 52 being clamped in position, the discharge outlet 50 proceeds to discharge and load bitumen therein.

Once the bag 52 is loaded with bitumen, a carriage assembly 65 including carriage members 66 positioned at each side of the bag 52 and movably mounted on respective rails 68 engage the bag 52. Each carriage member 66 includes a movable top platform 70 movably mounted on the top end thereof and including an outwardly protruding longitudinal clamp member 72. Carriage members 66 move along their respective rails 68 to interface with the bag 52 which is positioned at the discharge outlet 50. The platforms 70 move towards the bag 52 providing for the clamp members 72 to clamp the bag 52. The clamps 62 release the bag 52 and the spreader elements 64 pivot inwardly to disengage the top open edge of the bag 52 as shown in FIG. 6.

The carriage members 66 move along their rails 68 towards and through a Y-shaped guide 74 which keeps the top of the bag 52 above the portion clamped by clamp members 72 from outwardly spreading. At the exit of the a Y-shaped guide 74 the carriage members 66 move the bag 52 towards a sealing assembly 76 comprising a pair of oppositely disposed and movable sealing arms 78 which include emitters 80 for ultrasound sealing of the bag 52 as shown in FIG. 6. Of course other types of sealing processes, such as heat sealing, can also be contemplated.

Once the bag 52 is sealed the clamp members 72 disengage the bag 52 as they are moved away from the bag 52 by their respective platforms 70 allowing the bag 52 with the to drop onto a conveyor 82 as better shown in FIG. 7.

Therefore the sealed bag 52 and bitumen therein provides a bitumen bag, product or package 84.

As shown in FIG. 7, the package is conveyed downstream to support mounting station 83 from conveyor 82. More specifically, conveyor 82 moves the package 84 to a lower conveyor 86 including a tagging station 88 with a laser tag 90 for tagging the package 84. The package 84 is then moved downstream onto a conveyor platform 92 which is laterally moved above an adjacent conveyor 94 (hence, conveyor 92 is a higher conveyor and conveyor 94 is a lower conveyor) for mounting the package 84 onto a movable support such as a tray 96 discharged from a movable support or tray discharging station 98.

With reference to both FIGS. 7 and 8, the tray discharging station 98 includes a plurality of stacked trays 96 on a support surface 100 positioned above the conveyor 94 and having an opening 102 for allowing the trays 96 to fall onto the conveyor 94. The stack of trays 98 is held in place by a pair of oppositely disposed lateral grips 104 including reciprocating lateral grips 103 elements movably extendible from pistons 105. As shown in FIG. 8, support elements 108, having reciprocating L-shaped support fingers 107 movably extendible from pistons 109 which provide for holding the bottom most tray 96 from falling through the opening 102. When the support elements 108 retract, the bottom most tray 96 falls onto the conveyor 94. The grips 104 are positioned above the bottom most tray 96 so as not to grip it and prevent it from falling. Once the bottom most tray 96 has fallen onto the conveyor 94, the support elements 108 return to their initial position. The grips 104 retract so as to allow the stack to fall via the opening 102 for a distance of one tray 96, namely the next bottom most tray. The stack is prevented from falling onto the conveyor 94 by the support elements 108. The grips 104 again engage the stack with the exception of the next bottom most tray 96 which is positioned within the opening 102. Each bottom tray 96 is discharged in a similar fashion until expiry of the stack. Sensors detect the position of the trays within the tray discharging station 98.

As shown in FIG. 7, once the tray 96 is discharged onto conveyor 94, the tray 96 is moved forwardly beneath the platform conveyor 92, as the leading edge of the tray 96 exceeds the front edge of the platform conveyor 92, the conveyor 92 is actuated to move the package 84 forwardly so as to progressively fall onto the moving tray 96, thereby mounting the package 84 on the tray 96.

In this example, each tray 96 includes a relatively flat platform 95 surrounded by a upwardly protruding short lip edge 97 in order to maintain the package therein during the conveying operation which will be described herein. In this example, small protrusions 99 at each corner 93 thereof which act as supports so that the trays 96 when they are stacked do not get stuck one within the other. The trays 96 allow the packages 84 to be manipulated without tearing the bag 52.

Moreover, the bitumen product within the sealed bag 52 is non-cured and therefore the uncured package 84 would be difficult to move along a conveyor system as it would deform and get stuck at various positions along the conveying circuit. Pusher elements, rollers and various conveyor belts would further deform the uncured package 84 causing the finished products to have greatly varying configurations which would not be convenient for packaging. The tray 96 thus allow the bitumen within the bag 52 to settle and provide a generally uniform package 84 as the product is not directly engaged by any of the conveying elements prior to curing and after it has been positioned on the tray 96. Therefore, it is convenient that once the bag 52 is loaded with bitumen, the conveying process until it is positioned on a tray is short. The structures described above meet these requirements as the bag 52 with bitumen is dropped directly on a conveyor 82 which is slightly longer than the length the of the package 4 providing for the package 84 to begin being dropped onto the lower conveyor 86 for tagging once it is fully dropped onto the conveyor 82. Conveyor 86 is also slightly longer than the package 84 thereby providing for progressively moving the package 84 on the platform 92 as the package 84 almost concurrently with tagging. The package 84 then rests on the platform 92 and is progressively dropped onto the tray 96 as the tray 96 is moved forward. In this way, movement of the uncured package 84 is minimized prior to it being positioned on the tray 96.

As shown in FIG. 9, the tray 96 carrying the package 84 on the tray 96 is conveyed onto a ramp conveyor 110 towards a rack positioning and package loading station 112 including a tower structure 114. More specifically, both tray 96 with the package 84 positioned thereon are conveyed upwardly along the ramp conveyor 110 towards the top 115 of the tower structure 115.

The rack positioning and package loading station 112 includes longitudinal conveyor 116 (such as a conveyor belt or rollers) for carrying a rack structure 118 thereon and conveying this rack 118 towards an elevator 120 which lifts up the rack 118 by way of a movable platform 122 that is lifted by an actuator assembly 124 (such as a hydraulic cylinder) towards the top 115 of a tower structure 114, in position to receive trays 96. The elevator 120 includes a pair of alignment members 126 for keeping the rack 118 in position during conveying.

As shown in FIG. 10, the ramp 110 brings the tray 96 carrying the package 84 to a first conveyor 128 made of a plurality of rollers which causes the tray 96 to engage a centrally positioned vertical roller rod 130 which rotates the tray 96 carrying the package 84 causing it to change directions from a longitudinally conveyed position to a transversal position for example and be moved to a platform 132 shown in FIG. 11. The vertical roller rod 130 is retractable so as to selectively provide for trays 96 carrying packages 84 to not be rotated as shown in FIG. 10 and thus be conveyed onto platform 132 in the same position that they are in when being moved along ramp 110.

Turning now to FIG. 11, a pusher 134 is positioned at platform 132 and connected to a piston actuator assembly 135 for imparting a reciprocal forward and rearward movement thereto as is guided along lateral guide-rack 137. The pusher 134 provides for pushing the trays 96 carrying the packages 84 towards the rack 118 by way of roller conveyor 136 interposed between the rack 118 and the platform 132. The rack 118 includes a plurality of rack shelves 138, the elevator platform 122 provides for positioning a given rack shelf 136 at the same level as the conveyor 136 thereby allowing conveyor 136 and pusher 134 to feed load a given shelf 136 with trays 96 carrying bitumen packages 84 on trays 72. In the current example, three trays 96 carrying bitumen packages 84 are simultaneously as a row pushed onto a shelf 138.

Sensors provide for detecting when a preferred number of bitumen packages 84 on trays 96 have been positioned for being conveyed onto the rack 118. Each time a tray 96 with a bitumen bag 84 is positioned on the platform 132, the sensors provide for detecting its position, transmitting this information to a controller which in turn controls the various conveyors and pushers of the present circuit or system S. Such sensors also provide detecting the speed at which the trays 96 with bitumen packages 84 or as separate elements are conveyed throughout the system S. The sensors can also be used to detect the number of bitumen packages 84 on trays 96 positioned on each shelf 138 or on each rack 118, thereby providing greater bitumen packaging control.

Each time a shelf 138 receives a capacity number of bitumen trays 96 carrying packages 84, the rack 118 moves up one level to place the next lower shelf 138 at the level of the conveyor feeding conveyor 136, thereby filling each shelf 138 with trays 96 carrying bitumen packages 84. Alternatively, the rack 118 is fully raised upwardly by platform 122 and then moved down one level as each next upper shelf 138 is fully loaded until it reaches the bottom.

Turning now to FIG. 12, once a rack 118 has been loaded with a predetermined number of trays 96 carrying bitumen packages 84 it is descended downwardly via the elevator platform 122 which includes a conveyor surface that is continuous to an adjacent out-feed conveyor 140 for removing the rack 118 loaded with bitumen packages 84 and trays 96 from the rack positioning and bag loading station 112.

A fork lift (not shown) removes the rack 118 from the conveyor 124, to place the hot bitumen packages 84 on the trays in an appropriate location for curing. Once curing is complete the fork lift recuperated the rack 118 with the bitumen packages 84 on trays 96 to bring load to a subsequent processing line for separating the bitumen packages 84 from the rack 118 and the trays 96.

FIGS. 13 shows a rack unloading station 140 comprising a tower structure 152 similar to the tower structure 114 with an elevator platform that lifts the rack 118 towards the top end 153 of the tower structure 152 providing for each shelf to be positioned adjacent an out-feed conveyor 154 comprising a plurality of independently actuated rollers 156. A pusher member 158 opposite the shelf 138 pushes each row of trays 96 carrying packages 84 from a given shelf 138 onto the conveyor 154. Once a given shelf 138 is unloaded the rack 118 is descended so that the next upped shelf 138 is similarly unloaded until the full rack 118 is emptied. Again, the foregoing is controlled and monitored by sensors along the pathway of the packages 84 linked to a controller which is linked to each actuator of the present system S.

The conveyor 154 leads each tray 96 carrying a package to a downstream separating station for separating the cured package 84 from the tray 96.

FIG. 14, 14A, 14B, 140 and 14D show various separating stations that will be described herein.

FIGS. 14 and 14A shows a separation station 160 comprising a separation conveyor 162 contiguous with the conveyor 154 for receiving the coupled package 84 and tray 96; guide walls 164 keep the package tray combination in position as it moves towards the separation conveyor 162. The separation conveyor 162 includes a first sub conveyor 168 comprising a pair of side conveying chains 170 which engage the package 84 but not the tray 96 thus moving the package 84 and therewith dragging the tray 96 in the downstream direction. The separation conveyor 162 also includes a chute or ramp 172. The ramp 172 and an upper level floor portion 174 define a split floor structure 176 at the mouth of the chute or ramp 172. Therefore, as the chains 170 convey the package 84, the dragged tray 96 thereunder falls onto the ramp 172 and slides towards a bottom tray recuperating area (not show) while the package 84 continues on upper level floor portion 174 to be conveyed onto a downstream conveyor belt 178.

In another embodiment, the chains 170 are mounted to lateral and movable shafts 180 that provide for lifting the chains 170 therewith and thereby the engaged package 84 so as to mount it to the upper level floor portion 174.

FIG. 14B shows a separating station 182 comprising a clamping assembly 184 including a pair of clamping members 186 (only one shown here) having an arm 188 mounted to top horizontal guide track 190 and an actuator 192 at one end and having a clamping element 192 at its free end. The clamping members 186 clamp the package 84 therebetween as it is being conveyed on the tray 96 by the conveyor 154. The arms 188 are retractable and hence, lift the package 84 from the tray 96, the tray continued to move towards the and onto the downstream ramp 172. The lifted package 84 is conveyed by the clamp members 186 as they move forward along the guide track 190 above the conveyor 178. At this point, the arms 188 are extended until the package 84 is placed on the conveyor 178 and the clamp members 186 release the package 84 allowing it to be conveyed by conveyor 178.

FIG. 14C shows a separating station 192 comprising a platform 194 in the form of a conveyor including a belt 196 on a pair of rollers 198 and being so positioned at higher position relative to the tray as to block passage of the tray 96 while it is being conveyed yet allowing the package 84 to be frictionally engaged by the speed of the belt 196 in such a way as to be conveyed thereon to be moved towards the downstream conveyor 178. A small passage 200 is provided between the conveyor 194 and the conveyor 158, thereby allowing the tray 96 to move therein and slide along the ramp 72 due to the pressure exerted thereon by the package 84 as it is being conveyed onto the conveyor 194.

FIG. 14D shows a separating station 202 comprising a liftable conveyor 204 that blocks the movement of the package 84 when lifted upwards and provides a passage 206 for allowing the tray 96 to be conveyed onto the ramp 172 by conveyor 158. Thereafter, the conveyor 204 is descended and actuated to allow the package 84 to be conveyed onto the downstream conveyor 178.

In an embodiment, the ramp 172 comprises a conveyor belt or conveyor rollers.

It should be noted that the liftable conveyor 204 can be used in conjunction with the clamping members 184 so as to support the lifted package 84 and to allow the tray to fall into the ramp by creating an opening thereunder.

It should be noted that the various elements of the separating stations described above can be combined in a variety of ways.

Sensors linked to a controller provide for sensing the position of the package 84 and tray 96 in order to take the appropriate action during the separation step.

Once the bitumen package 84 is removed from the tray is moved downstream towards a pallet loading station 210 shown in FIG. 16.

As shown in FIG. 15, a conveyor 208 contiguous with conveyor 178 provides for moving the cured package 84 within the system S, if the position of the package 84 needs to be rotates this can be accomplished by various roller rods 130 strategically positioned along the system S trajectory.

Turning back to FIG. 16, the pallet loading station 210 includes a platform 212 having an opening 214 for providing packages to be mounted onto a pallet 216 (see FIG. 17) via the opening 214. The pallet 216 is mounted on an elevator platform 218 which lifts the pallet up to opening 214. The packages are conveyed onto a guide floor 220 via the conveyor 208. The pallet loading station 210 comprises a pusher 222 having a pushing element 224 for engaging and pushing packages 84 towards opening 214. The pushing element 224 depends from an upper beam 226 having downwardly extending guide fingers 228 for slidably engaging a guide track 230. Pinion gears 232 mounted to the beam 226 via supports (not shown), provide for moving the pusher 222 forward towards the opening 214 along the guide-rack 234. In this way, pusher element 224 pushes packages 84 into the opening 214 and onto the pallet 216. As the pallet 216 received rows of packages 84 thereon the elevator platform 218 subsequently descends in order to create a space for the next row of packages 84 thereby building a bundle 240 on the pallet 216 as the platform 218 descends (see FIG. 17). A top pusher 242, movably actuated by piston rods 242, pushes the packages 84 of the bundle 240 downwards onto the pallet 216 to stabilize the bundle 240 and maintain the packages 84 under tension between the force of the pusher 242 and the pallet 216. Once a sufficient number of packages 84 is mounted on the pallet, the bundle 240 is sent downstream to be wrapped for shipment.

As shown in FIG. 17, a wrapping station 250 comprises a wrapping dispenser comprising a roller 252 carrying a wrapping material 254, the elevator platform 218 is mounted to a pivoting assembly thereunder (not shown) providing for the platform 218 along with the bundle 240 thereby wrapping the bundle 240 in the material 254. Once the bundle 240 is wrapped, the platform 218 provides via its conveyor rollers 256 to convey the pallet with the wrapped bundle on an out-feed conveyor 258 for shipment.

Again, sensors determined the number and position of bitumen bags or packages 84 during the above operations so as to send this information to a controller which can thereby actuate the various movable components described above.

When using the packages 84, the user may simply melt the bag 84 along with the contents in there. The polymeric material of the external bag 52 melts and disperses with the bitumen when heated and in this way users have a greater control of the amount of bitumen that is used as well as facilitating the handling of bitumen for transport and use and the while reducing loss of the product during handling and use.

It should be noted that the various components and features of the embodiments described above can be combined in a variety of ways so as to provide other non-illustrated embodiments within the scope of the disclosure. As such, it is to be understood that the disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation.

Hence, although the present disclosure has been described hereinabove by way of embodiments thereof, it can be modified, without departing from the spirit, scope and nature of the subject disclosure as defined herein and in the appended claims.

Claims

1. An assembly for packaging bitumen comprising:

a loading and bagging station for loading bitumen into a bag and sealing the bag once the bag has been filled with bitumen thereby providing a package;

a support mounting station downstream the bagging station for positioning the package on a movable support;

a curing station downstream the support mounting station for curing the bitumen within the bag on the movable support; and

a separating station downstream the curing station for separating the package after curing from the movable support.

2. An assembly according to claim 1 further comprising a conveying assembly for:

conveying the package between the bagging station and the support mounting station;

conveying movable support carrying the package between the support mounting station said curing station; and

conveying the movable support carrying the package between the curing station and the separating station.

3. An assembly according to claim 1, wherein the support mounting station comprises a movable support discharge station comprising a platform for holding a stack of movable supports and having an opening positioned above a lower conveyor, a higher conveyor positioned downstream the platform and above the lower conveyor provides for carrying the package and selectively conveying the package, the discharge station providing for selectively allowing a movable support to be discharged via the opening onto the lower conveyor, the lower conveyor providing for conveying the package under the higher conveyor downstream thereof, the higher conveyor providing for conveying the package onto the movable support.

4. An assembly according to claim 3, wherein the higher conveyor comprises a font edge, the higher conveyor providing for causing the package to fall off the front edge onto the movable support being conveyed thereunder and downstream thereof.

5. An assembly according to claim 3, wherein the movable support discharge station further comprises movable supporting elements being positioned beneath the platform for holding the bottom movable support of the stack, the movable holding elements being retractable so as to allow the bottom movable support to fall through the opening onto the lower conveyor.

6. An assembly according to claim 5, wherein the movable support discharge station further comprises lateral grips for gripping the stack so as not to fall though the opening when discharging the bottom movable support.

7. An assembly according to claim 1, wherein the movable support comprises a tray.

8. An assembly according to claim 1, further comprising a separation station downstream the curing station for separating the package from the movable support.

9. An assembly according to claim 8, wherein the separating station comprises:

a conveyor for conveying the movable support carrying the package in a downstream direction;

a first sub conveyor downstream from and contiguous to the conveyor for engaging the package only and conveying the package in the downstream direction; and

a second sub conveyor for receiving the movable support once the package is engaged by the first sub conveyor for conveying the movable support separately from the package.

10. An assembly according to claim 9, wherein the second sub conveyor is a ramp.

11. An assembly according to claim 9, wherein the separating station further comprises a split floor structure defining an upper floor portion providing for the package to be conveyed thereon and a lower floor portion providing for receiving the movable support thereon and being contiguous with the second sub conveyor.

12. An assembly according to claim 8, wherein the separating station comprises a conveyor for conveying the movable support carrying the package in a downstream direction and a clamp for clamping and lifting the package from the tray.

13. An assembly according to claim 12, wherein the separating station further comprises a movable platform continuous with the conveyor providing for moving upwardly relative the conveyor thereby providing a space for the movable support to be conveyed therein.

14. An assembly according to claim 8, wherein the separating station comprises a conveyor for conveying the movable support carrying the package in a downstream direction and movable platform continuous with the conveyor providing for moving upwardly relative the conveyor thereby blocking the package from moving downstream and providing a space for the movable support to be conveyed therein.

15. An assembly according to claim 1, wherein the loading and bagging station comprises a reservoir with bitumen having a discharge outlet, a first arm with a suction for suctionally engaging the bag at one side thereof and positioning the bag to the discharge outlet, a second arm with a suction for suctionally engaging the bag at another opposite side thereof, the arms providing for being moved away from each other thereby opening the top edge of the bag so as to receive bitumen therein from the discharge outlet.

16. An assembly according to claim 15, wherein the loading and bagging station further comprises clamp members for holding the bag at opposite longitudinal ends of the top edge thereof and spreading members for being positioned within the open top edge to maintain the top edge in an open position.

17. An assembly according to claim 15, further comprising a pair of oppositely disposed carriages mounted on respective rails and comprising top arm members for engaging the bag therebetween when the bitumen has been discharged within the bag so as to move the bag along the rails to a sealing station.

18. An assembly according to claim 1, further comprising a rack positioning and loading station for loading the packages on the movable supports on a rack having a plurality of shelves, the rack positioning and loading station comprising:

a ramp conveyor for conveying the packages on the movable supports to a top conveyor;

an elevator for carrying the rack thereon providing for lifting the rack so that each shelf is positioned adjacent the top conveyor; and

a pusher for pushing the packages on the top conveyor unto the adjacent shelf.

19. An assembly according to claim 18, further comprising a rack unloading station for uloading the packages on the movable supports from the rack, the rack unloading station comprising:

an out-feed conveyor providing for receiving the packages on the trays from the rack;

an elevator for carrying the rack thereon providing for lifting the rack so that each shelf is positioned adjacent the out-feed conveyor; and

a pusher for pushing the packages from each shelf adjacent the out-feed conveyor onto the out-feed conveyor.

20. An assembly according to claim 8, further comprising a pallet loading station for loading the separated packages onto a pallet thereby building a bundle, the pallet loading station comprising:

a top platform comprising an opening and a floor adjacent the opening;

an elevator platform for carrying the pallet and lifting the pallet or the top most packages of the bundle mounted thereon to the opening so as to be adjacent to the floor;

a pusher for pushing the packages on the floor onto the pallet or the top most packages of the bundle mounted thereon when the pallet or the top most package is adjacent the floor; and

a top pusher for exerting a top pressure on the bundle.

21. An assembly according to claim 20, wherein the platform is rotatable so as to provide for wrapping the bundle in a wrapping material from a dispenser during rotation thereof.

22. A bitumen package provided by the assembly of claim 1.

23. A method for packaging bitumen comprising:

positioning a bag at the discharge outlet of bitumen reservoir;

suctionally opening the bag;

pouring the bitumen within a bag;

sealing the bag thereby providing a package;

positioning the package on a tray;

positioning a plurality of trays with packeges thereon on a rack with shelves for curing;

curing the bitumen;

separating the packages from the trays; and

stacking the packages on a pallet.