CA2921452C

CA2921452C - Peristaltic mixing dispenser

Info

Publication number: CA2921452C
Application number: CA2921452A
Authority: CA
Inventors: Danny Livshitz; Irina Livshitz
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-02-19
Filing date: 2016-02-19
Publication date: 2018-05-15
Anticipated expiration: 2036-02-19
Also published as: CA2921452A1

Abstract

The current invention enables dynamic mixing of mortar or stucco ingredients such as sand, binder: lime or cement, and water, by continuous preparation of small volume batches of the ingredients. The invention comprises means for controlled feeding of the ingredients to a chamber, where all the ingredients immediately and simultaneously proceed to an inlet of an improved peristaltic pump for mixing and dispensing. The pump comprises determined number of rollers or shoes per certain unit length of a flexible peristaltic hose in the pump. The inlet of the pump is coupled with the chamber in a vertical position, so that all the ingredients fall into the inlet by gravity. The invention also comprises a synchronizing unit for simultaneous feeding of the ingredients into the chamber.

Description

2 Peristaltic mixing dispenser This invention provides a form of a new mechanical device, of the type commonly called a mortar mixer, which implements a new method for mortar or stucco preparation and simultaneous dispensing.
Background of the invention Mortar and stucco, which are widely used all over the world, are made with sand as an aggregate, and the resulting mixture is relatively smooth and creamy. The second component, (or ingredient), of the mix contains lime or cement or both. Additional component may be, such as coloring agent. Mortar and stucco can be prepared by manual mixing of the ingredients, when needed in small quantities.
Existing mortar motorized mixers, contain rotating paddles inside a stationary barrel to create the mixing action. There are vertical and horizontal shaft mixers. Vertical shaft mixers have paddles mounted on a vertical shaft in the center of a vertically oriented drum. These mixers typically can mix concrete or mortar faster than horizontal-shaft mixers, and they work well with both thin mortar mixtures and coarser concrete mixtures, but size of the mixture's aggregate is limited by the manufacturer recommendation. The mixing method of existing mixers is a batch type, where one large batch of a mix is produced. Time required to produce a ready batch is a function of a batch volume required, labor availability, accessory equipment on site, climate and weather and worker skills.
Typical mixers of this type are shown, for example, in the following patents:
US 4,195,933, method of mixing mortar US 7,165,877 B2, slurry mixing apparatus US 7,784,996 B2, mortar mixing apparatus US D534, 551, mortar mixer US 5,772, 318, portable hand-help concrete and mortar mixer US 5,918,975 Mortar mixer with powered dump control US 6,030,112 slurry butcher mixer

3 A process to prepare and dispense one batch of mortar or stucco mix, (the mix), is quite bulky and time consuming. Upon arrival to a construction site, a worker needs to load sand, into a mixer, by using shovel or additional heavy equipment like a skid steer loader. After that, the worker puts bags of lime or cement into the mixer. The last step, is involved with using breathing respirator and suitable protective equipment, due to a massive cloud of lime or cement, when poured into a mixer. The worker adds water into the mixer while mixer is activated. Mixing action produces a cloud of lime or cement dust around the mixing area.
The prior art described, has several disadvantages:
1. Bulky - massive size and weight of the mixer, which might in some cases require additional lifting and transporting equipment. This makes it pricy, time consuming and bulky, for a contractor, to move the mixer from site to site. Although there are portable mixers, such as described in US 5,772,318, but it is capable of producing only limited volumes of mortar per unit time, and will not be used by those, who require bigger volume products per same unit time. There are continuous type of mixers in the industry, they usually are stationary, very bulky in their size and pricy, thus usually not used by brick or plaster professionals.
2. A requirement for additional labor and time, to execute mortar preparation actions, such as pouring sand and lime to the mixer, operating mixer and dispensing. A requirement for additional heavy equipment to load sand, such as a skid steer loader, might be needed.
3. Environmental and safety: The environmental impact, by disposing wasted mortar, which contains chemicals, such as lime. Waste of material is due to shallow control of prepared material volumes, (due to a large batch preparation method). It means, the unused material is potentially to be wasted, due to drying till next time use. In addition, some material is wasted, due to material uncontrolled splashes during mixing and dispensing, which makes it mandatory, cleaning a work site after finishing work, wasting time and money. Cleaning the mixer surfaces also produces material waste. Disposing any kind of waste has always negative impact on the environment.

4. Environmental and safety: creating a cloud of lime or cement dust (dry power of lime or cement), while mixing and pouring ingredients into the mixer, which potentially may cause health problems.

5. A batch method of preparation, makes it problematic, while working in hot and dry climate, due to fast drying of the prepared batch. The bricklayer must work fast, in order, not to let the prepared batch to dry up. This might cause waste and uncomfortable work environment.

The current invention completely eliminates the waste and the climate impact on ready mortar or stucco mix, described earlier, by precise control of produced mortar volume.
The current invention, does not comprise of any turning or moving blades, which are in contact with the mortar components, thus there is no need for cleaning any parts. The mortar components are conveyed and dispensed to the current invention. The process of mixing is completely isolated from the outside environment which eliminates the dust cloud when mixing and dispensing.
The current invention is modular and small sized, and could be used in variety of combinations with conventional conveying and feeding equipment, which makes it suitable for an easy transportation, without special lifting and transporting needs. No additional labor required for preparations, such as loading the mortar ingredients on work site. Once loaded, it is used till finished, for plurality of times.
The current invention can be pre-programmed, for several consistencies of mortar or stucco when needed, which makes it suitable for working in a range of temperatures, moisture and types of works.
The consumer price for the current invention approximately is the same as existing mid-high quality mixers of similar mortar mix production rate (volume per unit time).
The production rate of the current invention is about the same as conventional types of mixers with a difference of mortar mix flow rate per unit time in the current invention, rather than a batch per unit time, in existing mixers.
Energy consumption of the current invention is about 3 to 5 times less, then the conventional type of mixers, thus it is more friendly to the environment and cost effective. To summarize: the current invention completely isolates factors such as: a shallow control of produced mortar or stucco, labor availability, accessory equipment on site, climate, weather and worker skills.
Summary of the invention The current invention provides a new method for mortar or stucco preparation and simultaneous dispensing, and its practical application in a form of a mechanical device, of the type commonly called a mortar mixer, which is widely used in brickwork, plaster and stucco works.
The current invention addresses to a field of use, where there is a need for motorized mortar mixer to produce mortar or stucco. In the current invention, mortar components: lime, cement, sand and water are fed simultaneously by calculated feed rate into one chamber, wherein feeding process is controlled and synchronized by a programmable logic controller. Then, the mortar components immediately continue into a mixing peristaltic pump, which applies a mixing action, while forcing a small volume batch through the pump. To mix the mortar components to a homogeneous slurry, the pump is having certain improvements such as specific number of rollers or shoes per unit length.
List of drawings:
FIG.1 is showing main components, which integrate with the control system of the current invention.
FIG.2 is showing the current invention main components and the way they integrate with each other.
FIG.3 is showing a mobile example of practical use for the current invention.
Detailed description of the current invention An aggregate (sand), water and a binder (lime, cement or both), represent mortar mix components, are fed through inlets 4 and 3 to a coupling chamber 2. The coupling chamber is located in a vertical position and is built in a way that when the aggregate and binder are introduced to the coupling chamber, they are falling naturally into a component outlet 27, by gravity.
Water is supplied to the coupling chamber 2 and dispensed into the component outlet 27, through a water nozzle 5. Inlet 16 is optional inlet for an additional component such as coloring agent or additional binder component, such as cement or lime, wherein the configuration of the inlet 16 is similar to the configuration of the other inlets 3 and 4. A feeding process of the components: aggregate (sand), lime and cement, is controlled by a control system of FIG.1. The components are drawn from conventional storage containers, combined with conventional feeders 24, 25, 26, such as screw conveyors, which further dispensing their contents into the coupling chamber 2, through inlets 3, 4 and 16. Feeding rate is controlled by programmable logic controller - PLC, 22, through conventional means for automation and control, such as conveyor motor speed control, which explanation should not be extended here.
Water source is supplied to inlet 17. Valve 18 activates and deactivates water supply and is controlled by the PLC. Water flow rate is controlled by a flow controller 19 and is processed by the PLC. Water pressure is regulated by a pressure regulator 28. Water continues its way by tube 20 into the water nozzle 5.
All the mortar mix components: the aggregate (sand), water and the binder (lime, cement or both), are programmed to enter to the coupling chamber 2 simultaneously in determined proportions per same time unit. The proportions are determined by the user, through a user interface 23. The process data is displayed on a display 21.

6 A peristaltic pump, which is comprising a flexible hose 1, a roller assembly 10 with rollers 7, 8 and 9 and a rigid circular frame 13, wherein one end of the flexible hose 1, is fluidly connected to the coupling chamber 2, by the component outlet 27, in a way, it produces a vertical continuation of coupling chamber 2. The flexible hose 1 is rolled around rollers 7, 8 and 9.
The other end of the flexible hose fluidly integrates with a mortar outlet 14. Said flexible hose is pressed against rigid circular frame 13, by rollers 7, 8 and 9.
A cavity 15 of the flexible hose 1 is being filled with all the mortar mix components, unmixed. The roller assembly 10 turns using conventional motorized means, creating a peristaltic action on the hose 1 and forcing cavities 15, 11, 12 and 6, filled with the mortar mix components, towards the mortar outlet 14.
Rollers 7, 8 and 9 are dividing the hose 1, to small volume portions, creating small batches, captured in cavities 11, 12 and 6 inside the hose. The small batch starts its way as non-homogeneous composition of the mortar mix components: the aggregate (sand), the binder (lime or cement) and water, filled from the coupling chamber 2 and accumulated in cavity 15 of the hose. As the small batch is moved along the hose, forced by a peristaltic action of the rollers

7, 8 and 9 against the rigid frame 13, the mortar mix components are mixed towards a finally homogeneous mortar mix at the mortar outlet 14. The mixing action occurs, when shear forces, apply on the small batches, captured in cavities 11, 12 and 6, during the peristaltic action. Rollers 7, 8 and 9 set a volume limit of the each cavity, to estimated calculated value. The volume of contents, captured in the cavities, is small enough to homogenize completely the small batch, as it forced along the hose 1. A
number of the rollers is a key factor for full homogenizing of the mortar mix components, since it limits the volume of the small batch. The number of the rollers is at least one per a unit length wherein said unit length equals about four inner diameters of the hose for homogeneous mixing of the aggregate, the binder and water fed through the water nozzle. The current invention considers "shoes", "wipers", or "lobes" as alternatives for the rollers, since those alternatives are not changing the main concept of the current invention.
A vibratory mechanism 37 is transferring vibratory movements to the hose 1, for smoothening a movement of the mortar mix components towards and inside the hose 1.
Functional steps of the current invention can be described as following:
1. The mortar components: the aggregate (sand), the binder (lime or cement or their mix), and water, simultaneously and at controlled by the PLC flow rates, are dispensed, directly to the hose 1, through the coupling chamber 2, filling cavity 15.

2. Roller set 10, which is turned by conventional means, such as a gear motor, forces rollers 7, 8 and 9 to apply the peristaltic action on the hose 1, against the rigid circular frame 13, further advancing of the contents of cavity 15, enclosed by a pair of the rollers, along the hose.
3. Due to the limited volume, captured between pair of the rollers, the mortar mix components are mixed as they being forced through the hose, towards the mortar outlet 14.
4. A length of the hose 1, is long enough to enable the limited volume of the mortar mix components, enclosed in the hose between a pair of the rollers, to be mixed into a homogeneous slurry at the mortar outlet 14, where the process is finished. The length of the hose should not be less than about ten times of the inner diameter of the hose 1.
Fig. 3, shows an example of mobile use of the current invention, with conventional type of components, such as conveyors and dispensing hopers, all installed on a small ¨ mid size truck 29 as one integrated unit. An aggregate hopper 30, contains sand, which is conveyed to the current invention 36, using sand conveyor 34, such as screw type conveyor. Lime or cement is fed to the current invention from a storage hopper 31, through a binder conveyor 33. Water is supplied from a refillable barrel 32, through a water tube 35, or may be alternatively connected with an outside source.
The current invention 36, is installed on said truck, and starts production of ready mortar or stucco mix, upon the user request. The user is not required to load sand, lime and cement each time a new batch is required.

Claims

We claim:

1. A peristaltic mixing dispenser, comprising:
a. a coupling chamber comprising a component outlet and at least one water nozzle;
b. means for controlled water feeding for feeding water to the peristaltic mixing dispenser and controlling a water flow rate into the water nozzle;
c. means for controlled material supply for supplying an aggregate and a binder to the peristaltic mixing dispenser and controlling a feeding rate of the aggregate and the binder into said coupling chamber;
d. the coupling chamber having a structure , which structure enabling immediate gravitational falling of the aggregate and the binder into the component outlet, upon introducing the aggregate and the binder into the coupling chamber by said means for controlled material supply;
e. a peristaltic pump having a vertical inlet coupled with the component outlet for immediate and direct dispensing of the aggregate and the binder into said vertical inlet;
f. said water nozzle located inside the coupling chamber for immediate dispensing of water from said water nozzle into the vertical inlet; and g. a synchronizing unit for synchronizing said means for controlled material supply with said means for controlled water feeding, for simultaneous feeding of the aggregate, the binder and water into the coupling chamber.

2. A peristaltic mixing dispenser in accordance with claim 1, wherein the peristaltic pump further comprising a flexible hose and a number of items selected from the group consisting of rollers, shoes, wipers or lobes, for an application of a peristaltic action on said hose, wherein the number of the items is at least one per a unit length, which unit length is about four inner diameters of said flexible hose, for homogeneous mixing of the aggregate, the binder and water fed through the water nozzle.

3. A peristaltic mixing dispenser in accordance with claim 2, further comprising means for a vibratory action for creating vibrational movement of the flexible hose for smoothening a movement of the aggregate and the binder towards the component outlet and inside the flexible hose.