Concrete fiber injector
09963318 ยท 2018-05-08
Inventors
Cpc classification
E04G2021/049
FIXED CONSTRUCTIONS
B28C7/16
PERFORMING OPERATIONS; TRANSPORTING
B28C5/40
PERFORMING OPERATIONS; TRANSPORTING
B65H43/06
PERFORMING OPERATIONS; TRANSPORTING
E04C5/076
FIXED CONSTRUCTIONS
International classification
B28C5/40
PERFORMING OPERATIONS; TRANSPORTING
E04C5/07
FIXED CONSTRUCTIONS
Abstract
A fiber injector (8) has a fixed attachment (10) rigidly secured to the end of a material delivery boom. The fixed attachment (10) has a control handle (20) for controlling the location of the boom and distribution of fibers (62) into the material flowing through the boom. A rotary attachment (30) is rotatably secured to the fixed attachment (10) and is selectively rotated by an electric motor (12). A fiber distribution ring (40) is removably secured to the rotary attachment (30) and has a number of box holders (50) for receiving fiber boxes (60). The fiber boxes (60) contain the fiber (62) being injected into a material flow stream. A fiber brake (24) is mounted for selectively moving to cover fiber delivery apertures (52) in the fiber distribution ring (40) to selectively stop injection of the fiber (62) into the material flow stream.
Claims
1. A fiber injector for passing fiber into a material flow stream passing through a flow conductor, the fiber injector comprising: a fixed attachment rigidly secured to said flow conductor; a rotary attachment rotatably secured to said fixed attachment, with a motor powered to rotate the rotary attachment relative to said fixed attachment; a fiber distribution ring secured to said rotary attachment, wherein said fiber distribution ring has a number of fiber box holders for securing fiber boxes to said fiber distribution ring; said fiber distribution ring further having a plurality of fiber delivery apertures aligned with said fiber box holders for passing fibers from said fiber boxes through said fiber distribution ring and into the material flow stream passing through the flow conductor; and a plurality of said fiber boxes which contain said fibers for passing into the material flow stream, said fiber boxes being disposed in respective ones of said fiber box holders and aligned therewith for passing said fiber into said fiber delivery apertures.
2. The fiber injector according to claim 1, further comprising: a fiber brake mounted to said fixed attachment for selectively moving between said material flow stream and said fiber distribution ring to cover said fiber delivery apertures and preventing said fibers from passing through said fiber delivery apertures and into said material flow stream.
3. The fiber injector according to claim 1, wherein said fiber distribution ring is removably secured to said fixed attachment, attaching and detaching thereto, providing for loading additional fiber distribution rings during a material delivery.
4. The fiber injector according to claim 1, further comprising a control handle secured to said fixed attachment for a user to manually locate an end of said flow conductor to control the location of the flow of the material flow from the flow conductor.
5. The fiber injector according to claim 1, further comprising a lock positioner having three detent positions, and a control handle having a handle lock set which engages with said lock positioner in respective ones of said three detent positions, wherein: in a first position said rotary attachment and said fiber distribution ring are stationary and not rotating relative to said fixed attachment, and said fiber is stationary within said fiber boxes and is not passing through said fiber delivery apertures and into the material flow stream, in said second position said rotary attachment and said fiber distribution ring are stationary and not rotating relative to said fixed attachment, and said fiber is passing through said fiber delivery apertures and into the material flow stream, and in said third position said rotary attachment and said fiber distribution ring are rotating relative to said fixed attachment, and said fiber is passing through said fiber delivery apertures and into the material flow stream.
6. The fiber injector according to claim 5, further comprising said control handle secured to said fixed attachment for a user to manually locate an end of the flow conductor to control the location where the material flow exits the flow conductor.
7. The fiber injector according to claim 6, wherein said fibers are included into said material flow stream in various three dimensional relationships, controlled manually by said control handle and said handle lock set in relation to said three detent positions of said lock positioner, selectively passing said fibers into said material flow stream through sequentially selecting rotary action and non-rotary action of said rotary attachment and said fiber distribution ring.
8. The fiber injector according to claim 1, further comprising a feed tab for easily threading said fibers through said fiber delivery apertures.
9. The fiber injector according to claim 1, further comprising a frangible electrical conductor connected to an inward terminal end of one of said fibers for detecting when said inward terminal end is removed from a respective one of said fiber boxes.
10. A fiber injector for passing fiber into a flow of concrete passing through a flow conductor, the fiber injector comprising: a fixed attachment rigidly secured to said flow conductor; a rotary attachment rotatably secured to said fixed attachment, with a motor powered to rotate the rotary attachment relative to said fixed attachment; a fiber distribution ring secured to said rotary attachment, wherein said fiber distribution ring has a number of fiber box holders for securing fiber boxes to said fiber distribution ring; said fiber distribution ring further having a plurality of fiber delivery apertures aligned with said fiber box holders for passing fibers from said fiber boxes through said fiber distribution ring and into the material flow stream passing through the flow conductor; a plurality of said fiber boxes which contain said fibers for passing into the concrete flow, said fiber boxes being disposed in respective ones of said fiber box holders and aligned therewith for passing said fiber into said fiber delivery apertures; a fiber brake mounted to said fixed attachment for selectively moving between said material flow stream and said fiber distribution ring to cover said fiber delivery apertures and preventing said fibers from passing through said fiber delivery apertures and into said material flow stream; and wherein said fiber distribution ring is removably secured to said fixed attachment, attaching and detaching thereto, providing for loading additional fiber distribution rings during a concrete delivery.
11. The fiber injector according to claim 10, further comprising a control handle secured to said fixed attachment for a user to manually locate an end of the flow conductor to control the location of the flow of the concrete flow from the flow conductor.
12. The fiber injector according to claim 10, further comprising a lock positioner having three detent positions, and a control handle having a handle lock set which engages with said lock positioner in respective ones of said three detent positions, wherein: in a first position said rotary attachment and said fiber distribution ring are stationary and not rotating relative to said fixed attachment, and said fiber is stationary within said fiber boxes and not passing through said fiber delivery apertures and into the concrete flow; in said second position said rotary attachment and said fiber distribution ring are stationary and are not rotating relative to said fixed attachment, and said fiber is passing through said fiber delivery apertures and into the concrete flow, and in said third position said rotary attachment and said fiber distribution ring are rotating relative to said fixed attachment, and said fiber is passing through said fiber delivery apertures and into the concrete flow.
13. The fiber injector according to claim 12, further comprising said control handle secured to said fixed attachment for a user to manually locate an end of the flow conductor to control the location where the concrete flow exits the flow conductor.
14. The fiber injector according to claim 13, wherein said fibers are included into the concrete flow in various three dimensional relationships, controlled manually by said control handle and said handle lock set in relation to said three detent positions of said lock positioner, selectively passing said fibers into said concrete flow through sequentially selecting rotary action and non-rotary action of said rotary attachment and said fiber distribution ring.
15. The fiber injector according to claim 10, further comprising a feed tab for easily threading said fibers through said fiber delivery apertures.
16. The fiber injector according to claim 10, further comprising a frangible electrical conductor connected to an inward terminal end of one of said fibers for detecting when said inward terminal end is removed from a respective one of said fiber boxes.
Description
DESCRIPTION OF THE DRAWINGS
(1) For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which
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DETAILED DESCRIPTION OF THE INVENTION
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(12) The fiber injector 8 has a longitudinal axis 9 and a fixed attachment 10 which is concentrically disposed with the longitudinal axis 9. The fixed attachment 10 is annular shaped and has an upper end 17 and a lower end 19. A fiber brake 24 is a cylindrical sleeve which is slidably mounted to a lower end of the fixed attachment 10. The fiber brake 24 is concentrically disposed around the longitudinal axis 9 and has a cylindrical shaped body 27, a lower terminal end defining a lower rim 29 and an annular-shaped stop 25 which protrudes outward from an upper end of the cylindrical shaped body 27. Two mounting pins 82 extend outward from the stop 25 on opposite sides of the fiber brake 24. A plurality of stanchion windows 74 are formed through the cylindrical shaped body 27 for passing stanchions 13. The stanchions 13 have needle bearings 15 and are fixedly mounted to the lower end 19 of the fixed attachment 10 after the fiber brake 24 is aligned in position for permanently mounting to the fixed attachment 10.
(13) A rotary attachment 30 is ring-shaped and rotatably mounted to the lower end 19 of the fixed attachment 10 concentric with the longitudinal axis 9. The rotary attachment 30 extends around an upper end of the fiber brake 24. The rotary attachment 30 is defined by a gear drive ring 32 having two gear ring halves 76 and 78 which are removably secured together with fasteners 38. The gear ring halves 76 and 78 each have exteriorly protruding gear teeth 80 to together define a cylindrical gear rack for engaging with the pinion gear 18. Two interiorly disposed protrusions extend from an inner surface of the gear drive ring 32 to define a bearing race 36 for fitting around the needle bearings 15, rotatably securing the rotary attachment 30 to the lower end 19 of the fixed attachment 10. The rotary attachment 30 is mounted around the stanchions 13 and needle bearings 15 after the fiber brake sleeve 24 and its attendant brake actuator rod 26 are slid into position on the fixed attachment 10. Fasteners 38 allow the two halves 76 and 78 of the rotary attachment to be fastened around fixed attachment 10 supporting the part via the bearing race 36 which encases the bearing stanchions 13.
(14) A fiber distribution ring 40 is annular shaped and has a cylindrical upper end 45 and a tapered lower end 47 which are concentrically disposed with the longitudinal axis 9. The cylindrical upper end of the ring 40 is mounted to the rotary attachment 30 for rotating therewith about the fixed attachment 10 and the fiber brake 24. The lower end 47 is tapered at a taper angle 49 to the vertical. (Shown in
(15) A control handle 20 is preferably U-shaped and has two terminal ends which are pivotally mounted to a lower portion of the upper end 17 of the fixed attachment 10 by means of two pivot pins 28. The control handle 20 includes two mounting pins 21 which extend from opposite sides, offset from the two terminal ends, and are aligned for pivotally connecting respective ones of two brake actuator rods 26 which pivotally connect to the two mounting pins 82 protruding laterally outward and to the side of the stop 25 of the fiber brake 24. The brake actuator rods 26 provide links pivotally connecting from the two pins 21 to the two mounting pins 82 extending outward from the annular shaped stop 25 of the upper terminal end of the fiber brake 24.
(16) A handle lock set 22 is slidably mounted to the control handle 20 and includes an elongate grip bar 86 which fits into an interior portion of the hand grip portion of the control handle 20. A lock pin 84 extends from a central portion of the grip bar 86 and has a terminal end to which an insert tab 88 is mounted. The insert tab 88 engages a lock positioner 23 which is mounted to a lower end of the upper portion 17 of the fixed attachment 10. The lock positioner 23 has three indentations formed into one side for providing detents 94, 96 and 98 for engaging with the insert tab 88 of the lock pin 84 to selectively position the control handle 20 in three selected positions rotated about the pins 28 and relative to the fixed attachment 10. Each of the detents 94, 96 and 98 are configured in cooperative relation with the control handle 20 and the brake actuator rods 26 to selectively position the fiber brake 24 in the three respective positions shown in
(17) A switch 16 is preferably provided by a proximity switch which detects when the control handle 20 is angularly moved about the pin 28 to be disposed in the upper angular position shown in
(18) A control console 41 is provided on the upper end 17 of the fixed attachment 10. The control console 41 includes a control device 46 which designates how many fiber boxes should be loaded and active, thereby controlling density of material added to the material flow stream, and which is controlled by a control knob 46. In addition, it shows the LED status display 42 which indicates when a fiber box 60 has emptied and which fiber boxes 60 are still active. The LED status display 42 preferably has the LED status lights displayed in a circular pattern. In the center of the LED status display 42 is the system status LED 44 which designates whether the fiber distribution ring 40 currently has loaded the correct number of functioning fiber boxes. There is a battery 43 which powers the LEDs. Whenever the number of fiber boxes designated are not available to stream fiber into the concrete stream, the system status LED 44 will turn red and preferably sound an alarm. Preferably, the contacts 64 of the fiber boxes 60 on the fiber distribution ring 40 are connected to the control console 41 through a wireless connection, such that the control console 41 will correctly display the status of the fiber boxes 60 on the LED display 42. Preferably, a microprocessor based controller will control the wireless signal from the fiber distribution ring 40 corresponding to the status of the fiber 62 in respective ones of the fiber boxes 60. Similarly a microprocessor based controller within the control console 41 will selectively power the LED display 42 according to the fiber box status wireless signal received from the fiber distribution ring 40.
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(21) In other embodiments, a conductive coating may be placed on a frangible element which extends between the two contacts 64, such as paper coated with a conductive coating. The end of the fiber 62 may be secured to the frangible element with an adhesive, a rivet, or tied around the frangible element, such that pulling the fiber 62 on the frangible element will tear the frangible element and break electric conductivity between the two contacts 64.
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(29) In typical usage, fiber injector 8 is affixed to the boom end of a delivery system, in this example a concrete pump. At the start, a fiber distribution ring 40 is fully loaded with the appropriate type and number of fiber boxes 60 attached to the fiber distribution ring 40 of the fiber injector 8. In general the fiber boxes 60 would be scaled to require no mid-service reloads. For example, the fiber boxes 60 would be scaled to complete a ten yard, or whatever is typical, load from a concrete truck, the used fiber distribution ring 40 is then snapped off and a new pre-loaded fiber ring would be installed and the next load would commence. In order to be most efficient, each system would have two fiber distribution rings 40 so that one could be loaded while the other is being used. The fiber boxes 60 would be pulled out, and the fiber end, fiber install tabs 66 of the new boxes 60 would be threaded though fiber apertures 52, the box inserted validating that the LED is active showing proper installation. After all the boxes 60, or whatever number of the boxes 60 required are loaded, the status LED registers green, then it is ready to be attached to fiber injector 8 for the next load.
(30) In alternative embodiments, the LED status lights of the control console 31 may be mounted on the fiber distribution ring 40, and then a contacts 54 of the fiber box holders 50 may be connected directly to the LED Status lights 42 by hard wiring, to directly connect the contacts 64 of the fiber boxes 60. Other embodiments may use pneumatic or hydraulic components, such as for the motor 12, or for actuating operation of the fiber brake 24. For example, the brake actuator rod 26 may be replaced by a linear actuator, such as that operated by an electric solenoid, stepper motor, pneumatic actuator or hydraulic actuator, connected directly to the fixed attachment 10.
(31) As the concrete is delivered to the deeper areas of the form, the fibers are delivered via either the rotational aspect, or directly without rotation. For example, the typical install for flatwork versus structural columns versus cantilevered structures will evolve. The type, number, and style of fiber application will be dependent and enhanced with further research. As the delivery approaches the upper finished inch, that is, the upper surface of the concrete being deposited, the handle will be put in the DOWN position, stopping the fiber injection, so that the final finished surface is without fibers protruding.
(32) The present invention describes a new way to apply various materials in a quantitative way to pumpable materials, which is in this example concrete. While the current application is described using concrete pumps as an example, there is no reason it cannot be expanded to any number of applications.
(33) The increase in utility of concrete due to the inclusion of more technically superior products, such as carbon graphite fibers, eventually graphene and carbon nanotubules, in such a uniform and quantifiable means controlled at the point of delivery has unlimited growth potential.
(34) Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims.