Note: Descriptions are shown in the official language in which they were submitted.
CA 02626835 2008-04-17
STRUCTURE FORMING METHOD, APPARATUS AND PRODUCT
This invention relates to a novel continuous structure
forming method and apparatus and to a new continuous structure
produced thereby.
The present invention provides a novel method, apparatus and
structure which overcome the shortcomings of previous expedients.
In addition, the method, apparatus and structure provide features
and advantages not found in earlier technology.
The method and 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 method and
apparatus of the invention.
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The method of the invention can be modified to form a variety
of different structures with the apparatus of the invention.
Variations in physical dimensions, composition and surface
appearance, etc. can be achieved. Even with such changes, uniform
high quality can be maintained without difficulty employing the
method and apparatus of the present invention.
A novel method of the present invention for forming a
substantially continuous composite structure includes the steps
of preselecting a first liquid reactive resin forming material,
a particulate solid additive material and a porous blanket. The
additive particles are mixed with the first liquid resin forming
material substantially continuously to form a substantially
uniform mixture thereof. Substantially all of the additive
particles are encapsulated with the first liquid resin forming
material.
The porous blanket is advanced through the first liquid
resin/additive mixture. Part of the mixture is migrated through
= the blanket substantially uniformly to form a continuous resin
matrix within the blanket with the outer surfaces being adhesive.
A thin coating of a preselected second resin forming material
which substantially cures immediately upon application is applied
to the matrix/blanket. The second resin forming material is
applied over both major adhesive surfaces of the matrix/blanket.
A thin coating of a preselected substantially immediately
curing resin forming material is applied over a preselected final
surface e.g. a path, a ditch, etc. Advantageously, a coated
matrix/blanket is advanced into a ditch closely adjacent to its
coated sidewall and bottom surfaces until the coated
matrix/blanket is disposed in a preselected final configuration.
Pressure is applied to tightly affix the configured coated
matrix/blanket to the coated ditch surfaces and form a water
impervious liner in the ditch. Advantageously, liquid in the
ditch may be utilized to apply pressure against the coated
matrix/blanket to tightly affix it to the coated ditch surface.
With ditches of considerable width, iengths of the coated
matrix/blanket may be positioned across a ditch from one side to
the other, either individually or as part of a pre-formed
composite structural assembly. Preferably, continuous reinforcing
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elements are combined with a blanket in the formation of the
matrix/blanket.
Benefits and advantages of the novel method, apparatus and
composite structure 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 a side view of the structure forming apparatus
of the invention shown in Figure 1;
Figure 3 is an enlarged fragmentary side view of a
positioning module of the structure forming apparatus of the
invention shown in Figures 1 and 2;
Figure 4 is a schematic illustration of the positioning of
matrix/blankets during the structure forming method of the
invention; and
Figure 5 is a fragmentary enlarged cross sectional view of
a continuous composite structure of the invention.
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.
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The mixing portion 14 of the structure forming apparatus 11
of the invention includes an elongated mixing chamber 39
adjustably disposed adjacent 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
also includes spaced adjustable arcuate members 46,47 disposed in
a generally horizontal orientation.
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.
The positioning means extends outwardly from the supporting
portion 12. As shown in the drawings, the positioning means
preferably includes a cantilevered extendable multijointed arm
assembly 51 extending from a horizontal cross frame member.
Positioning means 50 advantageously includes a module 53
which includes elongated structure grasping means 52 translatably
movable along the cantilevered arm assembly 51 extending from the
supporting portion 12. Preferably, the elongated structure
grasping means 52 includes a pair of cooperating hinged sections
54.
Pressure applying means 56 may be disposed adjacent the arm
assembly 51. The pressure applying means advantageously includes
roller means 57 disposed within module 53 adjacent the grasping
means 52.
To form a continuous composite structure employing the method
and apparatus of the invention as shown in the drawings, a first
liquid reactive resin forming material is advanced from a
reservoir 36 through a conduit 37 into mixing chamber 39.
Simultaneously, other minor ingredients e.g. colors, catalysts,
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inhibitors, etc. from other reservoirs (not shown) advance through
conduits into the mixing chamber.
At the same time, a particulate solid additive material from
a hopper 38 enters the mixing chamber 39. The additive particles
are mixed with the first liquid resin forming material
substantially continuously, preferably in a proportion
significantly greater than that of the resin forming material.
During this mixing operation, substantially all of the additive
particles are encapsulated with the liquid resin forming material
to a preselected thickness.
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.
As the treated blanket passes through the second mixture
distributing means 44, a thin coating of a second resin forming
material which cures substantially immediately is applied to the
matrix/blanket. As shown in Figure 2, the thin coating is applied
over both major adhesive surfaces.
The coated matrix/blanket 49 then is advanced by grasping
means 52 carried by module 53 disposed on the free end of arm
assembly 51 and placed into a preselected final configuration such
as a ditch while it is flexible and has a thin cured coating of
the second resin forming material. Preferably, the lower surface
of the matrix/blanket is in contact with a firm base surface such
as packed soil or gravel which has a thin cured coating of a
preselected substantially immediately curing resin forming
material applied by nozzles 55 extending from module 53.
As the coated matrix/blanket 49 is positioned in its final
configuration, pressure is applied thereto. Advantageously, this
is accomplished with a roller 57 disposed within module 53 as it
is advanced by the cantilevered arm assembly 51. Also, as a
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matrix/blanket is positioned into a liquid filled ditch, the
pressure of the liquid will hold it against the ditch surface.
When the matrix/blanket is properly positioned in its
preselected final configuration, the arm assembly 51 and module
53 are withdrawn to receive another length of the coated
matrix/blanket. During this action, the roller 57 disposed within
module 53 is shifted to an operating position and applies pressure
to tightly affix the matrix/blanket to the ditch surface 60.
Thereafter, additional lengths of the coated matrix/blanket
49 are positioned in succession into an overlapping orientation
(Figure 4). At the same time, rock 61 can be delivered through
passages 58 and/or 59 into the ditch and distributed over the
blanket/ditch surface.
To facilitate the creation of a water-tight continuous
composite liner structure, it may be desirable in the formation
of each matrix/blanket length 62 to allow an area 63 of each
adhesive surface to remain exposed when the second immediately
curing resin forming material is applied to form the thin coating.
Preferably, the exposed adhesive area of one major surface is
disposed along an edge remote from the edge adjacent the exposed
adhesive area of the opposed major surface of the same
matrix/blanket.
As shown in Figure 4, a plurality of coated matrix/blankets
62 are interconnected by positioning a first blanket with an
25, exposed adhesive area 63 along one edge of its upper surface and
then positioning a second coated matrix/blanket 64 adjacent to the
first placed length 62 with overlapping alignment of the adjacent
exposed adhesive areas of the first and second positioned lengths.
The exposed adhesive area of the second length is tightly affixed
to the exposed adhesive area of the first positioned length.
Thereafter, additional lengths of the coated matrix/blanket
individually in succession are positioned and tightly affixed in
overlapping alignment of the adjacent adhesive areas to form a
substantially continuous composite structure having high strength
and exceptional durability. Alternatively, if desired,
matrix/blanket lengths may be pre-assembled on a shoulder of a
ditch and lowered into place as a plurality of subassemblies.
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Advantageously, pressure is applied along the overlapped
adhesive surfaces immediately upon the positioning of each
succeeding length of the coated matrix/blanket. Preferably,
rolling pressure is applied to the overlapped adhesive
surfaces.
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 66 and actuating means 67 responsive
thereto in combination with coordinating means 68 to control the
operation of the various components of apparatus 11. Preferably,
the coordinating means includes a process controller 69 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 66.
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
69. The operating information is compared with the preselected
programming parameters stored in the memory 66. If differences
are detected, instructions from the controller change the
operation of the components to restore the various operations to
the preselected processing specifications.
The reactive resin forming materials employed to produce
composite structures of the invention are selected to be capable
of reaction to form the particular resin matrix or coating desired
in the final structure. Advantageously, the materials form
thermosetting resins 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 resin forming
material in one reservoir and a catalyst, an inhibitor, each in
other reservoirs. Additional components can be premixed with one
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of the resin formers, e.g. fillers, reinforcements, colors and the
like.
The particulate solid additive material is mixed with the
first liquid reactive resin forming material substantially
continuously, 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. Particularly useful are particles formed by shredding
or grinding discarded tires. Since the particles are encapsulated
with the first resin forming material and not saturated therewith,
many different waste materials may be employed.
Suitable porous blankets include woven, knit, non-woven
structures, etc. The blankets e.g. fabrics, mats, etc. may be
formed of continuous or discontinuous fibers, yarns, slit ribbons
and similar natural and synthetic fibrous materials. Reinforcing
members such as ropes, cables and the like that extend
longitudinally and/or transversely of the blanket centerline may
be included if desired.
As shown in Figure 5, a cross section of a typical composite
structure 70 of the invention includes a thin outer coating 71 of
an instanteously cured resin over both major surfaces with the
upper exposed surface having a layer of rocks 72 scattered
thereover. Thick central sections 73,74 include a plurality of
encapsulated solid particles 75 such as sand, gravel, particles
from grinding discarded tires, etc. A continuous resin matrix 76
extends throughout each central section. Continuous reinforcing
elements 77 e.g. mesh, cables, etc. are disposed between the
central sections.
The above description and the accompanying drawings show that
the present invention provides a novel method, apparatus and
composite structure which overcome the shortcomings of previous
expedients and in addition, provide features and advantages not
found in earlier technology.
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The composite structure produced with the method and
apparatus of the invention can include major proportions of
recycled, waste or other materials which are readily available at
a job site. These structures are of high quality and may exhibit
properties not usually found in products formed with conventional
ingredients.
The method of the invention may be conducted by individuals
with only limited mechanical skills and experience to produce high
quality structures safely and efficiently. The method can be
modified to form a variety of different structures. Variations
in configuration, composition, physical dimensions and surface
appearance, etc. can be achieved easily. Even with such changes,
uniformity and high quality can be maintained without difficulty.
It will be apparent that various modifications can be made
in the particular method, apparatus and composite structure
described in detail above and shown in the drawings within the
scope of the present invention. The method steps, apparatus
components and types of materials employed can be changed to meet
specific process and structural requirements.
These and other changes can be made in the method, apparatus
and composite structure 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.
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