Apparatus and method for moving and placing granulate material Number:7,094,004 from the United States Patent and Trademark Office (PTO) owispatent

Title: Apparatus and method for moving and placing granulate material

Abstract: A method and system are disclosed for moving and placing in hard to reach locations granular and other particulate material such as sand, gravel, earth and similar materials. The system includes an improved augar for moving the material and an improved rotary airlock mechanism designed to withstand the abrasive action of the particulate material and at the same time move the material several hundred feet through a flexible conduit for placement in a pre-designated location. A system and apparatus is also disclosed for transporting on one vehicle all of the devices needed at a remote site for operation the particulate placement system, including a front loader.

Patent Number: 7,094,004 Issued on 08/22/2006 to Dunlop,   et al.

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Inventors:	Dunlop; Richard (Mission Viejo, CA), Griffin; Robert (Aliso Viejo, CA), Stokes; Stephen C. (Costa Mesa, CA), Stokes; Denis A. (Santa Ana, CA), Bonney; Gary (Corona, CA)
Assignee:	Air Pump Industries (Mission Viejo, CA)
Appl. No.:	10/340,214
Filed:	January 9, 2003

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Current U.S. Class:	406/68 ; 406/145; 406/146; 406/63
Current International Class:	B65G 53/08 (20060101)
Field of Search:	406/43,62,63,68,124,127,128,145,146,169

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References Cited [Referenced By]

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U.S. Patent Documents

	2634872		April 1953		Gosse
	2639949		May 1953		Zollars et al.
	2695816		November 1954		McClellan et al.
	2728469		December 1955		Sonntag
	3096968		July 1963		Kempthorne
	3161442		December 1964		Reed
	3350014		October 1967		Pfister
	3378309		April 1968		Copley et al.
	4154486		May 1979		Nishikawa
	5147156		September 1992		Guettler
	5150991		September 1992		Stoner et al.
	5403128		April 1995		Thomas
	5645379		July 1997		Stoner et al.
	5647696		July 1997		Sperber
	5795108		August 1998		Lightle
	5915887		June 1999		Sulman et al.
	6336774		January 2002		Dunlop et al.

Other References

Advertisement in Contractor Trader, Oct. 2001 Air Pumped Sand & Gravel of California. cited by other . Advertisement in Concerete Construction, Mar. 1996 Air Pump Increases Material-Handling Options. cited by other . Advertisement "Napalco TM 432 Mix-Elevator TM Gunite Mixer With C-7 Rotary Gunite Placement Gun". cited by other . Advertisement "Airplaco TM 432 Mix-Elevator TM". cited by other . Advertisement "Napalco TM C-10HSL Ridley TM Rotary Gunite Machine". cited by other . Advertisement "Airplaco TM C-10HSL Rotary Gun". cited by other.

Primary Examiner: Hess; Douglas
Attorney, Agent or Firm: Miller; Terry L.

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Claims

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We claim:

1. A rotary air lock pump mechanism comprising: a) a material feed bowl with a plurality of chambers, said bowl being configured for rotational movement around a central axis of said bowl and a power source to rotate said bowl about said axis; b) a collection barrel positioned over an open end of said bowl with a central axis of said barrel being congruent with said central axis of said bowl, said barrel remaining fixed while said bowl rotates about said central axis, said barrel directing flowable material deposited in an end of said barrel opposite said bowl into exposed ends of said chambers of said bowl; c) an air intake material ejection manifold that when positioned in a receiving recess on said barrel is serially presented to an open end of each chamber of said bowl as said bowl is rotated about said central axis and wherein when air is injected into an air receiving portion of said manifold it is injected into a chamber of said bowl being presented to said manifold and thereby causing flowable material deposited in said chamber to be ejected out through a material ejection portion of said manifold; d) a wear gasket positioned between a first side of a faceplate of said manifold and said bowl, said gasket facilitating smooth rotation of said bowl; e) a pressure mechanism engagedly positioned against a second side of said face plate to assure even wear of said wear gasket and to thereby maintain a suitable seal between said face plate of said manifold and said bowl; said pressure mechanism being operated by an incompressible fluid to exert an adjustable constant-pressure force against said face plate; and f) wherein as said bowl rotates flowable material is deposited through said barrel into a portion of said chambers, the ends of which are exposed in said barrel and as each chamber is serially presented to said manifold, by rotation of said bowl, the flowable material is ejected by said manifold.

2. The apparatus of claim 1 wherein said air receiving portion of said manifold includes a first conduit that connects on said second side of said face plate to a first opening through said face plate and said material ejection portion includes a second conduit that connects on said second side of said face plate to a second opening through said face plate, said second conduit including an elongate flexible conduit liner extending from adjacent said second side of said face plate to a material discharge end of said flexible conduit liner which is disposed substantially beyond a termination end of said second conduit.

3. The apparatus of claim 2 wherein each of said plurality of chambers has a first opening and a second opening and when a selected one of said plurality of chambers is serially presented to said manifold in response to rotation of said bowl said first opening of said selected chamber is aligned with said first opening of said face plate and said second opening of said selected chamber is aligned with said second opening in said face plate so that pressurized air introduced by said air intake conduit is injected into said chamber through said first opening in said chamber and material in said chamber is ejected out through said second opening into said material ejection conduit.

4. The apparatus of claim 1 wherein a deflector is located adjacent to but outside of said receiving recess of said barrel on a side of said receiving recess that said chambers move to after being presented to said manifold, said deflector covering said chambers as they pass beyond said manifold and said receiving recess to prevent blow back of any flowable material that may be left in a chamber after being presented to said manifold.

5. The apparatus of claim 4 wherein said deflector is made of a hard but flexible rubber like material.

6. The apparatus of claim 1 wherein said bowl has a wear template at its top and said wear template is that portion of said bowl that faces said barrel and wear gasket.

7. The apparatus of claim 6 wherein said wear template is metal and said bowl is made of a hard but light and durable material that is less denser than the metal making up said wear plate.

8. The apparatus of claim 7 where in said hard but light durable material is selected from a group consisting of polyurethane, polypropylene and polyethylene.

9. The apparatus of claim 7 wherein said wear template is connected to said hard but light and durable material of said bowl by an interleaving connection.

10. The apparatus of claim 9 wherein a tongue and grove type of connection forms said interleaving type of connection in which a side of said wear template that connects to said hard but light and durable material of said bowl has a projection that extends into a recess on said hard but light and durable material and wherein said projection has apertures that receive a portion of said light but hard and durable material during a fabrication process of said bowl.

11. The apparatus of claim 9 wherein said wear template is of two-part construction, including a first metal part that is integral with said hard but light and durable material of said bowl via said interleaving connection, and a second metal part substantially identical to said first metal part in plan view and removably attached thereto for rotation in unison, said second metal part making rubbing contact with said wear gasket.

12. The apparatus of claim 1 wherein said pressure mechanism includes at least two hydraulic pistons that engage said second side of said face plate of said manifold.

13. The apparatus of claim 12 wherein said hydraulic pistons are connected to a common hydraulic fluid source, which source provides equal pressure to each piston.

14. The apparatus of claim 1 wherein a reversible adjustable wear collar is positioned around the juncture of an inside edge of said barrel and said bowl, where said barrel and said bowl meet to form a seal to prevent leakage of flowable material out through said juncture of said bowl and said barrel.

15. The apparatus of claim 14 wherein said reversible adjustable wear collar is of a flexible and strong rubber like material.

16. The apparatus of claim 1 further including an air cooler receiving pressurized air from a source thereof, and cooling said pressurized air before this air is injected into said air receiving portion of said manifold.

17. The apparatus of claim 16 wherein said air cooler is sized sufficiently that air is cooled to within 10.degree. to 20.degree. of ambient air temperature.

18. The apparatus of claim 1 wherein said material ejection portion of said air intake material ejection manifold is adapted to receive a portion of a first end of a material depositing hose such that said portion of said first end of said material depositing hose forms an interior liner of said ejection portion so that said first end of said hose protects an interior surface of said material ejection portion from wear by flowable material passing through said ejection portion.

19. The apparatus of claim 18 wherein said portion of said first end of said material depositing hose forms a secure but detachable tight seal with the interior surface of said material ejection portion.

20. The apparatus of claim 19 wherein said portion of said first end of said material depositing hose positioned in said interior of said ejection portion can be removed from said ejection portion and cut from said depositing hose to thereby form a new portion of said first end of said hose which than can be inserted into said ejection portion to form a new interior liner.

21. The apparatus of claim 20 wherein said hose is a long flexible conduit used for placing flowable material ejected through said manifold and the flowable material is placed when it exits a second end portion of said hose.

22. The apparatus of claim 21 wherein said hose is at least one-hundred feet long.

23. The apparatus of claim 1 wherein air is injected into said air receiving portion by an air compressor providing pressurized air at a pressure of at least 40 PSIG.

24. The apparatus of claim 23 further including an air cooler receiving pressurized air wherein after said air leaves said compressor but before it is injected into said air-receiving portion of said manifold it is cooled.

25. The apparatus of claim 1 wherein said power source that rotates said bowl includes a hydraulic system.

26. The apparatus of claim 1 further including a hinged support assembly carrying said rotary air lock pump mechanism for controllably tilting said rotary air lock pump mechanism outwardly and away from a vertical orientation to an angulated orientation designed for ease of maintenance of said rotary air lock pump mechanism.

27. The apparatus of claim 26 wherein said hydraulic system includes a hydraulic motor directly driving said bowl at a 1:1 speed ratio.

28. The apparatus of claim 1 further including an outside wear patch located adjacent to and covering a juncture between said bowl and a lower edge of said receiving recess on said collection barrel to thereby prevent ejection of flowable material at said juncture.

29. The apparatus of claim 1 wherein the flowable material is selected from a group consisting of gravel, sands dirt, soil, mixtures thereof, or a granular material.

30. The apparatus of claim 1 wherein a first end of a long flexible conduit connects to said material ejection portion of said manifold in a sealed fashion and flowable material that enters said conduit at said first end of said conduit from said material ejection portion moves through said long flexible conduit and exits at a second end of said conduit.

31. The apparatus of claim 30 wherein said conduit is at least one-hundred feet long.

32. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; a power source to rotate said material feed bowl about said axis of rotation, said power source including a hydraulic motor directly driving said material feed bowl at a 1:1 speed ratio; a collection barrel positioned over said material feed bowl and having a substantially open upper end for directing flowable material deposited therein to said material feed bowl and into said chambers; an air intake and material ejection manifold positioned on said barrel for injecting pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold; a wear gasket positioned between a faceplate of said manifold and said bowl and facilitating rotation of said bowl while sealingly engaging about successive ones of said plural chambers; a pressure mechanism engaging against said face plate to exert an adjustable constant pressure force of said face plate and wear gasket toward said material feed bowl; whereby as said material feed bowl rotates flowable material is deposited into an upper end of said barrel and into said plural chambers, and successive ones of said plural chambers are serially presented to said manifold so that flowable material is ejected via said manifold.

33. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; a power source to rotate said material feed bowl about said axis of rotation; a collection barrel positioned over said material feed bowl and having a substantially open upper end for directing flowable material deposited therein to said material feed bowl and into said chambers; a flowable material metering auger having a discharge portion positioned above said collection barrel and a receiving portion positioned in a hopper for receiving flowable material deposited in said hopper and feeding flowable material at a selected and adjustable metered rate to said collection barrel and material feed bowl; a power source for rotating said metering auger at a selected speed, said power source including a hydraulic motor directly driving said metering auger at a 1:1 speed ratio; an air intake and material ejection manifold positioned on said barrel for injecting pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold; a wear gasket positioned between a faceplate of said manifold and said bowl and facilitating rotation of said bowl while sealingly engaging about successive ones of said plural chambers; a pressure mechanism engaging against said face plate to exert an adjustable constant pressure force of said face plate and wear gasket toward said material feed bowl; whereby as said material feed bowl rotates flowable material is deposited at a selected adjustable metered rate by said metering auger into an upper end of said barrel and into said plural chambers, and successive ones of said plural chambers are serially presented to said manifold by rotation of said bowl so that flowable material is ejected via said manifold.

34. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; a power source to rotate said material feed bowl about said axis of rotation; said power source including a hydraulic motor directly driving said bowl at a 1:1 speed ratio; a collection barrel positioned over said material feed bowl and having a substantially open upper end for directing flowable material deposited therein to said material feed bowl and into said chambers; a flowable material metering auger positioned in a hopper for receiving flowable material deposited in said hopper and feeding flowable material to said collection barrel and material feed bowl; said metering auger including a discharge portion positioned above said collection barrel and a receiving portion positioned in said hopper for receiving flowable material deposited in said hopper, said metering auger feeding flowable material at a selected and adjustable metered rate to said collection barrel and material feed bowl; a power source for rotating said metering auger at a selected speed, said power source for said metering auger including a hydraulic motor directly driving said metering auger at a 1:1 speed ratio; an agitator disposed in said hopper, said agitator including a rotational shaft and projections extending from said rotational shaft within said hopper; a power source for rotating said shaft of said agitator at a selected speed, said power source for said agitator including a hydraulic motor directly driving said shaft of said agitator at a 1:1 speed ratio; an air intake and material ejection manifold positioned on said barrel for injecting pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold; a wear gasket positioned between a faceplate of said manifold and said bowl and facilitating rotation of said bowl while sealingly engaging about successive ones of said plural chambers; a pressure mechanism engaging against said face plate to effect pressing of said face plate and wear gasket toward said material feed bowl; said pressure mechanism being operated by substantially incompressible hydraulic fluid to exert an adjustable constant-pressure force against said face plate; a source of hydraulic power; and a control panel effective with respect to said source of hydraulic power and providing centralized control of hydraulic pressure supplied to said pressure mechanism, and also providing centralized control of hydraulic fluid flow rates to: said hydraulic motor driving said material feed bowl, to said hydraulic motor driving said metering auger, and to said hydraulic motor driving said agitator.

35. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; a power source to rotate said material feed bowl about said axis of rotation; a collection barrel positioned over said material feed bowl and having a substantially open upper end for directing flowable material deposited therein to said material feed bowl and into said chambers; an air intake and material ejection manifold positioned at a recess opening on said barrel for injecting pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold; a wear gasket positioned between a faceplate of said manifold and said bowl and facilitating rotation of said bowl while sealingly engaging about successive ones of said plural chambers; a pressure mechanism engaging against said face plate to exert an adjustable constant pressure force of said face plate and wear gasket toward said material feed bowl; wherein a deflector is disposed within said bowl adjacent to said manifold and is positioned so that said chambers move under said deflector after being presented to said manifold, said deflector covering said chambers as they pass rotationally beyond said manifold in order to prevent pressurized air trapped in said chambers from blowing back any flowable material remaining in a chamber.

36. The apparatus of claim 35 wherein said deflector is made of a hard but flexible rubber like material.

37. The apparatus of claim 35 wherein said manifold includes a material ejection conduit, and said material ejection conduit is adapted to receive therein a termination portion of a material transport hose, said material ejection conduit including a first portion adjacent to said bowl and having a passage size approximately the same as an inside diameter of said material transport hose, and defining a set on said conduit leading to a second portion of inside diameter sized to slidably receive said material transport hose, and said material transport hose being engageable with said step on said conduit such that said termination portion of said material transport hose forms an interior liner of said material ejection conduit to protect said material ejection conduit from wear by flowable material passing therethrough.

38. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; a power source to rotate said material feed bowl about said axis of rotation; a collection barrel positioned over said material feed bowl and having a substantially open upper end for directing flowable material deposited therein to said material feed bowl and into said chambers; an air intake and material ejection manifold positioned at a recess opening on said barrel for injecting pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold; a wear gasket positioned between a faceplate of said manifold and said bowl and facilitating rotation of said bowl while sealingly engaging about successive ones of said plural chambers; a pressure mechanism engaging against said face plate to exert an adjustable constant pressure force of said face plate and wear gasket toward said material feed bowl; wherein an adjustable wear collar is positioned within said barrel circumferentially around a juncture of an inside surface of said barrel and at an upper surface of said bowl, whereby said wear collar forms a seal to substantially prevent leakage of flowable material out through said juncture of said bowl and said barrel.

39. The apparatus of claim 38 wherein said reversible adjustable wear collar is made of a flexible and strong rubber like material.

40. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; a power source to rotate said material feed bowl about said axis of rotation; a collection barrel positioned over said material feed bowl and having a substantially open upper end for directing flowable material deposited therein to said material feed bowl and into said chambers; an air intake and material ejection manifold positioned at a recess opening on said barrel for injecting pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold; a wear gasket positioned between a faceplate of said manifold and said bowl and facilitating rotation of said bowl while sealingly engaging about successive ones of said plural chambers; a pressure mechanism engaging against said face plate to exert an adjustable constant pressure force of said face plate and wear gasket toward said material feed bowl; further including an outside wear patch disposed on said barrel adjacent to and covering said juncture between said bowl and said barrel at said recess and circumferentially outwardly of said manifold, said outside wear patch sealingly engaging said barrel and also sealing engaging a radially outwardly disposed surface of said bowl to thereby prevent ejection of flowable material at said juncture, said wear patch including an elastomeric wearing portion and an arcuate durable metallic portion effective for pressing said elastomeric wearing portion into sealing engagement with said bowl, and said wearing portion being removably secured to said durable metallic portion via a tongue-and-groove connection cooperatively defined by said portions of said wear patch.

41. A rotary air lock pump mechanism comprising: a rotational material feed bowl with a plurality of chambers arrayed about a central axis of rotation; said material feed bowl at an upper extent including a wear template of metal, and a lower portion made of a hard but light and durable wear resistant polymer material; said wear template and said lower portion of said bowl being united into a unitary structure via an interleaving connection cooperatively defined by said wear template and said polymer material of said lower portion; whereby said material feed bowl is receivable into a collection barrel for receiving abrasive granular flowable material; said barrel carrying an air intake and material ejection manifold positioned in juxtaposition to said bowl and engageable with said wear template, said manifold providing for injection of pressurized air into a chamber of said bowl and receiving flowable material ejected out of said chamber via a material ejection portion of said manifold, and said hard but light and durable wear resistant polymer material providing improved wear resistance.

42. The apparatus of claim 41 where in said hard but light durable wear resistant polymer material is selected from a group consisting of polyurethane, polypropylene and polyethylene.

43. The apparatus of claim 41 wherein said interleaving connection is configured as a tongue and groove type of connection, in which said wear template has an axially and circumferentially extending projection defining an engagement feature, and said hard but light and durable wear resistant polymer material is cast about said projection and into engagement with said engagement feature.

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Description

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BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to the placement of granular materials and more specifically, to an Improved Apparatus and Method for Moving and Placing Granulate.

2. Description of Related Art

Sand, gravel and rock are used in a variety of applications for the construction industry. From aggregate base for concrete slabs, to back fill for retaining walls, granular materials, or granulates, are probably the most widely used substance, outside of concrete, in the construction industry. What has been a common problem has been moving the granulate from place to place when a dump truck and/or cranes and mechanical shovels do not have easy access.

Another application, namely the construction of concrete flatwork (slabs on grade and the like) typically require a 2- to 6-inch layer of sand, gravel or other granular material underneath a concrete slab. In these applications, a vapor barrier is often required in order to provide moisture protection. The material of choice for vapor barriers is typically of a size and material that is job-site-specific, and therefore delivered directly from the vendor to a location adjacent to the flatwork in progress. Since the vapor barrier and subsequent granulate installation are the final steps preceding the actual concrete pouring, they are not completed until all other mechanical, electrical lines and footing reinforcement bars have been installed. As such, heavy equipment cannot be driven over the pad (and lines and bars) because the lines and bars (and vapor barrier) would be disturbed. Because of this restriction, the granulate has heretofore been applied manually with wheelbarrows and shovels.

Furthermore, the process of concrete flatwork usually involves the installation of a perimeter forms for the slab (i.e. within which the concrete would be poured). These perimeter forms also interfere with the use of heavy equipment to load the granulate into the pad. What is needed is a device and method that permits the transfer of granulate into a concrete flatwork pad without disturbing the mechanical and electrical lines, the reinforcing bars, the vapor barrier or the perimeter forms.

A number of improvements have been made to mechanisms for the pumping sand and gravel. One such system is disclosed in U.S. Pat. No. 6,336,774, which is owned by the same entity that owns this application. That patent discloses a system that, among other things has a screw type auger that has an upward inclination and creates a constant even stream of gravel. U.S. Pat. No. 6,336,774 is hereby incorporated herein as set forth here, and at length. However, even this invention as disclosed herein has certain deficiencies.

An on going problem experienced by systems used for placing flowable material, in particular materials like sand and gravel, is the extreme wear and tear these abrasive materials cause to these systems. These abrasive materials rapidly break down and even destroy the parts of the handling systems. Additionally, even with various improvements a significant amount of inefficiencies exist in currently available systems. Leaks caused by the wear and tear of various parts of the system reduce significantly the operational characteristics of these systems. Additionally, problems still exist and significant improvements can still be made to improve the operational characteristics of these systems. Thus, it is a further object of the improved version of the present invention to achieve a significant increase in the efficiencies of the system and reduce occurrence and frequency of equipment break.

SUMMARY OF THE INVENTION

In light of the aforementioned problems associated with the prior devices and methods, it is an object of the present invention to provide an Improved Apparatus and Method for Moving and Placing Granulate. It is an object that the present invention provide a portable, self-contained apparatus capable of discharging granulate into hard-to-reach areas, as well as providing assistance in covering vast open areas with granulate in a short time. It is a further object that the device and method permit the application of granulate into areas that are normally inaccessible and would require many hours of human labor, and thereby potentially avoiding damage to the site that might be incurred if employing a prior method and device. It is a still further object that the present invention serve to provide discharge of granulate near or adjacent to retaining walls and underneath concrete flatwork.

In an aspect of the improved version of the present invention it provides A rotary air lock pump mechanism having: a) a material feed bowl with a plurality of chambers, the bowl being configured for rotational movement around a central axis of the bowl and a power source to rotate the bowl about the axis; b) a collection barrel positioned over an open end of the bowl with a central axis of the barrel being congruent with the central axis of the bowl, the barrel remaining fixed while said bowl rotates about the central axis, the barrel directing flowable material deposited into exposed ends of the chambers of the bowl; c) an air intake material ejection manifold that when positioned in a receiving recess on the barrel is serially presented to an open end of each chamber of the bowl as the bowl is rotated about the central axis and wherein when air is injected into an air receiving portion of the manifold it is injected into a chamber of the bowl being presented to the manifold and thereby causing flowable material deposited in the chamber to be ejected out through a material ejections portion of the manifold; d) a wear gasket positioned between a first side of a face plate of the manifold and the bowl, the gasket facilitating smooth rotation of the bowl; e) a pressure mechanism engagedly positioned against a second side of the face plate to assure even wear of the wear gasket and to thereby maintain a suitable seal between the face plate of the manifold and the bowl; and f) wherein as the bowl rotates flowable material is deposited through the barrel into a portion of the chambers the ends of which are exposed in the barrel and as each chamber is serially presented to the manifold, by rotation of the bowl, the flowable material is ejected by the manifold.

In yet another aspect of the present invention it provides a material handling mechanism having: a) a loading hopper with a first opening at a top end for receiving flowable material and a second opening at a bottom end for collecting and directing flowable material placed in the first opening; b) a compactor drive apparatus located below and adjacent to the second opening of the second opening of the hopper, the compactor drive apparatus forming the flowable material from the hopper into a steady and even stream; c) a rotary air lock pump mechanism for receiving the steady even stream created by the compactor drive apparatus, the rotary air lock pump mechanism having appropriate seating and wear mechanisms to facilitate operation and prevent leakage of flowable material and even wear of moving parts; and d) a long flexible conduit connected to a material ejections conduit of the rotary air lock pump mechanism to place the flowable material in a preselected location. In a further aspect of the present invention it includes a mechanism to cool pressurized air being injected into the rotary air pump.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which:

FIGS. 1A and 1B are views of each side of an improved version of the self-propelled granulate placement system of the present invention;

FIG. 1C is a schematic block diagram of one version of a power take off system for use with present invention;

FIG. 1D is a schematic diagram of another version of a power take off system for use with the present invention;

FIG. 2 is a sectional view along line IX--IX of FIGS. 1A and 1B;

FIG. 3 a view of the rear of the improved version of the self-propelled granulate placement system;

FIG. 3A is a top view of the interior of the loading hopper;

FIG. 4 schematics blow up view of the major functional components of the rotary air lock pump mechanism;

FIG. 4A is a cross sectional view of one chamber of the bowl along line 11A;

FIG. 4B is a perspective view of the portion of FIG. 4A in circle 11B;

FIG. 5 a side view of a portion of an assembled rotary air lock pump system;

FIG. 5A is front view of the exterior blow out seal pad;

FIG. 5b is a perspective view of the exterior blow out seal pad

FIG. 6 cross-sectional view of the rotary air lock system of FIG. 5 along plane VI--VI;

FIG. 6a is a close up view of the items in circle VIA of FIG. 6

FIG. 7 a top view of a portion of a rotary air lock pump system;

FIG. 7A is a perspective view of a deflector of the present invention;

FIG. 8 is rear perspective view of a system of the present invention with two rotary air lock pumps;

FIG. 9 is schematic block diagram of the system used to cool the pressurized air used to eject material from the rotary air lock mechanism; and

FIG. 10 is a frontal view of a control panel of a preferred embodiment of the present invention.

FIG. 11 is a cross-sectional view of the material ejection manifold along XI--XI in FIG. 6;

FIG. 11A is a close up view of the cross-sectional area designated XIA in FIG. 11;

FIG. 11B is a close up of the cross-sectional area of the manifold identified as XIB in FIG. 11;

FIG. 12 is another version of the entire system in a tractor-trailer arrangement;

FIG. 13 depicts the system of the present invention being used to fill sandbags and;

FIG. 14 is a view of the system adapted for sandblasting.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventors of carrying out their invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide an Improved Apparatus and Method for Moving and Placing Granulate.

FIG. 1A and FIG. 1B are views of both sides of an improved self-propelled granulate application system of the present invention. In one preferred embodiment the system is configured on a flat bed truck 121. In FIGS. 1A and 1B the truck 121 has the typical set up with it motor 123 located in the front. The unit also includes the following viewable on both sides of the truck: a tractor loader 125, air compressor 127, air cooler 128, for cooling air leaving compressor 127, control panel 129, pump hose 131 on a hydraulic driven reel 132 and loading hopper 133. Viewable on the side of truck 121 in FIG. 1A are in addition: a rotary airlock pump mechanism 135, a tractor loading bucket 137, ramp parts 139, ramp extensions 141, a power take off unit 143 for drawing power for the hydraulic systems from the truck motor and hydraulic lines that connect to the various hydraulic systems. In the embodiment of the invention disclosed herein the air compressor has its own power source; however, as will be discussed in more detail below in an alternate version the air compressor could be powered from a power take off system that uses the truck engine for power.

The tractor loader 125 is a typical small tractor loader that typically weights in the range and sized to fit on the truck as well as a loading capacity to meet the demands of the pump output. A single individual sitting in the seat of the tractor operates tractor loader 125, and in the preferred embodiment the tractor is a front loader type of tractor. When the tractor is not being used and it is on truck 121 front scoop 137 of tractor 125 is stored securely under bed 147 of truck 121. Tractor loader 125 is moved off and onto truck 121 under its own power with tilt ramp sections 139 and ramp extensions 141. FIG. 2 a cross sectional view of truck 121 along line II--II of FIGS. 1A and 1B depict the structure of the of tilt ramp sections 139, ramp sections 141 and truck bed 147A configured to allow the moving of tractor 125 on or off truck 121. The entire assembled ramp 149 is depicted in FIG. 2.

One of the problems of providing for the driving a tractor onto or driving it off of a standard truck bed is the steepness required for the ramp and/or the length required to make it feasible and safe. If the ramp is too steep it creates serious safety problems and the tractor might not have sufficient power to move up the ramp. If the ramp is to long it may make using a ramp impractical to carry or strong enough to bridge the gap. The present invention makes two modifications to make it safe and feasible to drive a tractor off and onto a standard truck bed. The first modification involves lowering by six inches that portion of the standard truck bed which will carry tractor 125 from the standard height of four feet above the ground to three and half feet. In FIGS. 1A and 1B the truck bed is divided with an upper section 147 and a lower section 147A. Naturally, the bed could be towered even more than six inches or less than six inches and this portion of the invention would still be practicable. However, in the preferred embodiment six inches appears to be best. The second modification is to start the ramp that tractor 125 will move up and down with tilt ramp section or sections 139 as part of the truck bed. As can be seen in FIG. 2 tilt ramp section 139 is formed from a portion of truck bed 147A that is beveled down. Tilt ramp section 139 starts just beyond where the wheels of tractor 125 sit when it is parked on truck bed 147A for transportation. Ramp extension or extensions 141 then can be connected to tilt ramp sections 139 to complete ramp 149. Thus, by the time tractor reaches the edge 151 of truck bed 147A it is only two feet nine inches above the ground in the embodiment depicted in FIGS. 1A and 1B.

Referring to FIG. 1A a version of the ramp is depicted in which the ramp is divided up into two sections one each for the sets of wheels on either side of tractor 125 the set on the left side 153A and the set on the right side 153B. Ramp section 139 and ramp extension 141 on the left side in FIG. 1A being used for the wheels 153A on the left side and ramp section 139 and ramp extension 141 on the right side being used for the set of wheels 153B on the right side of tractor 125. When not in use ramp the extension/extensions as the case maybe 141 can be stored under tractor 125 on the bed of the truck as depicted in FIG. 1A. As an alternative embodiment not depicted, tilt ramp section 139 could extend across the entire section of bed 147A in front of tractor 125 and ramp extension 141 could be on flat unit that connects to the entire front of the ramp section that form part of the bed of the truck if tilt ramp section 139 were to extend across the entire bed in front of the tractor as it sits on the bed of the truck.

The ramp system and lowered truck bed for carrying and moving a tractor on and off of the truck, allows the tractor to be carried on the truck. It eliminates the need for a separate trailer for carrying the tractor. The ramp system and lowered truck bed accomplish this for several reasons. It lowers the center of gravity of the weight of the tractor when being carried. It reduces the length of the ramp sections to under 8 feet. It also reduces the angle of inclination of the ramp to allow the tractor to be safely driven off or onto the truck bed under its own power.

Transporting the tractor on the truck instead of towing it on a trailer attached to the truck or transporting it to the job site on its own separate truck and trailer has a number of advantages. Among them it saves in trailer costs: licensing, tires, equipment, brakes, lights etc. It provides a fully self-contained unit that among other things reduces the number of persons necessary for operation. Additionally, it eliminates the need for extra storage space at a yard at night and storage of the trailer on the street at the job site during operation of the system.

Compressor 127 as depicted in the disclosed embodiment is a fairly standard type of compressor that is driven by its stand-alone gas or diesel powered supply. However, compressor 127 could receive power from a power take off system that works directly off of truck engine 123 or from a power take off operating off of the trucks gear system. The power transfer mechanism from the engine of the transmission could be a hydraulic based system. Compressor 127 provides the flow of compressed air used by rotary air lock pump mechanism 135. As will be discussed in detail below a flow of compressed air from compressor 127 is piped by appropriate hoses to a rotary air lock mechanism, to be described in detail below, where it is used to create the stream of flowable material that is being placed. The term flowable is used to described what in fact the system can accomplish, that is to take a basically dry or reasonably dry granulate material and turn it into a flowable stream to thus allow for depositing the granulate material in a desired and often hard to reach location. Typically, these hard to reach locations are on construction sites but any other application where such material has to be moved, and precisely placed as possible. The types of granulate material can vary from sand or gravel to topsoil or many other type of granulate materials.

The system described herein based on the improvements detailed above and below thus, can move various flowable materials varying from sand to gravel of 1/2 inch or smaller size through a hose of about two to three inches in diameter up to five hundred feet or more away from the system and up to an elevation several hundred feet or more above the system. The advantages of the system are significant and have applications in the construction industry as well as other industries that require a means to move dry bulk flowable material. Often sand, gravel or similar dry or relatively dry flowable material have to be moved to a location that may not be accessible to a dump truck, tractor or similar device used to move dry flowable material in bulk. The system can pump the dry flowable material up several stories to fill hollow steel columns to add strength to the columns. It can pump dry flowable material across water to locations normally only accessible by boat to fill in locations that may pose danger to boaters. It can be used to pump dry flowable materials on to roofs of multistory buildings that are inaccessible to most other means of moving these materials. It can be used to move dry flowable materials across methane or moisture barriers that would be damaged by trucks, tractors or other devices moving across them.

One of the significant improvements of the present invention Is the use of the trucks engine 123 to provide the power for the hydraulic systems of the present invention. This is accomplished by the addition of power take off unit 143 that connects to the trucks gear system and allows it to take power from the engine of the truck and power the hydraulic systems through lines 145. The power take off connects to the hydraulic pump that pumps hydraulic fluid to the motors that turn the hose reel, the agitator, the auger, the feed bowl and pressurizes the cylinders of the hydraulic pad adjusters. As will be discussed below In more detail the system is controlled from a control panel that sends electrical signals to a manifold of electric/hydraulic cartridge valves that release the proper amount of hydraulic fluid as the demand for the system increases or decreases. The various hydraulic systems that the power take off system provides hydraulic power to are the mechanism that rotates the rotary feed bowl (to be discussed in detail below) and hose reel 132 that is driven by a hydraulic system. The hydraulic system can also power the auger, the agitator, the hydraulic pad adjusters and the vibrator. As mentioned above and elsewhere herein while the air compressor in the embodiment described Is powered by Its own engine It can just as easily be powered by the power take off system being described herein.

FIG. 1C is a schematic block type diagram that depicts one type of power take off configuration that the present Invention could use. In the example shown the power take off provides power to the air compressor; however, it can just as easily be used to power any of the other systems of the invention. A transfer box 155 takes power from truck driveline 156, which in turn connects to the trucks transmission 157 and thereby receives power from truck engine 123. Transfer box 155 connects into the rear end of driveline 156 in a standard and well-known fashion. Transfer box 155 (also known as a split shaft power take off unit) when activated in turn transfers power from driveline l56 to the air end 158A of compressor 158. Transfer box 155 can also provide power to hydraulic pump 159. In turn hydraulic pump 159 can provide power to the various other systems such as the rotary air lock turning mechanism, the pad adjusters of the rotary air lock system, the auger, the agitator, the hose reel and any other systems needing power. Various types of power take off units could be used including those that take power off of the engine flywheel or transmission.

Consequently, the engine of the truck, provided it has sufficient horsepower, can power all of the systems of the invention at a job site. Thus, motor 123 not only is used to operate the vehicle over the highway it can be used at the job site as the power source for all of the various systems of the invention. These allows for fuel savings, noise control (the truck engine is usually much quieter than ancillary engines that would otherwise be necessary) and also results in reduction of polluting emissions into the atmosphere (the standard truck engine is designed to produce reduced emissions as compared to other stand alone engines). Additionally, it would reduce the cost of the overall system by reducing the need for one or two stand alone motors to power the system.

FIG. 1D displays another option for the power take-off drive system. The compressor 158 is either mounted on a truck bed or a trailer unit. The compressor engine 158E drives air end 158A to produce the air flow for the air pump. A hydraulic pump 160 is mounted onto the engine at a port that provides a power take-off shaft to turn the pump. The hydraulic pump 160 pumps hydraulic oil through the hydraulic lines 160L to the control panel where it is distributed to the different drive systems, the sand and gravel pumps.

FIG. 3 provides a rear view of the improved version the self-propelled granulate placement system. In FIG. 3 you can see the top of air compressor 127, a portion of hydraulic hose reel 131, rotary air pump mechanism 135 loading hopper 133 and compactor drive apparatus 161. During operation of the system to place flowable material the tractor loader with bucket will deposit the material in hopper 133 which is open at its top 133T. The material falls down through hopper 133 and into a slot like opening along the lower end 161L of compactor drives apparatus 161. FIGS. 3, 3A and 5 the description provided for these figures below describe in part how this part of the system works. Compactor drive apparatus 161 in the preferred embodiment is a screw auger 168 positioned in conduit 167. The screw auger 168 is configured to turn is a direction that moves the flowable material up, as indicated by arrow 169, to an opening at the top 161U of conduit 167. The material once it reaches this point falls into rotary air lock pump system 135. Auger 168 is rotated by hydraulic drive 168D, which receives power from the hydraulic system. Agitator 165 is rotated by hydraulic drive 165D, which receives power from the hydraulic system.

FIG. 3A is a top down view of loading hopper 133. The bottom end 133B of loading hopper 133 forms a slot like opening 163 over lower end 161L of the compactor drive apparatus. Within the slot like opening into conduit 167 a portion of auger 168 can be seen. The granulate material when it is deposited in hopper 133 it falls to the bottom of hopper 133 and in through opining 63. Auger 168 which rotates during operation of the system moves the material in the direction of arrow 169, as discussed above. The top end of slot 163 is covered with plate shroud 170 to prevent granulate material from causing, as will be discussed in detail below, an excessive build up at the top end of auger 168 and discharging prematurely into the pumping device and overloading and flooding the collection barrel. The system includes an agitator 165 with spokes 166 spaced out along shaft 165S of agitator 165. Agitator 165 turns during operation of the auger when aggregate or granulate is placed in hopper 133. As can be seen in FIG. 3A agitator 165 is designed to prevent bridging of the granulate or aggregate material deposited in hopper 133. Referring back to FIG. 3 the end of auger 168 with its drive mechanism 168D can be seen. Additionally the end of agitator 165 and its drive mechanism 165D can be seen. In the preferred embodiment both drives mechanisms receive their power from the hydraulic system in the standard manner.

FIG. 4 provides a schematic blow up view of the rotary air lock pump system and the major functional components of the rotary air lock pump system. The system consists of a material feed bowl 171, a wear pad 173, an air intake and material ejection manifold 175, a material collection barrel 177, a double piston cylinder 178, a double piston cylinder piston 179 and an adjustable hydraulic pressure gauge 181. Material feed bowl 171 has a series of chambers 183 and each chamber 183 has two openings 183A and 183B.

When assembled for operation the top edge of material feed bowl 171 is positioned partly inside the lower edge of material collection barrel 177. Wear pad 173 rests on top of material feed bowl positioned in receiving recess 177R of material collection barrel 177. Air intake and material ejection manifold sits on top of wear pad 173. Pistons 178 and on 179 in the preferred embodiment are attached to the sidewalls 177W that form receiving recess 177R of material collection barrel 177. Pistons 178 and 179 apply uniform pressure to the topside of base plate 175T of manifold 175. Application of uniform pressure to base plate promotes an even wear of wear pad 173 and prevents the development of leaks at the seal of wear pad and the top of bowl 171. In operation bowl 171 rotates in a counter clockwise direction as indicated by arrow 191 while material collection barrel 177, wear pad 173, manifold 175 and pistons 178 and 179 are held in place, in the preferred embodiment pistons 178 and 179 are driven by the systems hydraulic system, which in turn is powered by the trucks engine through the power take off unit as discussed above. Pressure in pistons 178 and 179 is controlled by adjustable hydraulic regulator 181 with pressure gauge 181a. Prior to the innovation of using pistons 178 and 179 to maintain constant pressure on manifold 175 and wear pad 173 the system operator had to make manual adjustments to the manifold 175 wear pad 173 with a clamping type system. Given the highly abrasive material the system was handling, sand, gravel, etc., wear pad 173 could easily get out of proper alignment and it would prematurely wear and leaks would develop requiring constant maintenance and replacement of wear pad 173 on a hourly basis during operation. Use of the piston arrangement to provide a system that can deliver constant and even pressure over the entire manifold 175 base plate 175T and wear pad 173 solves this problem. Wear pad 173 thus in many respects acts as a wear gasket. As noted above and discussed in detail below the air injected into the chambers 183 of the material feed bowl 171 to eject the aggregate material deposited in the chambers is cooled to at least close to ambient air temperature. Cooling the air eliminates a lot of problems with operation of the rotary air lock system and prolongs its operation without the need for maintenance.

Wear pad 173 in the preferred embodiment is made of a thick and durable rubber material that when used under constant pressure can withstand a significant amount of wear before being replaced. Side walls 177W of material collection barrel have projections that come down to a point adjacent to the sides of wear pad 173 just above bowl 171 and help hold wear pad 173 in place.

In its preferred embodiment material collection bowl is made of a polyurethane lower part 171U to reduce wear and prevent material from sticking to a hot bowl. Wear template 171T connects to lower part 171U to complete bowl 171. Wear template 171T is that portion of bowl 171 that makes contact with the rest of the system when in operation. Thus, wear template 171T during operation is constantly rubbing against the lower side of wear gasket or pad 173. Given the extensive amount of abrasion wear template experiences during operation it has been found that metal, in particularly steel is a preferred material, although other materials both metals and non metals could be used. However, one of the drawbacks of using metal for wear template 171T is the amount of heat it generates and transmits to the rest of the bowl. This has resulted in breaking the standard adhesive bond between wear template 171T and lower bowl portion 171U. Once the bond breaks down between template 171T and bowl 171U leaks of material develop at the bond area. This problem has been solved by employing an interleaving type of connection 171S (FIGS. 4A and 4B) between bowl section 171U and wear template 171T to prevent leakage developing during use. One interleaving technique is to use a tongue and groove connection as depicted in FIG. 4A which depicts a cross sectional area with wear template 171T and bowl portion 171U. As can be seen a portion 171P of wear plate 171T projects down into bowl portion 171U. FIGS. 4A and 4B show the preferred method of the present invention of connecting steel wear template 171T to urethane bowl 171U. 171P is a solid key weld to wear template 171T. 171S is a screened interleaving steel mesh welded connection that allows the molded urethane bowl to cling to and interweave around 171S. This creates a very tight bond that eliminates the problem of delamination of bowl 171U from wear template 171T if the bowl and wear template become to hot from friction. Also, as can be seen in FIG. 4 wear template 171T sits on the top edge of bowl 171 and frames openings 183A and 183B of chambers 183 of bowl 171.

FIG. 5 provides a side view of the assembled rotary air lock mechanism. Upper end 161U of compactor drive apparatus is positioned above the rotary air lock mechanism. When fully assembled collection barrel 177 surrounds the material collection bowl Collection barrel 177 sits on pivoting base plate 184. Pivoting base plate 184 connects to support member 185 of the body of truck that carries the system. The truck is described above and depicted in several of the FIGS. Pivot member 205 rigidly connects to base plate 184 but is pivotally and detachably connected by hinge assembly member 205A to support member 185. Cam 206 is pivotally and detachably connected to truck support member 186 at the pivot point by hinge assembly member 206A. Thus, when hand lever 207 is inserted in sleeve pocket 208 and pushed in a downward motion cam lever 206 pivots on 206A allowing the entire pump unit 200 to tilt on hinge assembly 205A. Thi