WO2006028442A2

WO2006028442A2 - Structure forming method and apparatus

Info

Publication number: WO2006028442A2
Application number: PCT/US2004/028435
Authority: WO
Inventors: Leroy Payne
Original assignee: Leroy Payne
Priority date: 2004-09-02
Filing date: 2004-09-02
Publication date: 2006-03-16
Also published as: WO2006028442A3

Abstract

A method of forming a continuous composite structure with a forming apparatus (11) includes the steps of predetermining relative proportions of a liquid resin forming material, a catalyst and an inhibitor based on the ambient temperature and a porous blanket (44). The predetermined proportions are recirculated independently substantially continuously and coordinated at preselected rates. This is performed with a material supply portion (13). The predetermined proportions are simultaneously withdrawn and continuously mixed with a mixing portion (14) of the apparatus (11). A pool of the mixture is formed on the blanket (44) and part of the catalyzed and inhibited resin forming material is migrated through pores of the blanket (44) substantially uniformly to form a continuous resin matrix through the blanket (44) while a leading edge (68) thereof is advanced substantially immediately into permanent contact with a preselected final substrate surface and adhered thereto.

Description

STRUCTURE FORMING METHOD AND APPARATUS

This application is a continuation-in-part of pending International application No. PCT/US02/35062, filed November 27, 2002, which in turn is a continuation-in-part of pending International application No. PCT/US02/02916, filed February 4, 2002, which in turn is a continuation-in part of pending International application No. PCT/USOl/25740, filed April 26, 2001, which in turn is a continuation-in-part of pending International application No. PCT/USOO/19248, filed July 13, 2000, which in turn is a continuation-in-part of pending International application No. PCT/US99/21675, filed September 20, 1999, now U.S. Patent No. 6,562,177, which in turn is a continuation-in-part of pending International application No. PCT/US98/23034, filed October 30, 1998, now U.S. Patent No. 6,554,935, 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, now U.S. Patent No. 6,139,663, 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 method and apparatus. The present invention provides a novel method and apparatus which overcome the shortcomings of previous expedients. In addition, the method and apparatus provide features and advantages not found in earlier technology. The method and apparatus of the invention can be modified to form a variety of structures of high quality.

A novel method of the present invention for forming a substantially continuous composite structure includes the steps of preselecting a liquid reactive resin forming material, a catalyst, an inhibitor and a porous film blanket. The ambient temperature is measured and the relative proportions of the resin forming material, the catalyst, and the inhibitor are determined based on the ambient temperature and the blanket.

A mixture of the above components is formed by recirculating independently the predetermined proportions of the resin forming material, the catalyst and the inhibitor substantially continously while coordinating the independent recirculation at preselected rates. Simultaneously, the predetermined proportion of each component is withdrawn from the independently recirculating resin forming material, catalyst and inhibitor and the withdrawn components mixed substantially continously.

A pool of the mixture is formed on the blanket while it is moving over an elongated arcuate surface disposed in a preselected orientation closely adjacent to a preselected final location. A leading edge of the mixture-treated blanket is advanced substantially immediately into permanent contact with a preselected final substrate surface. The leading edge is adhered to the final surface.

The apparatus is withdrawn and a moving blanket is deposited along a preselected path of the final surface. The moving blanket is adhered to the final surface while migrating part of the catalyzed and inhibited resin forming material through pores of the blanket substantially uniformly to form a continuous resin matrix through the blanket. A tight permanent bond is formed between the matrix/blanket and the final substrate surface.

Advantageously, a foam of the mixture is formed prior to contacting the blanket. Preferably, pressure is applied to the matrix/blanket while the exposed surface thereof is partially cured to form a permanent bond. A plurality of spaced pores advantageously are formed through the blanket before forming a pool of the mixture thereon. A liquid resin forming material may be sprayed onto an exposed surface of the matrix/blanket while adhering it to the final substrate surface. Preferably, the liquid resin forming material sprayed onto to the exposed surface is an instanteous curing material.

The mixture-treated blanket preferably is cut into predetermined lengths and a plurality of the treated blanket lengths arranged successively in a preselected overlapping relationship to form a continuous structural assembly of considerable length.

Benefits and advantages of the novel method and 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 continuous structure forming apparatus of the present invention;

Figure 2 is enlarged fragmentary side view of the mixing and matrix forming portions of the structure forming apparatus of the invention shown in Figure 1;

Figure 3 is an enlarged fragmentary side view of the positioning portion of the structure forming apparatus of the invention shown in Figure 1;

Figure 4 is a fragmentary alternate form of the positioning portion of the apparatus of the invention in use;

Figure 5 is a fragmentary side view of an alternate for the material supplying portion of the apparatus of the invention ; and

Figure 6 is a schematic illustration of a structure assembly formed with the apparatus of the invention.

As shown in the drawings, one form of novel 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, a positioning portion 16 and a control portion 17.

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 frame members 25,26,27,28 join the frame members 20-23 to provide a frame assembly 29. The supporting portion 12 advantageously includes connector means 31 as well as accessories such as electrical generators, air compressors, hydraulic pumps, etc. (not shown). Such accessories 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 32,33,34 operatively connected with the supporting portion 12. The reservoirs which advantageously are located on a separate vehicle 35 are connected independently with the mixing portion 14, preferably through conduit means 37,38.

The mixing portion 14 of the structure forming apparatus 11 of the invention includes one or more elongated mixing chambers 39 adjustably disposed on the supporting portion 12. Each delivery conduit 37 is connected with a valve assembly 41,42,43 arranged around the periphery of a mixing chamber 39. A recirculating conduit 38 extends between each valve assembly 41,42,43 back to each respective reservior 32,33,34 (Figure 2).

The matrix forming portion 14 of the apparatus 11 includes mixture distributing means 45 adjacent an outlet 40 of the mixing chamber 39 and adjustable downwardly therefrom. The mixture distributing means 45 as shown in the Figure 2 includes a pair of spaced elongated transversely disposed arcuate members 47,48 with generally horizontal lower edges adjustably oriented closer together than upper edges thereof.

The matrix forming portion 14 also may include second mixture distributing means 49 adjacent the first mixture distributing means 45. The second mixture distributing means may include a plurality of spaced spray nozzles 50 or other distributing means.

The positioning portion 16 of the structure forming apparatus of the invention includes pressure applying means 52 which is preselectably spaced from the mixture distributing means. The pressure applying means includes a platform 53 supported on inflatable carriage means 54. The carriage is operatively connected with supporting portion 12. Advantageously, the positioning portion 16 is adjustably connected with the supportimg portion preferably with a winch 55 (Figure 3). The positioning means 16 most preferably includes a drive means 56 on the platform 53 and a pivotable extendable cantilever arm member 57 together with an operator's position 58. A rotatable elongated brush assembly 59 may be supported on a free end of the cantilever arm member. Likewise_/ a pivotable bucket member 60 with a hinged lid 61 may be associated with the brush assembly (Figure 4). in the formation of a substantially continuous composite structure with the apparatus 11 of the invention as shown in the drawings, the structure forming apparatus is suspended from a second cantilever extendable arm assembly 65 extending from a 360 degree rotatable turntable on a vehicle 35 such as a tractor, truck, trailer or the like. The machinery is transferred to a job site and positioned adjacent to a previously selected starting position.

Operation of the structure forming apparatus 11 is begun by preselecting a liquid reactive resin forming material, a catalyst, an inhibitor and a porous film blanket. The ambient temperature is measured. With this information, the relative proportions of the resin forming material, catalyst and inhibitor are determined based on the ambient temperature and the construction of the blanket.

The liquid reactive resin forming material is recirculated continously from a reservior 32 through a delivery conduit 37 into valve assembly 41 adjacent mixing chamber 39 and back through return conduit 38 to its reservior. In the same way, catalyst and inhibitor each in a separate reservior 33,34 respectively, is independently recirculated through separate delivery conduits 37 into respective valve assemblies 42,43 and back through return conduits 38, each to its own reservior 33 or 34. The recircultation of the components is coordinated at preselected rates.

The predetermined proportions are withdrawn from the independently recirculating resin forming material, catalyst and inhibitor by activating valve assemblies 41,42,43 simultaneously. The withdrawn predetermined proportions are continuously mixed in chamber 39 by driven impeller 36 (Figure 2).

The mixture delivered from outlet 40 of the mixing chamber 39 passes downwardly between elongated arcuate members 47,48 into contact with a blanket or blankets 44 moving therethrough. The mixture is delivered at a rate sufficient to form a residual pool 46 between the arcuate members (Figure 2) . As the leading edge 68 of blanket 44 exits the liquid pool with the arcuate members closely adjacent to the preselected final location, the leading edge is placed into permanent contact with a preselected ditch surface 66 and adhered thereto (Figure 2). With the leading edge 68 in permanent contact with the ditch surface, the apparatus 11 suspended from the cantilever arm assembly 65 of vehicle 35 is withdrawn (Figure 1).

The blanket being delivered from the apparatus is deposited along a preselected path along the ditch surface while migrating part of the resin forming materials through the blanket substantially uniformly to form a continuous resin matrix through the blanket. A tight permanent bond between the matrix/blanket and the final substrate surface is created. Uniform tension is maintained by adjusting the relative speed of the apparatus across the ditch surface.

During this interval, pressure is applied to tightly bond the structure to the ditch surface 69. This is accomplished through the use of pressure applying means 67 which follows at a distance to allow the exposed surface of the blanket to partially cure. Blade 70 then is pivoted against roller 71 to cut the blanket into a preselected length (Figure 2).

Should debris fall into the ditch during the placement of the structure lengths, or even prior to or subsequent to placement, the debris can be removed easily by activating the brush assembly 59 on cantilever member 57 extending from platform 53 and brushing the debris into the bucket 60 for later disposal (Figure 4).

Thereafter, the apparatus 11 can be moved to a position adjacent to and slightly overlapping the blanket deposited previously. The steps of the method are repeated to deposit additional lengths of the structure individually in an overlapping relationship with the previous structure length and thereby form a continuous structural assembly of considerable length. Since each length is maintained under tension until installed into the ditch, the structural liner produced is uniform and smooth without folds or other imperfections (Figure 6).

To produce high quality continuous composite structures of the invention, it is important that all of the steps of the method be carefully coordinated by control portion 17. The control portion 17 of the structure forming apparatus 11 of the invention includes programmable memory means 72 and actuating means 73 responsive thereto in combination with coordinating means 74 to control the operation of the various components of apparatus 11. Preferably, the coordinating means includes a process controller 75 that initiates changes in the flows of materials and speeds of drives to bring variations therein back to the rates specified in the programs present in the memory 72. Advantageously, the control portion may control the lateral position of the blanket 44 with respect to a preselected path.

This coordination commonly is achieved through the transmission of information such as digital pulses from monitors and/or sensors at the control components to the process controller 75. The operating information is compared with the preselected programming parameters stored in the memory 72. If differences are detected, instructions from the controller 73 change the operation of the components to restore the various operations to the preselected processing specifications.

The reactive resin forming material employed to produce composite structures of the invention is selected to be capable of reaction to form the particular resin matrix or coating desired in the final structure. Advantageously, the material forms a thermosetting resin such as a polyurethane or polyester.

Should a polyurethane be desired, one reservoir may contain an isocyanate and another reservoir may contain a polyol. More commonly, the reservoirs may contain different partially formed materials which upon mixing interact to form the desired polyurethane. Examples of such partially formed materials include so-called "A stage" resins and "B stage" resins. Other resin forming systems may utilize a single resin forming material in one reservoir and a catalyst and an inhibitor, each in other reservoirs. Additional components can be premixed with one of the resin formers, e.g. fillers, reinforcements, colors and the like. A particulate solid additive material may be mixed with the liquid reactive resin forming material, preferably, in a proportion significantly greater than that of the resin forming material. The additive particles may be any of a wide variety of inexpensive materials readily available at a particular job site. Natural mineral particulate materials such as sand and gravel normally are available or can be produced simply by crushing rock at the site. Also, materials such as waste or recycled materials which can be shredded or ground into particles of suitable size can be utilized. Especially useful are particles formed by shredding or grinding discarded tires. Since the particles are encapsulated with resin forming material and not saturated therewith, many different waste materials may be employed.

Suitable porous film blankets may be formed of conventional materials such as polyethylene, polypropylene, polyamides, polyesters and similar film forming mateials. ϊhe desired porosity may be achieved by passing a film blanket over a roller 76 having a plurality of spaced outwardly extending spikes 7? (figure 5). "Reinforcing members such as ropes, cables, etc. extending longitudinally and/or transversely of the blanket centerline may be included if desired.

The above description and the accompanying drawings show that the present invention provides a novel method and apparatus which overcome the shortcomings of previous expedients and in addition, provide features and advantages not found in earlier technology. *-?he method and apparatus can be modified to form a variety of different structures of high quality. It will be apparent that various modifications can be made in the particular method and apparatus described in detail above and shown in the drawings within the scope of the present invention. Components and procedures employed can be changed to meet specific process and structural requirements. "ϊhese and other changes can be made in the method and apparatus 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. A method of forming a continuous composite structure including the steps of preselecting a liquid reactive resin forming material, a catalyst, an inhibitor and a porous film blanket, measuring ambient temperature, determining relative proportions of said resin forming material, said catalyst and said inhibitor based on said ambient temperature and said blanket, recirculating independently said predetermined proportions of said resin forming material, said catalyst and said inhibitor substantially continuously, coordinating said independent predetermined proportions from said independently recirculating resin forming material, catalyst and inhibitor, continuously mixing said withdrawn predetermined proportions, forming a pool of said mixture on said blanket while it is moving over an elongated arcuate surface disposed in a preselected orientation closely adjacent to a preselected final location, advancing a leading edge of said mixture-treated blanket substantially immediately into permanent contact with a preselected final surface, adhering said leading edge to said final surface, withdrawing said arcuate surface from said leading edge, depositing a moving blanket along a preselected path of said final surface, adhering said moving blanket to said final surface while migrating part of said catalyzed and inhibited resin forming material through,pores of said blanket substantially uniformly to form a continuous resin matrix through said blanket and forming a tight permanent bond between said matrix/blanket and said final surface.

2. A method of forming a continuous composite structurre according to Claim 1 including the step of forming a foam of said mixture prior to contacting said blanket.

3. A method of forming a continuous composite structure according to Claim 1 including the step of applying pressure to said matrix/blanket while the exposed surface thereof is partially cured and while the blanket is in contact with said final surface to form a tight permanent bond therebetween.

4. A method of forming a continuous composite structure according to Claim 1 including the step of forming a plurality of spaced pores through said blanket before forming a pool of said resin forming mixture on said blanket and adhering said blanket to said final surface.

5. A method of forming a continuous composite structure according to Claim 1 including the step of spraying a liquid resin forming material onto a surface of said matrix/blanket while adhering it to said final surface.

6. A method of forming a continuous composite structure according to Claim 5 wherein said liquid resin forming material is an instanteous curing material.

7. A method of forming a continuous composite structure according to Claim 1 including the step of cutting said matrix/blanket into a predetermined length as it is advanced into contact with said final surface.

8. A method of forming a continuous composite structure according to Claim 1 including the steps of successively repeating the steps of Claim 1 and arranging a plurality of matrix/blanket lengths in an overlapping relationship to form a continuous structural assembly of considerable length.

9. A method of forming a continuous composite structure according to Claim 8 including the step of arranging each successive matrix/blanket length with a preselected degree of overlap.

10. Continuous structure forming apparatus including a supporting portion_/ a material supplying portion, a mixing portion, a matrix forming portion, a positioning 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 said upstanding frame members, said supporting portion including connector means adjustably suspending said apparatus closely spaced a precise distance above a preselected final location; said material supplying portion including a plurality of reservoirs operatively associated with said supporting portion, said reservoirs being connected independently with said mixing portion, recirculating means disposed along each independent connecting means, valve means disposed along each independent connecting means adjacent said mixing portion, said valve means being interconnected to provide coordinated operation thereof; said mixing portion including an elongated mixing chamber adjustably disposed adjacent said supporting portion, a driven mixing element disposed axially within said elongated mixing chamber; said matrix forming portion including mixture distributing means extending adjustably downwardly from said mixing chamber and being disposed adjacent an outlet thereof, said mixture distributing means including at least one elongated arcuate member disposed in a generally horizontal orientaion; said positioning portion including pressure applying means preselectably spaced from said mixture distributing means, said pressure applying means including a platform supported on inflatable carriage means operatively connected with 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.

11. Continuous structure forming apparatus according to Claim 10 wherein said pressure applying meams is adjustably connected with said supporting portion by a winch.

12. Continuous structure forming apparatus according to Claim 10 wherein said pressure applying means includes a roller.

13. Continuous structure forming apparatus according to Claim 10 wherein said pressure applying means includes a hydraulic line.

14. Continuous structure forming apparatus according to Claim 10 wherein said material supplying means includes a roller with a plurality of spaced outwardly extending spikes.

15. Continuous structure forming apparatus according to Claim 10 wherein said platform includes an operator's position.

16. Continuous structure forming apparatus according to Claim 10 wherein said pressure applying means includes a pivotable extendable cantilever arm member.

17. Continuous structure forming apparatus according to Claim 16 wherein said pressure applying means includes a rotatable elongated brush assembly supported on the free end of said cantilever arm member.

18. Continuous structure forming apparatus according to Claim 10 wherein said pressure applying means includes a pivotable bucket member adjacent said brush assembly.

19. Continuous structure forming apparatus according to Claim 18 wherein said bucket member includes a hinged lid.

20. Continuous structure forming apparatus according to Claim 10 wherein said pressure applying means includes drive means mounted on said platform.