Pulverizing apparatus and method of pulverizing rocks

Abstract

A rock crushing assembly is provided in the form of a pulverizing tumbler. The apparatus includes a faceted tumbler having a plurality of faceted end walls, a pair of parallel sidewalls, and an open interior. A power source and a drivetrain assembly attach to the sidewalls of the tumbler and rotate the same. Within the tumbler is adapted to be placed rocks and minerals to be pulverized, wherein pulverizing media is placed in the tumbler with the rocks to break down the rocks into fine, granular material. One of the end walls of the tumbler is removable to allow access to the tumbler interior. One or more gaps or apertures through one or more of the end walls allow the pulverized material to exit the tumbler during operation, thereby reducing build-up of loose material that can dampen impacts within the tumbler.

Claims

1. A pulverizing assembly, comprising: a tumbler having a pair of sidewalls and a plurality of end walls forming an enclosed interior volume; said end walls and said pair of sidewalls comprising planar surfaces joined at their ends; wherein said end walls and said pair of sidewalls each lie in separate planes; an access door through one of said end walls; a shaft connected to said tumbler; a power source providing rotational input to said shaft; a plurality of openings disposed between the pair of sidewalls and said access door, whereby said plurality of openings are configured to permit powdered material to escape said interior volume; wherein each of the plurality of openings comprise a gap extending along an entire length of a lateral side of the access door when the access door is in a closed position such that powdered material can escape when the tumbler is rotating; a pulverizing media.

2. The pulverizing assembly of claim 1, wherein: said end walls abut one another in a faceted configuration and at a given angle; said end walls each abut said pair of sidewalls at a right angle.

3. The pulverizing assembly of claim 2, wherein the given angle between each of the end walls is 45-degrees.

4. The pulverizing assembly of claim 1, wherein said power source comprises an internal combustion engine and a drivetrain assembly.

5. The pulverizing assembly of claim 1, wherein said power source comprises an electric motor.

6. The pulverizing assembly of claim 1, wherein said pulverizing media further comprises a plurality of spherical structures.

7. The pulverizing assembly of claim 1, wherein said pulverizing media further comprises a plurality of round stock material having a cylindrical profile and a substantially flat upper and lower surface.

8. The pulverizing assembly of claim 7, wherein an upper end of the cylindrical profile tapers towards the upper surface and a lower end of the cylindrical profile tapers towards the lower surface, such that a diameter of the upper surface and the lower surface is less than a diameter of the cylindrical profile.

9. The pulverizing assembly of claim 1, wherein the axis of the rotational input is perpendicular to the pair of sidewalls.

10. The pulverizing assembly of claim 1, further comprising a workbench assembly comprising a pair of planar surfaces separated by a distance, wherein opposing ends of the shaft are supported on each of the planar surfaces, such that the tumbler is supported therebetween allowing the tumbler to discharge the powder material into a collection area disposed below the workbench assembly.

11. The pulverizing assembly of claim 10, further comprising a pair of shaft supports, wherein the pair of shaft supports each comprise an A-shaped frame having a pair of legs configured to rest flush on the pair of planar surfaces.

12. A method of pulverizing mineral rocks using a tumbler assembly, comprising the steps of: loading a faceted tumbler, having a plurality of end walls and a pair of sidewalls, wherein said end walls and sidewalls are planar surfaces joined at their ends which each lie in separate planes, with mineral rocks and a pulverizing media such that at least half of said faceted tumbler is unoccupied; rotating said faceted tumbler using a power input at a given rotational speed; allowing powder from said mineral rocks to escape said faceted tumbler through a plurality of openings disposed between the pair of sidewalls an access door, wherein the access door is disposed through one of said end walls; wherein the plurality of openings comprise a gap extending along an entire length of a lateral side of the access door when the access door is in a closed position such that powdered material can escape when the tumbler is rotating; collecting said powder from said plurality of openings.

13. The method of claim 12, wherein said given rotational speed is between 10-70 revolutions per minute.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

(1) Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.

(2) FIG. 1 shows a perspective view of the rock pulverizing assembly of the present invention.

(3) FIG. 2 shows another view of the rock pulverizing assembly of the present invention, wherein the tumbler is shown in broken lines.

(4) FIG. 3 shows a view of the action of the tumbler depositing pulverized rock minerals from the tumbler interior during operation.

(5) FIG. 4 shows an internal view of the tumbler during operation.

(6) FIG. 5 shows one contemplated embodiment of the pulverizing media, wherein the media comprises hardened pellets.

(7) FIG. 6 shows another contemplated embodiment of the pulverizing media, wherein the media comprises hardened spheres.

DETAILED DESCRIPTION OF THE INVENTION

(8) Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the rock pulverizing assembly of the present invention. For the purposes of presenting a brief and clear description of the present invention, the preferred embodiment will be discussed as used for reducing mineral rocks into fine powder for further processing. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.

(9) Referring now to FIG. 1, there is shown a perspective view of the pulverizing assembly of the present invention. The assembly comprises a rock crushing tumbler 11 that comprises a faceted shape having an internal volume and a plurality of walls. A first and second of sidewall 12 form the sides of the tumbler 11 and are affixed to the output 17 of the pulverizing assembly power source 40 and drivetrain 41. The power source 40 provides power in the form of rotational energy, whereby the drivetrain assembly 41 is used (if necessary) to reduce the rotational speed of the input to one that is suitable for the rock pulverizing operation at its output 17.

(10) The tumbler 11 is used to support mineral rocks to be reduced, along with a pulverizing media that is placed therein with the rocks. The pulverizing media clashes and impacts the rocks as the tumbler 11 rotates, while the faceted shape of the tumbler increases the energy of the impacts when the rocks impact the inner walls thereof. The rocks and the pulverizing media cannot nestle into any curved portion, therefore the impacts are abrupt and cause a sharp change in momentum that causes stress on the rocks, pulverizing them into smaller proportions and eventually into a fine powder.

(11) The tumbler 11 is comprised of a faceted shape with a pair of sidewalls 12 and a plurality of end walls 13 disposed therebetween. The end walls 13 are joined to one another at an angle (shown in FIG. 4, 52) to form a faceted shape, while the end walls 13 and the sidewalls 12 are joined at a right angle 51. The assembly is preferably devoid of rounded edges or contours. As shown in FIG. 1, each of the pair of sidewalls 12 and each of the plurality of end walls 13 lie in separate planes. In the illustrated embodiment, the pair of sidewalls 12 occupy parallel vertical planes, whereas each of the plurality of end walls 13 occupy a separate plane offset from the planes of adjacent end walls 13 by an angle (shown in FIG. 4, 52). Furthermore, one of the end walls forms an access door 14 such that the enclosed interior volume of the tumbler 11 is accessible. The access door may be completely removable or is hingedly attached to an adjacent end wall using a hinge joint 14 and a securing fastener 15. The fastener 15 secures the door 14 in a closed state for operation. The configuration of the fastener 15 may take on several forms, and is presented herein as a pin lock joint by way of example. Additionally provided on the tumbler may be one or more repair access doors along the sidewalls 12, which allow routine maintenance of the tumbler and access to its interior through the sidewalls 12 thereof.

(12) The tumbler 11 is preferably mounted from a workstation 50 or similar support structure, wherein the first and second sidewall 12 are rotatable supported by about the central axis of the tumbler. Off-axis mounting is also contemplated to increase pulverizing effectiveness; however harmonics of the overall assembly and stress on the power source 40 and drivetrain 41 may favor a more balanced support. The power input 40 is preferably an internal combustion engine or electric motor that drives a belt pulley 42 or chain. The power input 40 may directly secure to the tumbler 11, however it is contemplated and shown effective to reduce the speed of the power input 40 by using a drivetrain assembly 41.

(13) The drivetrain assembly 41 comprises a plurality of gears or pulley wheels that are used to reduce the speed of the input to one that is desirable at the output in connection with the tumbler 11. Effective prototypes have shown that a tumbler rotational speed of 21 to 24 revolutions per minute (RPM) is an effective for processing a volume of rocks in the area of four to five gallons using an approximately twenty gallon tumbler with roughly four gallons of pulverizing media (by volume) therein. The exact ratio of pulverizing media to mineral rocks may vary, along with the size of the tumbler and the rotation speed thereof. The numbers stated show but one example that has been demonstrated as an effective implementation of the present invention in a production environment. Speeds between 10-70 RPM have been shown effective for pulverizing rocks using the process of the present invention. The drivetrain assembly 41 of the design prototype, and one contemplated as a configuration falling within the scope of the present invention, comprises a first 44 and second 45 pulley wheel sharing a common shaft, wherein the first pulley wheel 44 is driven by a belt 42 from the power source 40, and the second pulley wheel 45 drives another belt 42 secured to a final drive pulley wheel 43 sharing a common shaft with the input to the tumbler 11. This configuration allows the input to be changed to a specific ratio without compromising the torque input on the tumbler. If the power source comprises an internal combustion engine, the engine can run at an ideal speed while the tumbler rotates at a relatively low RPM. Furthermore, the engine and drivetrain may be coupled by a clutch assembly or controlled by tensioners, whereby the power source can be operably coupled and decoupled from the drivetrain if necessary during start-up and the like.

(14) Referring now to FIG. 2, there is shown another view of the pulverizing assembly of the present invention, wherein the tumbler 11 is shown in broken lines for clarity. As shown, the output 17 of the drivetrain assembly 41 secures to the sidewalls of the tumbler, whereby an output shaft secures to the tumbler using connection plates, or alternatively the output shaft extends through the central portion of the tumbler. The shaft is supported on both sides of the tumbler via shaft supports 21, which rotatably support the shaft in a stable position using bearings or necessary bushings. Similarly, the drivetrain assembly 41 and power input 40 are sufficiently affixed to a support using appropriate structure such that the assembly remains stable while in operation and during the dynamic motion of the assembly. One contemplated support is a workbench assembly 50, which supports the assembly on a planar surface and positions the tumbler 11 over an opening that provides clearance therefor and allows powder product of the process to flow from the tumbler and into a collection area.

(15) Referring now to FIG. 3, there is shown a crucial aspect of the tumbler while in operation pulverizing the mineral rocks into granular material. As the pulverizing material and tumbler break down the rocks into smaller proportions and eventually into powder form, the interior of the tumbler 11 will fill up with a layer of the powder. This causes the walls of the tumbler to be covered by a layer that is then impacted, as opposed to impacts that are adapted to occur between the rocks and the walls of the tumbler. This causes an attenuation of energy and a reduction in the effectiveness of the process. To address this, the process can be stopped and the tumbler can be emptied of the powder periodically. However, this is time consuming and slows down the overall process from start to finish. Therefore, the present invention contemplates apertures or openings 25 disposed along at least one of the end walls of the tumbler 11.

(16) The openings 25 are adapted to allow fine powder to escape the interior of the tumbler 11 while the same is spinning. The openings 25 may be disposed along the surface of the end walls, or preferably there may be provided a gap between the access door 14 and the sidewalls of the tumbler. As the access door 14 rotates below the rotational center of the tumbler, the powder 70 falls through the openings and into a collection area 71 disposed therebelow. The powder 70 deposits in the collection area and can be processed thereafter. This process reduces the build-up of fine powder in the tumbler and eliminates the need to stop the tumbler operation to clean out the same.

(17) Referring now to FIG. 4, there is shown a cross section view of the tumbler 11 in operation, whereby the tumbler supports a volume of rock minerals 72 and a volume of pulverizing media 80 therein. In operation, the tumbler 11 rotates in a single direction. The internal volume 19 of the tumbler 11 is open and bounded by the faceted sidewalls and end walls 13 thereof. The end walls 13 are preferably planar surfaces joined at their ends at a given angle, whereby curvature along the interior 19 of the tumbler is avoided. The volume 19 of the tumbler 11 is largely unoccupied by the pulverizing media 80 and the rock minerals 72 such that the contents of the tumbler are flung from one side of the tumbler to the other during a rotation. This cases impacts against the walls of the tumbler, against other rocks, and against the pulverizing media. Preferably at least half of the tumbler is unoccupied at the start of the operation, whereby the volume therein will gradually decrease as the rocks are reduced and broken down. During this process, the fine powder 70 created therefrom exits through the openings in the end walls 13 and/or the access door 14 and into a collection area. In the example recited above, rotation of the tumbler for a duration of 2-4 hours creates a steady output of roughly 1.5 gallons of powder per hour for collection.

(18) Referring now to FIGS. 5 and 6, there are shown two contemplated embodiments of the pulverizing media 80 of the present invention. In both embodiments, high strength, high stiffness, and high surface hardness material objects are used in the tumbler. These items are loaded with the mineral rocks in a defined ratio, and reused until pulverized themselves. This generally takes many cycles to occur, however the pulverizing media is a perishable item over the long-term. The first embodiment contemplates sections of round stock material that are cut to form short cylindrical pellets having a rounded outer profile 83 and flat upper and lower surfaces 82. These are metal sections having a higher strength and stiffness than the mineral rock being processed. A second embodiment of the pulverizing media 80 comprises a rounded spherical structure 81. This embodiment is comprised of metal material that comprises a rounded outer profile.

(19) The pulverizing media is mixed with mineral rocks to be broken down within the interior of the tumbler, whereby the assembly efficiently breaks down the rocks into powder form such that a user can further process the powder for precious minerals. In use, rocks are inserted into the tumbler and the motor is run at a slow speed for several hours. Once the cycle is complete, the fine powder is dispensed into a bucket or another suitable container. The tumbler is preferably supported via a shaft on each side thereof, which are secured in position by pillow block bearings for free rotation. Steel balls or round stock media are used as weights to crush the rocks, turning the rocks into a fine powder. The device pulverizes rocks for sluicing in a highly efficient manner while eliminating the need for individuals to manually hammer rocks into smaller pieces. Moreover, the present invention allows users to leave the machine unattended during the process while reducing the amount of time and effort needed to transform rocks into dust.

(20) It is submitted that the instant invention has been shown and described in what is considered to be the most practical and preferred embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.

(21) Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.