WO2004007198A1 - Structure forming method and apparatus - Google Patents
Structure forming method and apparatus Download PDFInfo
- Publication number
- WO2004007198A1 WO2004007198A1 PCT/US2001/025740 US0125740W WO2004007198A1 WO 2004007198 A1 WO2004007198 A1 WO 2004007198A1 US 0125740 W US0125740 W US 0125740W WO 2004007198 A1 WO2004007198 A1 WO 2004007198A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- continuous
- length
- forming
- preselected
- forming apparatus
- Prior art date
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
Definitions
- the present invention provides a novel method and apparatus which overcome the shortcomings of previous expedients.
- the method and apparatus provide features and advantages not found in earlier technology.
- 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, a particulate solid additive material and a porous 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 porous blanket.
- the additive particles are mixed with the predetermined proportions of the resin forming material, the catalyst and the inhibitor substantially continuously. Substantially all of the additive particles are encapsulated with the catalyzed and inhibited resin forming material to a preselected thickness.
- a pool of the mixture is formed on the blanket while it is moving over an elongated arcuate surface disposed in a preselected orientation.
- the mixture-treated blanket is advanced while migrating part of the catalyzed and inhibited resin forming material through the blanket substantially uniformly prior to gelling of the material to form a continuous resin matrix within the blanket.
- a leading edge of the matrix/blanket is grasped along substantiallly its entire width and advanced away from the arcuate surface along a preselected path. Opposite edges of a preselected length of the matrix/blanket structure are grasped and a preselected tension created in the structure length.
- the tension is maintained while the structure length is transferred to a final location.
- the structure length is deposited on a final surface while the length is flexible and adhesive. Pressure is applied to form a tight bond therebetween.
- the tension is maintained while the structure length is placed into contact with the final surface.
- the length of the structure is aligned into a preselected position before grasping opposite edges thereof.
- the structure length is lowered into a preselected position prior to grasping the opposite edges thereof.
- transverse edges of the structure length are grasped.
- the tensioned structure lengths may be transferred to a remote final location.
- a plurality of tensioned structure lengths are transferred sequentially to a common final location and deposited successively in an overlapping relationship to form a continuous structural assembly of considerable length.
- a plurality of structure lengths may be transferred successively to a plurality of spaced final locations arranged in a preselected pattern to form a plurality of spaced continuous structural assemblies arranged in a preselected pattern.
- Figure 1 is a view in perspective of one form of continuous structure forming apparatus of the present invention
- Figure 2 is a reduced side view of the structure transferring assenbly of the structure forming apparatus of the invention shown in Figure 1;
- FIG 3 is an enlarged fragmentary side view of the structure forming apparatus of the invention shown in Figure 1;
- Figure 4 is a fragmentary cross sectional view of the structure tensioning portion of the structure forming apparatus of the invention shown in Figure 1;
- Figure 5 is a greatly enlarged fragmentary side view of a tensioning rod member of the structure tensioning portion of the structure forming apparatus shown in Figure 4;
- Figure 6 is a greatly enlarged fragmentary side view of the structure transferring assembly shown in Figure 2 in use.
- 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 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 apparat ⁇ s 11 includes mixture distributing means 40 adjacent an outlet 41 of the mixing chamber 39 and adjustable downwardly therefrom.
- the 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 15 also may include 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 spaced arcuate members 46,47 disposed similarly to arcuate members 42,43.
- a reciprocating cutter mechanism 48 is mounted on the supporting portion subsequent to the second mixture distributing means.
- the positioning portion 16 of the structure forming apparatus of the invention includes a generally horizontally disposed frame section 50 extending outwardly from supporting portion 12 adjacent the matrix forming portion 15.
- Positioning portion 16 includes elongated structure grasping means 51 translatably movable along the frame section 50.
- the elongated structure grasping means 51 extends between and travels along spaced parallel side rails 52 of the frame section.
- the elongated structure grasping means 51 preferably includes a pair of cooperating hinged sections 53.
- the 11 of the invention also includes a structure transferring assembly 55 that is alignable with the frame section 50.
- the structure transferring assembly advantageously includes wheeled carriages 56, preferably with drive means 57.
- the positioning portion 16 further includes structure tensioning means 60.
- the tensioning means advantageously includes an open peripheral section 61.
- the peripheral section includes rod members 62,63 along opposite sides 64,65 thereof, A plurality of spaced pins 66,67 extend outwardly from each of the rod members 62,63 respectively, along the length of each rod member.
- Actuating means 70,71 selectively engage the pins 66,67 with a structure length 72 adjacent opposite edges 73,74 thereof. Also, the means 70,71 change the spacing between the pins 66 of rod member 62 and the pins 67 of rod member 63. As shown in Figure 5, spacing between the respective pins can be changed by rotating one or both rod members about their respective axes. This rotation creates a preselected tension in the structure length.
- the positioning means 50 also may include pressure applying means 76.
- the pressure applying means advantageously includes a pressure roller 77 which as shown in Figure 2 may be disposed on the free end 78 of an extendable arm member 79 that is mounted on the structure transferring assembly 55.
- the apparatus 11 includes outer shell sections 80 selectively hung from the apparatus to enclose the apparatus during storage. Also, the shell sections help to control wind, temperature, other weather conditions, etc. during operation.
- the apparatus disposed on a trailer or truck bed 10 is transferred to a job site and positioned adjacent thereto.
- 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.
- the relative proportions of the resin forming material, catalyst and inhibitor are determined based on the ambient temperature and the construction of the porous blanket.
- the liquid reactive resin forming material is advanced from reservoir 36 through conduit 37 into mixing chamber 39. Simultaneously, other ingredients e.g. particulate solid additive materials, colors, catalysts, inhibitors, etc. from other reservoirs (not shown) are advanced continuously through conduits into the mixing chamber 39. During this continuous mixing operation, substantially all of the additive particles are encapsulated with the catalyzed and inhibited resin forming material.
- 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.
- 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 then is advanced by grasping means 51 along the length of frame section 50.
- the resulting structure then is cut into preselected lengths 72 and individually permitted to settle onto a structure transferring assembly 55 aligned with the frame section.
- Rod members 62,63 are rotated slightly to move pins 66,67 extending therefrom into engagement with opposite edges 73,74 of the structure length 72. Thereafter, rotation of rod members 62,63 by actuating means 70,71 is continued to increase the spacing between the pins 66,67 of the respective rod members. This creates tension in the structure to a preselected level within peripheral section 61.
- the transferring assembly 55 supporting the peripheral section with the tensioned structural length 72 is advanced to a preselected final location e.g. a ditch 82.
- a preselected final location e.g. a ditch 82.
- the forward end 64 of the peripheral section 61 holding the tensioned structure length is lowered into contact with the remote bank 83 of a ditch.
- the transferring assembly 55 with the peripheral section thereon is withdrawn to place the full length of the structure into contact with the ditch bottom 84 and near bank 85.
- Uniform tension is maintained by adjusting the orientation of the rod members 62 and/or 63 as the transferring assembly is being withdrawn. Simultaneously therewith, roller 77 applies pressure to tightly bond the structure to the ditch surface 82.
- the structural lengths may be transferred individually in succession to a plurality of spaced final locations.
- a plurality of transferring assemblies 55 may be utilized.
- the structure transferring assembly 55 may take a variety of forms depending upon the particular job and its site as well as the machinery available. For example, a platform transferable with a forklift mechanism, a wheeled carriage with or without power, and the like may be utilized.
- a tractor with a forklift and/or backhoe attachment that can carry the tensioned structure to the final location.
- Other attachments can be incorporated on the machine e.g. cleaning brushes, patching mechanisms, etc, so that an operator can perform other duties on the return trip to the structure forming apparatus 11.
- control portion 17 of the structure forming apparatus 11 of the invention includes programmable memory means 88 and actuating means 89 responsive thereto in combination with coordinating means 90 to control the operation of the various components of apparatus 11.
- the coordinating means includes a process controller 91 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 88.
- 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 91.
- the operating information is compared with the preselected programming parameters stored in the memory 88. If differences are detected, instructions from the controller 91 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.
- the materials form thermosetting resins such as a polyurethane or polyester.
- one reservoir may contain an isocyanate and another reservoir may contain a polyol.
- 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.
- resin forming systems may utilize a 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.
- the particulate solid additive material is mixed with the 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 sand and gravel normally are available or can be produced simply by crushing rock at the site.
- 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 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.
- the method and 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
Description
Claims
Priority Applications (8)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/483,549 US20040200570A1 (en) | 2001-08-13 | 2001-08-13 | Structure forming method and apparatus |
AU2001288282A AU2001288282A1 (en) | 2001-08-13 | 2001-08-13 | Structure forming method and apparatus |
CA002457749A CA2457749A1 (en) | 2001-08-13 | 2001-08-13 | Structure forming method and apparatus |
PCT/US2002/002916 WO2002087879A1 (en) | 2001-04-26 | 2002-02-04 | Structure forming method and apparatus |
CA002443063A CA2443063A1 (en) | 2001-04-26 | 2002-02-04 | Structure forming method and apparatus |
PCT/US2002/012896 WO2002087878A1 (en) | 2001-04-26 | 2002-04-24 | Structure forming method and apparatus |
CA002442746A CA2442746A1 (en) | 2001-04-26 | 2002-04-24 | Structure forming method and apparatus |
US10/475,863 US20040129376A1 (en) | 2001-08-13 | 2002-04-24 | Structure forming method and apparatus |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2000/019248 WO2001025009A1 (en) | 1999-09-20 | 2000-07-13 | Structure forming apparatus and method |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2004007198A1 true WO2004007198A1 (en) | 2004-01-22 |
Family
ID=30442167
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2001/025740 WO2004007198A1 (en) | 2000-07-13 | 2001-08-13 | Structure forming method and apparatus |
Country Status (1)
Country | Link |
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WO (1) | WO2004007198A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104843169A (en) * | 2014-02-18 | 2015-08-19 | 波音公司 | Composite filler |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4758291A (en) * | 1984-06-14 | 1988-07-19 | Haw Harzer Apparatewerke Kg, Schwemann & Althoff | Method and apparatus for automatically applying lining material to large-area wall surfaces |
WO1996034743A1 (en) * | 1995-05-04 | 1996-11-07 | Leroy Payne | Structure forming method and apparatus |
WO1997038858A1 (en) * | 1996-04-15 | 1997-10-23 | Leroy Payne | Structure forming method, apparatus and product |
-
2001
- 2001-08-13 WO PCT/US2001/025740 patent/WO2004007198A1/en active Application Filing
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4758291A (en) * | 1984-06-14 | 1988-07-19 | Haw Harzer Apparatewerke Kg, Schwemann & Althoff | Method and apparatus for automatically applying lining material to large-area wall surfaces |
WO1996034743A1 (en) * | 1995-05-04 | 1996-11-07 | Leroy Payne | Structure forming method and apparatus |
WO1997038858A1 (en) * | 1996-04-15 | 1997-10-23 | Leroy Payne | Structure forming method, apparatus and product |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN104843169A (en) * | 2014-02-18 | 2015-08-19 | 波音公司 | Composite filler |
CN104843169B (en) * | 2014-02-18 | 2019-06-25 | 波音公司 | Composite material filler |
US10661495B2 (en) | 2014-02-18 | 2020-05-26 | The Boeing Company | Composite filler |
US11247383B2 (en) | 2014-02-18 | 2022-02-15 | The Boeing Company | Composite filler |
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