Sorting apparatus and method utilizing a mechanical diverter

1. A sorting apparatus for separating articles in a product stream, comprising:

an endless belt conveyor configured to transport articles in a product stream which includes acceptable articles, unacceptable articles, and foreign material, and then launch the product stream into a first trajectory;

an inspection station positioned along the first trajectory of the product stream, and which inspects the product stream to identify acceptable articles, unacceptable articles and foreign matter, and further generates a plurality of routing signals based upon the inspection of the product stream;

an air ejector assembly positioned adjacent to the product stream which is travelling in the first trajectory, and which selectively produces individual pulses of air in response to at least one of the routing signals, and which are directed toward the product stream, and wherein the pulses of air forcibly engage the product stream to dislodge foreign material from the product stream and direct the foreign material into a foreign matter trajectory; and

a diverter located in spaced relation relative to the endless belt conveyor, and controlled by at least one of the routing signals, and wherein the inspection station is located therebetween the endless belt conveyor, and the diverter, and wherein the diverter has a launching block having a concave surface, and which is moveable between a retracted position, and an extended position, and wherein the diverter is located in spaced relation relative to the endless belt conveyor such that the launching block, when located in the extended position is located at a nominal angle of less than about 20 degrees from the first trajectory, and wherein acceptable articles identified in the inspection station extend their travel in the first trajectory when the launching block is located in the retracted position, and further, unacceptable products identified in the inspection station travel along the concave surface of the launching block when the launching block is in the extended position and are launched into a second trajectory.

2. A sorting apparatus as claimed in claim 1 , and wherein the launching block further comprises:

a contact surface positioned along a portion of the concave surface;

a launching surface positioned along a portion of the concave surface; and

an aperture formed in the launching block.

3. A sorting apparatus as claimed in claim 2 , and wherein the diverter further comprises:

a mounting frame;

a pivot pin cooperating with the mounting frame, and launching block, and which is further matingly received through the aperture which is formed in the launching block; and

an actuator positioned between the mounting frame, and the launching block, and which is operable to orient the diverter in the retracted position when the actuator is in a first position, and the extended position, when the actuator is in a second position.

4. A sorting apparatus as claimed in claim 3 , and wherein the nominal angle of less than about 20 degrees is selected to reduce bruising of the articles as they contact the launching block.

5. A sorting apparatus as claimed in claim 4 , and wherein the diverter is operable to launch unacceptable articles in a third trajectory by imparting an upwardly directed force to the unacceptable articles.

6. A sorting apparatus as claimed in claim 5 , and wherein the air ejector assembly is operable to expel the foreign material from the product stream and move the foreign material into a fourth trajectory.