WO2001025009A1 - Structure forming apparatus and method - Google Patents

Structure forming apparatus and method Download PDF

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Publication number
WO2001025009A1
WO2001025009A1 PCT/US2000/019248 US0019248W WO0125009A1 WO 2001025009 A1 WO2001025009 A1 WO 2001025009A1 US 0019248 W US0019248 W US 0019248W WO 0125009 A1 WO0125009 A1 WO 0125009A1
Authority
WO
WIPO (PCT)
Prior art keywords
forming apparatus
supporting portion
frame assembly
continuous structure
structure forming
Prior art date
Application number
PCT/US2000/019248
Other languages
French (fr)
Inventor
Leroy Payne
Original Assignee
Leroy Payne
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to PCT/US1999/021675 priority Critical patent/WO2000026478A1/en
Application filed by Leroy Payne filed Critical Leroy Payne
Priority to AU60998/00A priority patent/AU6099800A/en
Priority to CA002386996A priority patent/CA2386996C/en
Priority to CA002626835A priority patent/CA2626835A1/en
Priority to PCT/US2000/025535 priority patent/WO2001021398A1/en
Priority to AU73842/00A priority patent/AU7384200A/en
Priority to CA002385011A priority patent/CA2385011C/en
Publication of WO2001025009A1 publication Critical patent/WO2001025009A1/en
Priority to PCT/US2001/025740 priority patent/WO2004007198A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B3/00—Engineering works in connection with control or use of streams, rivers, coasts, or other marine sites; Sealings or joints for engineering works in general
    • E02B3/04—Structures or apparatus for, or methods of, protecting banks, coasts, or harbours
    • E02B3/12—Revetment of banks, dams, watercourses, or the like, e.g. the sea-floor
    • E02B3/121—Devices for applying linings on banks or the water bottom
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02B—HYDRAULIC ENGINEERING
    • E02B5/00—Artificial water canals, e.g. irrigation canals
    • E02B5/02—Making or lining canals
    • E—FIXED CONSTRUCTIONS
    • E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
    • E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
    • E02D17/00—Excavations; Bordering of excavations; Making embankments
    • E02D17/02—Foundation pits
    • E02D17/04—Bordering surfacing or stiffening the sides of foundation pits

Definitions

  • Patent No. 5,725,716 which in turn is a continuation-in-part of U.S. application Serial No. 239,540, filed May 9, 1994, now U.S.
  • Patent No. 5,496,434 which in turn is a continuation-in-part of
  • This invention relates to a novel continuous structure forming apparatus and method.
  • the present invention provides a novel apparatus and method which overcomes the shortcomings of previous expedients.
  • the apparatus and method provide features and advantages not found in earlier technology.
  • FIG. 1 is a view in perspective of one form of mobile continuous structure forming apparatus of the present invention
  • Figure 2 is an enlarged side view of the structure forming apparatus of the invention shown in Figure 1;
  • FIGS 3, 4 and 5 are schematic illustrations of the structure forming apparatus of the invention during succeeding steps in the operation thereof;
  • Figure 6 is a fragmentary view of a turntable assembly of the structure forming apparatus of the invention.
  • Figure 7 is a fragmentary cross-sectional view of the turntable assembly shown in Figure 6 taken along line 7 - 7 thereof.
  • one form of novel mobile continuous structure forming apparatus 11 of the present invention includes a supporting portion 12, a material supplying portion 13, a mixing portion 14, a matrix forming portion 15 and a control portion 16.
  • the supporting portion 12 of the structure forming apparatus of the invention includes a plurality of spaced upstanding frame members 20,21,22,23.
  • a plurality of generally horizontally disposed frame members 25,26,27,28 join adjacent upper ends of the upstanding frame members, and horizontal frame members 30,31,32,33 join lower ends thereof.
  • the material supplying portion 13 of the apparatus 11 includes a plurality of reservoirs 36 operatively connected with the supporting portion 12.
  • the reservoirs are connected independently with the mixing portion 14, preferably through flexible conduit means 37.
  • the material supplying portion also may include hoppers 38 adjacent the mixing portion.
  • the mixing portion 14 of the structure forming apparatus 11 of the invention includes an elongated mixing chamber 39 adjustably disposed on the supporting portion 12.
  • the matrix forming portion 15 of the apparatus 11 includes first mixture distributing means 40 adjacent an outlet 41 of the mixing chamber 39 and adjustable downwardly therefrom.
  • the first mixture distributing means 40 as shown in the drawings includes a pair of spaced elongated transversely disposed arcuate members 42,43 with generally horizontal lower edges adjustably oriented closer together than upper edges thereof.
  • the matrix forming portion also includes second mixture distributing means 44 adjacent the first mixture distributing means 40.
  • the second mixture distributing means advantageously is disposed in a generally horizontal orientation.
  • the second mixture distributing means includes a tubular member 45 with a narrow slot 46 along its length disposed generally transversely of the movement of a blanket 34 through the apparatus 11.
  • the second mixture distributing means may include an orifice 47 mounted on a reciprocating cutter mechanism 48.
  • Positioning means 50 is disposed adjacent the second mixture distributing means 44 for placement of a structure 49 in a preselected final configuration while the structure is flexible and adhesive.
  • the positioning means extends outwardly from the supporting portion 12.
  • the positioning means includes a cantilevered frame assembly 51 extending from horizontal cross frame member 31 in a generally horizontal orientation.
  • the frame assembly 51 is movable from a generally horizontal structure positioning orientation to a storage position.
  • the positioning means 50 also includes frame assembly lifting means
  • the arm member 53 also has a free end 54 that is selectively engageable with the frame assembly 51 along the length thereof. As shown in Figure 1, the free end from the side of the frame assembly.
  • the frame assembly lifting means 52 includes drive means 55 operatively connected with the arm member 53 adjacent frame assembly 51.
  • the drive means 55 lifts the connected end 56 of the frame assembly over an upper cross frame member 26 of the supporting portion 12.
  • the drive means 55 is mounted on the supporting portion remote from the frame assembly 51.
  • the drive means 55 may be a hand crank 57 or an electric, hydraulic or air motor (not shown).
  • the drive means 55 as shown preferably includes endless flexible connecting means such as chain 58 and sprocket/ roller means 59 along the length of the chain.
  • a pair of lifting means 52 may be utilized with one lifting means along each side of the supporting portion 12.
  • the operation of the two lifting means is coordinated such as with a jack shaft 60.
  • Positioning means 50 advantageously includes elongated structure grasping means 62 translatably movable along the cantilevered frame assembly 51 extending from the supporting portion 12.
  • the elongated structure grasping means 62 translatably movable along the cantilevered frame assembly 51 extending from the supporting portion 12.
  • the elongated structure grasping means 62 translatably movable along the cantilevered frame assembly 51 extending from the supporting portion 12.
  • the elongated structure grasping means 62 advantageously includes a pair of cooperating hinged sections 64.
  • the travel of the grasping means 62 preferably is coordinated to equalize the tension across a structure 49 being placed into a preselected final configuration.
  • the positioning means 50 also may include pressure applying means 66.
  • the pressure applying means advantageously includes roller means 67 which as shown may be disposed along one edge of the cantilevered frame assembly 51.
  • the pressure applying means 66 includes spaced roller assemblies independently movable in a generally vertical plane.
  • the pressure applying means 66 advantageously are disposed above the coated matrix/blanket 61 being advanced along the frame assembly 51.
  • the operation of the pressure applying means preferably is coordinated with the travel of the elongated structure grasping means 62.
  • the supporting portion 12 of the mobile continuous structure forming apparatus 11 advantageuously includes a rotatable turntable assembly 70.
  • the turntable assembly includes an upper deck portion 71 and a lower base plate portion 72 spaced therefrom. Rotation between the two portions advantageously is achieved with a plurality of roller bearing members 73 arranged radially in a circular pattern 74 ( Figure 6).
  • the turntable assembly 70 includes two offset circular bearing patterns 74 and 75 as shown in Figure 7.
  • An intermediate horizontal guide section 76 is disposed between the upper and lower bearing patterns.
  • the turntable assembly also includes automatic orienting and locking means 77.
  • the structure forming apparatus 11 includes outer shell sections 78 selectively hung from the apparatus to enclose the apparatus during storage and to control wind, temperature, other weather conditions, etc. during operation.
  • the outer shell sections preferably include quick access openings 79.
  • drive means 55 is activated advancing endless chain 58 around sprocket/rollers 59 in a clockwise direction thereby pivoting the arm member 53 toward the front of the apparatus 11.
  • the supporting portion 12 is rotated on turntable assembly 70 to precisely orient the cantilevered frame assembly with respect to the ditch being lined.
  • Operation of the structure forming apparatus 11 is begun by preselecting a liquid reactive resin forming material, a catalyst, an inhibitor, particulate solid additive material and a porous blanket.
  • the ambient temperature is measured. From this information, the relative proportions of the resin forming material, catalyst and inhibitor are determined based on the ambient temperature and the constuction of the porous blanket.
  • the liquid reactive resin forming material is advanced from a reservoir 36 through a conduit 37 into mixing chamber 39.
  • other ingredients e.g. particulate solid additive materials, catalysts, inhibitors, etc. from other reservoirs (not shown) advance through conduits into the mixing chamber.
  • substantially all of the additive particles are encapsulated with the catalyzed and inhibited resin forming materia
  • the resulting mixture being delivered from outlet 41 of the mixing chamber 39 passes downwardly between arcuate members 42,43 into contact with a porous blanket or blankets 34 moving therethrough.
  • the mixture is delivered at a rate sufficient to form a residual pool 35 between the arcuate members.
  • the matrix/blanket structure 49 is coated with a second mixture at second distributing means 44 and then advanced by grasping means 62 along the length of frame assembly 51.
  • the resulting structure 61 is placed into a preselected final configuration such as a path or ditch liner while it is flexible and has an adhesive outer surface.
  • the adhesive lower surface is placed in contact with a firm base surface such as concrete or packed soil or gravel.
  • this is accomplished with a plurality of rollers 67 spaced along one edge of the cantilevered frame assembly 51.
  • the rollers 67 are located above the matrix/blanket being advanced along the frame assembly.
  • each of the independently movable rollers 67 is moved downwardly to engage the edge of the matrix/blanket and push the unsupported center of the blanket against the sidewalls and bottom of the ditch. Additional lengths of the coated matrix/blanket are individually positioned in succession into an overlapping orientation with each length tightly affixed to each previously positioned length to form a substantially continuous composite structure with high strength and exceptional durability.
  • control portion 16 of the structure forming apparatus 11 of the invention includes programmable memory means 85 and actuating means 86 responsive thereto in combination with coordinating means 87 to control the operation of the various components of apparatus 11.
  • the coordinating means includes a process controller 88 that initiates changes in the flows of materials and speeds of drives to bring variations therein back to the rates specified by programs present in the memory 85.
  • This coordination commonly is achieved through the transmission of information such as digital pulses from monitors and/or sensors at the control components (not shown) to the process controller 88. The operating information is compared with the preselected programming parameters stored in the memory 85.
  • instructions from the controller change the operation of the components to restore the various operations to the preselected processing specifications.
  • Normal maneuvering of the continuous structure forming apparatus of the invention to maintain it close to a preselected path ordinarily can be accomplished by advancing the truck or trailer on which the forming apparatus 11 is located along the edge of the ditch or path being covered. If obstacles such as bridges, trees, head gates, etc. are encountered, minor changes in the placement of the composite structure can be achieved by utilizing the turntable assembly 70.
  • Major changes of direction may be accomplished by returning the frame assembly 51 into its storage position on top of the supporting portion 12 and shifting the position of the trailer or truck on which the apparatus 11 is mounted.
  • the steps of moving the frame assembly 51 from its working position to its storage position are in the reverse order to the steps described in detail above for initiating the operation of the apparatus.
  • the pressure applying means 66 is pivoted to a stored position along the supporting portion 12.
  • the tension in cable 84 is eased so the free end 80 of the frame assembly rests on the ground.
  • the cable and crane are stored and drive means 55 extends arm member 53 so the free end 54 thereof is connected with rod member 65 located along the side of the frame assembly 51.
  • chain 58 is advanced in a counterclockwise direction by drive means 55 which pivots the arm member in the same direction which pulls the connected end 56 of the frame assembly over upper cross frame member 26 and advances it toward the rear of the apparatus.
  • drive means 55 which pivots the arm member in the same direction which pulls the connected end 56 of the frame assembly over upper cross frame member 26 and advances it toward the rear of the apparatus.
  • Continuing movement of chain 58 raises the frame assembly into a generally horizontal orientation on top of the apparatus, its normal storage position. In this orientation, the apparatus on the truck or trailer can be moved as a normal load to a new location and the frame assembly repositioned to resume operation of the structure forming apparatus of the invention.
  • the apparatus of the invention may be operated by individuals with only limited mechanical skills and experience to produce high quality structures safely and efficiently.
  • the apparatus and method can be modified to form a variety of different structures.

Abstract

Mobile continuous structure forming apparatus (11) includes a supporting portion (12) including a plurality of spaced upstanding frame members (20, 21, 22, 23), a plurality of horizontal frame members (25, 26, 27, 28) adjacent upper and lower ends of the upstanding frame members (20, 21, 22, 23), a distributor (40) includes a positioner (50) for placement of a structure in a final configuration including a horizontal frame assembly (51) extending from the supporting portion and movable from a structure positioning position to a storage position. A lifting assembly (52) mounted on the supporting portion includes an extendable arm member (53) pivotally connected along the length of a horizontal lower frame member of the supporting portion. A drive (55) is operatively connected with the arm member (53) adjacent the frame assembly lifting the connected end of the frame assembly over an upper cross frame member (31) of the supporting portion.

Description

STRUCTURE FORMING APPARATUS AND METHOD
This application is a continuation-in-part of pending International application No. PCT/US99/21675, filed September 30,
1999, which in turn is a continuation-in-part of pending
International application No. PCT/US98/23034, filed October 30,
1998, which in turn is a continuation-in-part of pending
International application No. PCT/US96/15499, filed September 26, 1996, which in turn is a continuation-in-part of pending
International application No. PCT/US96/05132, filed May 20, 1996, which in turn is a continuation-in-part of International application No. PCT/US95/05450, filed May 4, 1995, now U.S.
Patent No. 5,725,716, which in turn is a continuation-in-part of U.S. application Serial No. 239,540, filed May 9, 1994, now U.S.
Patent No. 5,496,434, which in turn is a continuation-in-part of
U.S. application Serial No. 870,927, filed April 20, 1992, now
U.S. Patent No. 5,330,603, which in turn is a continuation-in-part of U.S. application Serial No. 753,344, filed August 30, 1991, now U.S. Patent No. 5,145,282, which in turn is a continuation-in-part of U.S. application Serial No. 521,442, filed May 10, 1990, now
U.S. Patent No. 5,049,006, which in turn is a continuation-in-part of U.S. application Serial No. 417,501, filed October 5, 1989, now
U.S. Patent No. 4,955,760, which in turn is a continuation-in-part of U.S. application Serial No. 235,205, filed August 23, 1988, now
U.S. Patent No. 4,872,784.
This invention relates to a novel continuous structure forming apparatus and method.
The present invention provides a novel apparatus and method which overcomes the shortcomings of previous expedients. In addition, the apparatus and method provide features and advantages not found in earlier technology.
The apparatus of the present invention may be employed by individuals with only limited mechanical skills and experience. Structures can be produced by such individuals safely and efficiently without supervision utilizing the apparatus of the invention. The apparatus and method of the invention can be modified to form a variety of different structures. Benefits and advantages of the novel apparatus of the present invention will be apparent from the following description of the accompanying drawings in which: Figure 1 is a view in perspective of one form of mobile continuous structure forming apparatus of the present invention;
Figure 2 is an enlarged side view of the structure forming apparatus of the invention shown in Figure 1;
Figures 3, 4 and 5 are schematic illustrations of the structure forming apparatus of the invention during succeeding steps in the operation thereof;
Figure 6 is a fragmentary view of a turntable assembly of the structure forming apparatus of the invention; and
Figure 7 is a fragmentary cross-sectional view of the turntable assembly shown in Figure 6 taken along line 7 - 7 thereof.
As shown in the drawings, one form of novel mobile continuous structure forming apparatus 11 of the present invention includes a supporting portion 12, a material supplying portion 13, a mixing portion 14, a matrix forming portion 15 and a control portion 16.
The supporting portion 12 of the structure forming apparatus of the invention includes a plurality of spaced upstanding frame members 20,21,22,23. A plurality of generally horizontally disposed frame members 25,26,27,28 join adjacent upper ends of the upstanding frame members, and horizontal frame members 30,31,32,33 join lower ends thereof.
Components of the material supplying portion 13, as well as other components such as an operator's seat 29 or electrical generators, air compressors, hydraulic pumps and the like (not shown) also can be mounted on and/or suspended from the frame members.
The material supplying portion 13 of the apparatus 11 includes a plurality of reservoirs 36 operatively connected with the supporting portion 12. The reservoirs are connected independently with the mixing portion 14, preferably through flexible conduit means 37. The material supplying portion also may include hoppers 38 adjacent the mixing portion. The mixing portion 14 of the structure forming apparatus 11 of the invention includes an elongated mixing chamber 39 adjustably disposed on the supporting portion 12. The matrix forming portion 15 of the apparatus 11 includes first mixture distributing means 40 adjacent an outlet 41 of the mixing chamber 39 and adjustable downwardly therefrom. The first mixture distributing means 40 as shown in the drawings includes a pair of spaced elongated transversely disposed arcuate members 42,43 with generally horizontal lower edges adjustably oriented closer together than upper edges thereof.
The matrix forming portion also includes second mixture distributing means 44 adjacent the first mixture distributing means 40. The second mixture distributing means advantageously is disposed in a generally horizontal orientation. Preferably, the second mixture distributing means includes a tubular member 45 with a narrow slot 46 along its length disposed generally transversely of the movement of a blanket 34 through the apparatus 11. Alternatively, the second mixture distributing means may include an orifice 47 mounted on a reciprocating cutter mechanism 48.
Positioning means 50 is disposed adjacent the second mixture distributing means 44 for placement of a structure 49 in a preselected final configuration while the structure is flexible and adhesive. The positioning means extends outwardly from the supporting portion 12. As shown in the drawings, the positioning means includes a cantilevered frame assembly 51 extending from horizontal cross frame member 31 in a generally horizontal orientation. The frame assembly 51 is movable from a generally horizontal structure positioning orientation to a storage position. The positioning means 50 also includes frame assembly lifting means
52 mounted on the supporting portion 12 including an extendable rm member 53 that is pivotaUy connected along the length of lower horizontal frame member 30. The arm member 53 also has a free end 54 that is selectively engageable with the frame assembly 51 along the length thereof. As shown in Figure 1, the free end from the side of the frame assembly.
The frame assembly lifting means 52 includes drive means 55 operatively connected with the arm member 53 adjacent frame assembly 51. The drive means 55 lifts the connected end 56 of the frame assembly over an upper cross frame member 26 of the supporting portion 12. Advantageously, the drive means 55 is mounted on the supporting portion remote from the frame assembly 51. The drive means 55 may be a hand crank 57 or an electric, hydraulic or air motor (not shown).
The drive means 55 as shown preferably includes endless flexible connecting means such as chain 58 and sprocket/ roller means 59 along the length of the chain. Advantageously, a pair of lifting means 52 may be utilized with one lifting means along each side of the supporting portion 12. Preferably, the operation of the two lifting means is coordinated such as with a jack shaft 60.
Positioning means 50 advantageously includes elongated structure grasping means 62 translatably movable along the cantilevered frame assembly 51 extending from the supporting portion 12. Preferably, the elongated structure grasping means
62 extends between and travels along spaced parallel side rails
63 of the frame assembly 51. The elongated structure grasping means 62 advantageously includes a pair of cooperating hinged sections 64. The travel of the grasping means 62 preferably is coordinated to equalize the tension across a structure 49 being placed into a preselected final configuration. The positioning means 50 also may include pressure applying means 66. The pressure applying means advantageously includes roller means 67 which as shown may be disposed along one edge of the cantilevered frame assembly 51. Preferably, the pressure applying means 66 includes spaced roller assemblies independently movable in a generally vertical plane.
The pressure applying means 66 advantageously are disposed above the coated matrix/blanket 61 being advanced along the frame assembly 51. The operation of the pressure applying means preferably is coordinated with the travel of the elongated structure grasping means 62.
The supporting portion 12 of the mobile continuous structure forming apparatus 11 advantageuously includes a rotatable turntable assembly 70. Preferably, the turntable assembly includes an upper deck portion 71 and a lower base plate portion 72 spaced therefrom. Rotation between the two portions advantageously is achieved with a plurality of roller bearing members 73 arranged radially in a circular pattern 74 (Figure 6).
Most preferably, the turntable assembly 70 includes two offset circular bearing patterns 74 and 75 as shown in Figure 7.
An intermediate horizontal guide section 76 is disposed between the upper and lower bearing patterns. The turntable assembly also includes automatic orienting and locking means 77.
Advantageously, the structure forming apparatus 11 includes outer shell sections 78 selectively hung from the apparatus to enclose the apparatus during storage and to control wind, temperature, other weather conditions, etc. during operation. The outer shell sections preferably include quick access openings 79.
In the operation of the mobile continuous composite structure forming apparatus 11 of the invention as shown in the drawings, the apparatus disposed on a trailer or truck bed 10 is transferred to a job site and positioned therealong. At this point, frame assembly 51 of positioning means 50 is in a tied-down storage position along the top of supporting portion 12 as shown in Figure 3.
After freeing the frame assembly 51, drive means 55 is activated advancing endless chain 58 around sprocket/rollers 59 in a clockwise direction thereby pivoting the arm member 53 toward the front of the apparatus 11.
This movement of the the arm member causes the frame assembly 51 attached thereto to pivot about upper cross frame member 26 (Figure 4) so that the free end 80 of the frame assembly moves downwardly until it contacts the ground (Figure 5). As the arm member pivots downwardly into a generally horizontal orientation, the trailing end 56 of the frame assembly moves downwardly and engages yoke members 82 adjacent lower cross member 31 (Figure 2). The free end 54 of the extendable arm member which has been in engagement with rod 65 extending from the frame assembly then withdraws therefrom. A crane 83 which has been folded horizontally for storage is raised so a cable 84 wound thereon can be be extended for connection adjacent to the free end 80 of the frame assembly 51 to support it in an operating position. The pressure applying means 66 then is pivoted into place along the edge of frame assembly 51.
At this point, the supporting portion 12 is rotated on turntable assembly 70 to precisely orient the cantilevered frame assembly with respect to the ditch being lined.
Operation of the structure forming apparatus 11 is begun by preselecting a liquid reactive resin forming material, a catalyst, an inhibitor, particulate solid additive material and a porous blanket. The ambient temperature is measured. From this information, the relative proportions of the resin forming material, catalyst and inhibitor are determined based on the ambient temperature and the constuction of the porous blanket.
With the relative proportions determined, the liquid reactive resin forming material is advanced from a reservoir 36 through a conduit 37 into mixing chamber 39. Simultaneously, other ingredients e.g. particulate solid additive materials, catalysts, inhibitors, etc. from other reservoirs (not shown) advance through conduits into the mixing chamber. During this continuous mixing operation, substantially all of the additive particles are encapsulated with the catalyzed and inhibited resin forming materia The resulting mixture being delivered from outlet 41 of the mixing chamber 39 passes downwardly between arcuate members 42,43 into contact with a porous blanket or blankets 34 moving therethrough. The mixture is delivered at a rate sufficient to form a residual pool 35 between the arcuate members. As the blanket exits the liquid pool, part of the mixture migrates through the blanket substantially uniformly to form a continuous resin matrix within the blanket with the outer surfaces being adhesive. The matrix/blanket structure 49 is coated with a second mixture at second distributing means 44 and then advanced by grasping means 62 along the length of frame assembly 51. The resulting structure 61 is placed into a preselected final configuration such as a path or ditch liner while it is flexible and has an adhesive outer surface. Preferably, the adhesive lower surface is placed in contact with a firm base surface such as concrete or packed soil or gravel. As each length of the coated matrix/blanket structure 61 is positioned to partially overlap the previously positioned length, pressure may be applied to the overlapped area. Advantageously, this is accomplished with a plurality of rollers 67 spaced along one edge of the cantilevered frame assembly 51. During the operation of the grasping means 62, the rollers 67 are located above the matrix/blanket being advanced along the frame assembly.
When the matrix/blanket 61 is properly positioned in its preselected final configuration such as over a ditch, each of the independently movable rollers 67 is moved downwardly to engage the edge of the matrix/blanket and push the unsupported center of the blanket against the sidewalls and bottom of the ditch. Additional lengths of the coated matrix/blanket are individually positioned in succession into an overlapping orientation with each length tightly affixed to each previously positioned length to form a substantially continuous composite structure with high strength and exceptional durability.
To produce high quality continuous composite structures of the invention, it is important that all of the steps be carefully coordinated by control portion 16. The control portion 16 of the structure forming apparatus 11 of the invention includes programmable memory means 85 and actuating means 86 responsive thereto in combination with coordinating means 87 to control the operation of the various components of apparatus 11. Preferably, the coordinating means includes a process controller 88 that initiates changes in the flows of materials and speeds of drives to bring variations therein back to the rates specified by programs present in the memory 85. This coordination commonly is achieved through the transmission of information such as digital pulses from monitors and/or sensors at the control components (not shown) to the process controller 88. The operating information is compared with the preselected programming parameters stored in the memory 85. If differences are detected, instructions from the controller change the operation of the components to restore the various operations to the preselected processing specifications. Normal maneuvering of the continuous structure forming apparatus of the invention to maintain it close to a preselected path ordinarily can be accomplished by advancing the truck or trailer on which the forming apparatus 11 is located along the edge of the ditch or path being covered. If obstacles such as bridges, trees, head gates, etc. are encountered, minor changes in the placement of the composite structure can be achieved by utilizing the turntable assembly 70.
Major changes of direction may be accomplished by returning the frame assembly 51 into its storage position on top of the supporting portion 12 and shifting the position of the trailer or truck on which the apparatus 11 is mounted. The steps of moving the frame assembly 51 from its working position to its storage position are in the reverse order to the steps described in detail above for initiating the operation of the apparatus. The pressure applying means 66 is pivoted to a stored position along the supporting portion 12. The tension in cable 84 is eased so the free end 80 of the frame assembly rests on the ground. The cable and crane are stored and drive means 55 extends arm member 53 so the free end 54 thereof is connected with rod member 65 located along the side of the frame assembly 51.
Then, the chain 58 is advanced in a counterclockwise direction by drive means 55 which pivots the arm member in the same direction which pulls the connected end 56 of the frame assembly over upper cross frame member 26 and advances it toward the rear of the apparatus. Continuing movement of chain 58 raises the frame assembly into a generally horizontal orientation on top of the apparatus, its normal storage position. In this orientation, the apparatus on the truck or trailer can be moved as a normal load to a new location and the frame assembly repositioned to resume operation of the structure forming apparatus of the invention.
The above description and the accompanying drawings show that the present invention provides a novel apparatus which overcomes the shortcomings of previous expedients and in addition, provides features and advantages not found in earlier technology.
The apparatus of the invention may be operated by individuals with only limited mechanical skills and experience to produce high quality structures safely and efficiently. The apparatus and method can be modified to form a variety of different structures.
It will be apparent that various modifications can be made in the particular apparatus and method described in detail above and shown in the drawings within the scope of the present invention. Components employed in the apparatus and method can be changed to meet specific process and structural requirements.
These and other changes can be made in the apparatus and method of the invention provided the functioning and operation thereof are not adversely affected. Therefore, the scope of the present invention is to be limited only by the following claims.

Claims

1. Mobile continuous structure forming apparatus including a supporting portion, a material supplying portion, a mixing portion, a matrix forming portion and a control portion; said supporting portion including a plurality of spaced upstanding frame members, a plurality of generally horizontally disposed frame members joining adjacent upper and lower ends of said upstanding frame members; said material supplying portion including a plurality of reservoirs operatively connected with said supporting portion, said reservoirs being connected independently with said mixing portion; said mixing portion including an elongated mixing chamber adjustably disposed adjacent said supporting portion; said matrix forming portion including first mixture distributing means extending adjustably downwardly from said mixing chamber and being disposed adjacent an outlet thereof, second mixture distributing means disposed adjacent said first mixture distributing means, positioning means disposed adjacent said second mixture distributing means for placement of a structure in a preselected final configuration, said positioning means including a generally horizontally disposed frame assembly extending from said supporting portion, said frame assembly being movable from a structure positioning position to a storage position, frame assembly lifting means mounted on said supporting portion, said lifting means including an extendable arm member pivotaUy connected along the length of a generally horizontal lower frame member of said supporting portion, said arm member having a free end selectively engageable along the length of said frame assembly, and drive means operatively connected with said arm member adjacent said frame assembly lifting said connected end of said frame assembly over an upper cross frame member of said supporting portion; said control portion including programmable memory means, coordinating means, sensing means, actuating means, and circuitry transmitting signals from said sensing means to said coordinating means for comparison with said memory means and activation of said actuating means to form and place a continuous structure into a preselected final configuration while it is flexible and adhesive.
2. Mobile continuous structure forming apparatus according to Claim 1 wherein said drive means is mounted on said supporting portion remote from said frame assembly.
3. Mobile continuous structure forming apparatus according to Claim 1 wherein said drive means includes endless flexible connecting means, roller means disposed along the length of said endless connecting means, and actuating means activating said drive means drawing said frame assembly over a horizontal cross fame member and adjacent to said drive means and thereby raising said frame assembly into a generally horizontal orientation above said supporting portion.
4. Mobile continuous structure forming apparatus according to Claim 1 including a pair of lifting assemblies wherein one lifting assembly is disposed along each side of said supporting portion and operable in a coordinated relationship.
5. Mobile continuous structure forming apparatus according to Claim 1 wherein said positioning means includes elongated structure grasping means translatably movable along said frame assembly.
6. Mobile continuous structure forming apparatus according to Claim 5 wherein said elongated structure grasping means extends between and travels along spaced parallel side rails of said frame assembly.
7. Mobile continuous structure forming apparatus according to Claim 5 wherein said elongated structure grasping means includes a pair of cooperating hinged sections.
8. Mobile continuous structure forming apparatus according to Claim 5 including control means coordinating the travel of said elongated structure grasping means to equalize the tension across a structure being advanced along a preselected path.
9. Mobile continuous structure forming apparatus according to Claim 1 wherein said positioning means includes pressure applying means.
10. Mobile continuous structure forming apparatus according to Claim 9 wherein said pressure applying means is disposed along one edge said frame assembly.
11. Mobile continuous structure forming apparatus according to Claim 9 wherein said pressure applying means includes spaced roller means independently movable in a vertical plane.
12. Mobile continuous structure forming apparatus according to Claim 11 wherein at least one of said roller means includes reversible driven roller means.
13. Mobile continuous structure forming apparatus according to Claim 9 including control means coordinating the operation of said pressure applying means with the travel of said elongated structure grasping means.
14. Mobile continuous structure forming apparatus according to Claim 1 wherein said supporting portion includes a rotatable turntable assembly.
15. Mobile continuous structure forming apparatus according to Claim 14 wherein said turntable assembly includes a deck portion and a base plate portion spaced therefrom with a plurality of roller bearing members therebetween arranged radially in a circular pattern.
16. Mobile continuous structure forming apparatus according to Claim 15 wherein said turntable assembly includes two offset circular bearing patterns with a horizontally disposed guide section therebetween.
17. Mobile continuous structure forming apparatus according to Claim 14 wherein said turntable assOembly includes automatic orienting and locking means.
18. Mobile continuous structure forming apparatus according to Claim 1 includes outer shell sections selectively hung from said apparatus.
19. Mobile continuous structure forming apparatus according to Claim 18 wherein said outer shell sections include quick access openings .
20. A method of forming a continuous composite structure including the steps of preselecting a liquid reactive resin forming material, a catalyst, an inhibitor, a particulate solid additive material and a porous blanket, measuring ambient temperature, determining relative proportions of said resin forming material, said catalyst and said inhibitor based on said ambient temperature and said porous blanket, mixing said additive particles with said predetermined proportions of said resin forming material, said catalyst and said inhibitor substantially continuously, encapsulating substantially all of said additive particles with said catalyzed and inhibited resin forming material to a preselected thickness, forming a pool of said catalyzed and inhibited resin forming material on said blanket while it is moving over an elongated arcuate surface disposed in a preselected orientation, advancing said resin-treated blanket while migrating part of said catalyzed and inhibited resin forming material through said blanket substantially uniformly prior to gelling of said catalyzed and inhibited resin forming material to form a continuous resin matrix within said structure, grasping a leading edge of said structure along substantiallly its entire width, advancing said leading edge away from said arcuate surface along a preselected path, cutting said structure into a preselected length, placing said preselected structure length into a final configuration while said length is flexible and adhesive.
PCT/US2000/019248 1998-10-30 2000-07-13 Structure forming apparatus and method WO2001025009A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
PCT/US1999/021675 WO2000026478A1 (en) 1998-10-30 1999-09-20 Structure forming method, apparatus and product
AU60998/00A AU6099800A (en) 1999-09-20 2000-07-13 Structure forming apparatus and method
CA002386996A CA2386996C (en) 1999-09-20 2000-07-13 Structure forming apparatus and method
CA002626835A CA2626835A1 (en) 1999-09-20 2000-09-18 Structure forming method, apparatus and product
PCT/US2000/025535 WO2001021398A1 (en) 1999-09-20 2000-09-18 Structure forming method, apparatus and product
AU73842/00A AU7384200A (en) 1999-09-20 2000-09-18 Structure forming method, apparatus and product
CA002385011A CA2385011C (en) 1999-09-20 2000-09-18 Structure forming method, apparatus and product
PCT/US2001/025740 WO2004007198A1 (en) 2000-07-13 2001-08-13 Structure forming method and apparatus

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PCT/US1999/021675 WO2000026478A1 (en) 1998-10-30 1999-09-20 Structure forming method, apparatus and product
USPCT/US99/21675 1999-09-20

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WO2001025009A1 true WO2001025009A1 (en) 2001-04-12

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PCT/US1999/021675 WO2000026478A1 (en) 1988-08-23 1999-09-20 Structure forming method, apparatus and product
PCT/US2000/019248 WO2001025009A1 (en) 1998-10-30 2000-07-13 Structure forming apparatus and method
PCT/US2000/025535 WO2001021398A1 (en) 1999-09-20 2000-09-18 Structure forming method, apparatus and product

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AU (3) AU6394099A (en)
CA (5) CA2629316A1 (en)
WO (3) WO2000026478A1 (en)

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CA2348497A1 (en) 2000-05-11
CA2386996A1 (en) 2001-04-12
CA2629316A1 (en) 2000-05-11
AU6099800A (en) 2001-05-10
WO2001021398A1 (en) 2001-03-29
EP1147263A1 (en) 2001-10-24
CA2385011A1 (en) 2001-03-29
AU7384200A (en) 2001-04-24
CA2386996C (en) 2008-12-30
WO2000026478A1 (en) 2000-05-11
CA2626835A1 (en) 2001-03-29
AU6394099A (en) 2000-05-22
CA2348497C (en) 2008-11-25
CA2385011C (en) 2008-07-08

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