Abstract:
A soil processing tool for delivering a fluid slurry may include a barrel section to define placement of the fluid slurry, a core section being in a spaced relationship to the barrel section, and a flight section formed between the core section and the barrel section. The soil processing tool may include a first cutting tip to reduce debris and the barrel section may include a lower edge including a second cutting tip to reduce debris. The flight section may include a leading edge including a third cutting tip to reduce debris, and the core section may include a fourth cutting tip to reduce debris. The core section may include a first nozzle to dispense the fluid slurry, and the fluid slurry may be concrete slurry. The nozzle may be located approximately in the midsection of the core section, and the core section may include a second nozzle approximately in the bottom of the core section. The flight member may be inclined with respect to the core section. The soil processing tool may include a nozzle being positioned only within a space defined by the barrel section.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to drilling equipment and more particularly to a soil processing tool to be used as a soil mixing system. 
       BACKGROUND 
       [0002]    Soil mixing is a method and system for forming supporting piers in soils which may be soft and relatively homogeneous (substantially no structures in the soil) in which a rotating soil processing tool or other mixing device which may include pressurized jets of fluid which when displaced and mixed thoroughly with the soil may form a slurry within the resulting column. 
         [0003]    Cement may be formed with the pressurized fluid to form a cement-soil slurry which subsequently hardens to form the support pier. This method of drilling is substantially fast and many piers can be formed very quickly, resulting in an economical construction method. Typical drilling rates may approach 40 ft/m. 
         [0004]    A problem with the above described method and system is that there is little control of the lateral extent of the processed column produced by the pressurized jets due to variations in density of the soil being penetrated. In some parts of the resulting processed column the diameter of the column may be larger than the desired column size. This makes control of the cement-soil mixture and resulting strength of the column unpredictable and unable to be accurately calculated. 
         [0005]    U.S. Pat. No. 4,958,962 discloses a method of modifying the structural integrity of material in a subterranean earth situs. The method comprises the steps of mechanically digging into the situs to break the material into pieces and, simultaneously, hydraulically admixing a modifying agent with the pieces by introducing the modifying agent into the pieces at a velocity in the range of from about 300 ft./sec. to about 2500 ft./sec. The method is particularly suitable for improving the strength and load-bearing capacity of material in a subterranean earth situs. Also provided is a method of modifying the structural integrity of material in a subterranean earth situs and installing a pre-formed structural element therein. 
         [0006]    U.S. Pat. No. 5,396,964 discloses an apparatus for processing soil in a subterranean earth situs. The apparatus includes a parallelogram spotter or positioning portion with a drilling table support portion connected thereto. A rotary drilling table is mounted on the drilling table support portion. Relative movement is provided between the support portion and the positioning portion in a plurality of planes. A pivotation portion is disposed between the support portion and the positioning portion and pivotally connected thereto. Hydraulic cylinders are provided to shift the apparatus about a vertical axis, to move the drilling table support portion in a longitudinal direction, to tilt the pivotation portion and support portion about a horizontal axis and to tip the support portion with respect to the pivotation portion about a longitudinal axis. A table elevation winch is mounted on the support portion and has a table elevation cable extending there from which is engaged with a pulley connected to the support portion. A servo system is provided to sense angular displacement of the cable with respect to the pulley and to actuate the hydraulic cylinders to compensate for this angular displacement. Several soil processor embodiments are disclosed, as are methods of use. 
         [0007]    U.S. Pat. No. 5,890,844 discloses an apparatus and method for processing soil in a subterranean situs is provided wherein pressurized slurry is introduced through a soil processing tool and mixed with the soil. A single engine drives first and second pumps and a programmable, computerized process control system allocates driving power from the single engine to the first and second pumps to optimize the mixing of the slurry and soil while maximizing the amount of soil being processed. 
         [0008]    U.S. Pat. No. 6,183,166 discloses a method for centrifugally forming a subterranean, cylindrically shaped soil-cement casing in material located in a subterranean earth situs. A soil processing tool is advanced and rotated into the subterranean situs and as the tool advances a high velocity cement slurry is introduced through said tool to hydraulically divide the pieces of soil into particles and to mix the cement slurry with the particles to form a soil-cement slurry. As the soil processing tool is then withdrawn from the situs, the tool is rotated at a speed to exert a centrifugal force by the tool on the soil-cement slurry in excess of two G&#39;s, causing the solids of the soil-cement slurry to migrate away from the center of the hole to form a first cylindrical region at the edge of the hole and a second cylindrical region at the center of the hole. The first region has more of the dense solids and the second internal region has a greater proportion of free water and less of the dense solids. The mixture in the hole is then allowed to setup, leaving the soil-cement casing at the outer region of the hole. 
         [0009]    U.S. Pat. No. 6,241,426 discloses a method for forming an interconnected underground structure which avoids settling of adjacent soil structure. A plurality of underground support columns is initially formed, with the support columns being spaced apart in a predetermined pattern. Interconnecting holes are thereafter formed between the underground support columns, wherein the interconnecting holes are formed by mechanically cutting the soil and simultaneously hydraulically mixing the mechanically cut soil with slurry injected at velocities of 200 feet per second or higher while maintaining a positive hydrostatic head in the hole relative to adjacent soil. As the interconnecting holes are being formed, the diameter of each interconnecting hole is extended by positioning a second high velocity slurry nozzle near the outer diameter of the interconnecting hole which injects high velocity into the adjacent soil to hydraulically cut the adjacent soil and mix it with the slurry. The high velocity slurry injected through the second nozzle penetrates the surface of the adjacent underground support columns and forms an impermeable underground support wall. The method may be used to treat and stabilize highly toxic underground plumes. 
         [0010]    U.S. Pat. No. 6,988,856 discloses a method for centering and guiding a large diameter soil processing tool. A sacrificial guide is formed by using a small diameter soil processing tool to form a soil-cement column having a relatively hard outer section and a relatively soft center section. The relatively hard outer section is utilized to guide the large diameter soil processing tool. In one embodiment, the soft central region of the sacrificial guide is left in place and the pilot of the large tool carries an auger that simply drills through the central portion of the sacrificial guide. In a second embodiment, the sacrificial guide is hollow and the large tool need not have an auger at the tip of its pilot. The large tool advances downwardly through the sacrificial guide and, as it advances downwardly, the large tool breaks up the sacrificial guide and the sacrificial guide particles ultimately form a portion of the soil-cement column formed by the large soil processing tool. The method facilitates the use of soil processing tools having diameters of 8 to 20 feet, for example. Large volumes of subterranean material may be hardened or solidified by using an array of the sacrificial guides to precisely control and center the large processing tool so that the large quantities of subterranean material such as utilized to support an airport runway may be processed efficiently with the invention. The method is also usable with soil processing tools of any diameter. 
       SUMMARY 
       [0011]    A soil processing tool for delivering a fluid slurry may include a barrel section to define placement of the fluid slurry, a core section being in a spaced relationship to the barrel section, and a flight section formed between the core section and the barrel section. 
         [0012]    The soil processing tool may include a first cutting tip to reduce debris and the barrel section may include a lower edge including a second cutting tip to reduce debris. 
         [0013]    The flight section may include a leading edge including a third cutting tip to reduce debris, and the core section may include a fourth cutting tip to reduce debris. 
         [0014]    The core section may include a first nozzle to dispense the fluid slurry, and the fluid slurry may be concrete slurry. 
         [0015]    The nozzle may be located approximately in the midsection of the core section, and the core section may include a second nozzle approximately in the bottom of the core section. 
         [0016]    The soil processing tool may include a nozzle being positioned only within a space defined by the barrel section. 
         [0017]    The flight member may be inclined with respect to the core section. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which, like reference numerals identify like elements, and in which: 
           [0019]      FIG. 1  illustrates a cross-sectional view of the soil processing tool of the present invention; 
           [0020]      FIG. 2  illustrates a top view of the soil processing tool of the present invention; 
           [0021]      FIG. 3  illustrates a bottom view of the soil processing tool of the present invention; 
           [0022]      FIG. 4  illustrates a perspective view of the soil processing tool of the present invention; 
           [0023]      FIG. 5  illustrates a cross-sectional view of the soil processing tool of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    The present invention overcomes the above mentioned problem by the use of a core barrel which acts as a container for the pressurized, high speed fluid jets. The size of the column is substantially the diameter of the core barrel which reduces the penetration of the slurry jets outside the desired boundaries of the column. As a consequence, the volume of the resulting column is controlled allowing the mixture created to be carefully controlled and the resulting concrete to be held within the desired specifications of strength. Additionally, the core barrel and auger flights may have teeth along the edges of the auger flights and core barrel which facilitate the cutting and grinding of obstacles into substantially smaller pieces allowing the drilling to continue without pause. 
         [0025]      FIG. 1  illustrates a cross section of a soil processing tool  100  of the present invention which may include a core barrel or barrel section  101  which may be substantially cylindrical in shape and may have a substantially open top and an open bottom. The barrel section  101  may include an outer surface  103  and an inner surface  105  and may include an upper edge  107  and a lower edge  109 . A first support member  111  may extend across the barrel section  101  and connect opposing interior surfaces  105  to provide support and stability to the barrel section  101 . A second support member  111  may extend across the barrel section  101  substantially perpendicular to the first support member  111 . The soil processing tool  100  may include a core section  113  which may be substantially centrally positioned with respect to the barrel section  101  and the first and second support members  111  may be radially positioned to the core section  113 . The core section  113  may include a pocket member  115  which may extend axially in the top surface  117  of the core section  113  to accept a hollow kelly bar of the drilling rig (not shown). The bottom surface  119  of the core section  113  may be a truncated cone shaped and may include cutting tips  131  or teeth and may include nozzles  133  in order to output concrete in order to form the concrete-soil slurry. 
         [0026]      FIG. 1  additionally illustrates additional nozzles  133  positioned in the middle section of the core section  113  and illustrates that the additional nozzles  133  may be positioned at an angle relationship to the core section  113 .  FIG. 1  additionally illustrates a first and second flight member  137  which may extend between the core section  113  and the barrel inner surface  105  of the barrel section  107  and may be positioned at an angled relationship to the core section  113 . The first and second flight member  137  may include cutting tip  139  which may have a sharpened edge in order to cut through debris and irregularities in the underlying soil. The cutting tip  139  may be positioned on a leading edge of the first and second flight member  137 . 
         [0027]      FIG. 1  illustrates that cutting tips  139  may be positioned along the lower edge  109  of the barrel section  101 . 
         [0028]      FIG. 2  illustrates a top view of the soil processing tool  100  of the present invention which may include a core barrel or barrel section  101  which may have a substantially open top and an open bottom. The barrel section  101  may include an outer surface  103  and an inner surface  105  and may include an upper edge  107  and a lower edge  109 . A first support member  111  may extend across the barrel section  101  and connect opposing interior surfaces  105  to provide support and stability to the barrel section  101 . A second support member  111  may extend across the barrel section  101  substantially perpendicular to the first support member  111 . The soil processing tool  100  may include a core section  113  which may be substantially centrally positioned with respect to the barrel section  101  and the first and second support members  111  which may be radially positioned to the core section  113 . The core section  113  may include a pocket member  115  which may extend axially in the top surface  117  of the core section  113  to accept a kelly bar of the drilling rig (not shown). 
         [0029]      FIG. 2  illustrates additional nozzles  133  positioned in the middle section of the core section  113 , and the additional nozzles  133  may be positioned at an angle relationship to the core section  113 .  FIG. 2  additionally illustrates a first and second flight member  137  which may extend between the core section  113  and the barrel inner surface  105  of the barrel section  107  and may be positioned at an angled relationship to the core section  113 . The first and second flight member  137  may include cutting tip  139  which may have a sharpened edge in order to cut through debris and irregularities in the underlying soil. The cutting tip  139  may be positioned on a leading edge of the first and second flight member  137 . 
         [0030]      FIG. 3  illustrates a bottom view of the soil processing tool  100  of the present invention which may include a core barrel or barrel section  101  which may have a substantially open top and an open bottom. The barrel section  101  may include an outer surface  103  and an inner surface  105  and may include an upper edge  107  and a lower edge  109 . A first support member  111  may extend across the barrel section  101  and connect opposing interior surfaces  105  to provide support and stability to the barrel section  101 . A second support member  111  may extend across the barrel section  101  substantially perpendicular to the first support member  111 . The soil processing tool  100  may include a core section  113  which may be substantially centrally positioned with respect to the barrel section  101  and the first and second support members  111  which may be radially positioned to the core section  113 . 
         [0031]      FIG. 3  illustrates additional nozzles  133  positioned in the middle section of the core section  113 , and the additional nozzles  133  may be positioned at an angle relationship to the core section  113 .  FIG. 3  additionally illustrates a first and second flight member  137  which may extend between the core section  113  and the barrel inner surface  105  of the barrel section  107  and may be positioned at an angled relationship to the core section  113 . The first and second flight member  137  may include cutting tip  139  which may have a sharpened edge in order to cut through debris and underlying soil irregularities. The cutting tip  139  may be positioned on a leading edge of the first and second flight member  137 . 
         [0032]      FIG. 3  illustrates that the cutting tips  139  may be positioned along the lower edge  109  of the barrel section  101 . 
         [0033]    The bottom surface  119  of the core section  113  may be a truncated cone shaped and may include cutting tips  131  or teeth and may include nozzles  133  in order to output concrete in order to form the concrete-soil slurry. 
         [0034]      FIG. 4  illustrates a perspective view of the soil processing tool  100  of the present invention which may include a core barrel or barrel section  101  which may have a substantially open top and an open bottom. The barrel section  101  may include an outer surface  103  and an inner surface  105  and may include an upper edge  107  and a lower edge  109 . A first support member  111  may extend across the barrel section  101  and connect opposing interior surfaces  105  to provide support and stability to the barrel section  101 . A second support member  111  may extend across the barrel section  101  substantially perpendicular to the first support member  111 . The soil processing tool  100  may include a core section  113  which may be substantially centrally positioned with respect to the barrel section  101  and the first and second support members  111  which may be radially positioned to the core section  113 . The core section  113  may include a pocket member  115  which may extend axially in the top surface  117  of the core section  113  to accept a kelly bar of the drilling rig (not shown). 
         [0035]      FIG. 4  illustrates additional nozzles  133  positioned in the middle section of the core section  113 , and the additional nozzles  133  may be positioned at an angle relationship to the core section  113 .  FIG. 4  additionally illustrates a first and second flight member  137  which may extend between the core section  113  and the barrel inner surface  105  of the barrel section  107  and may be positioned at an angled relationship to the core section  113 . The first and second flight member  137  may include cutting tip  139  which may have a sharpened edge in order to cut through debris and underlying soil irregularities. The cutting tip  139  may be positioned on a leading edge of the first and second flight member  137 . 
         [0036]      FIG. 4  illustrates that the cutting tips  139  may be positioned along the lower edge  109  of the barrel section  101 . 
         [0037]    The bottom surface  119  of the core section  113  may be a truncated cone shaped and may include cutting tips  131  or teeth and may include nozzles  133  in order to output concrete in order to form the concrete-soil slurry. 
         [0038]    One objective in drilling with soil processing tool  500  is to achieve a well defined column surface  501  which is substantially adjacent to the outer surface of the soil processing tool  500 . A minimum gap between the column surface  501  and the outer surface of the soil processing tool  500  is desirable. However, the output of concrete from the nozzles of the soil processing tool  500  may extend beyond the outer surface of the soil processing tool  500  which may cause an enlarged gap between the outer surface of the soil processing tool  500  and the interior surface of the drill column. This enlarged gap is undesirable because the concrete mixture cannot be controlled to produce the desired strength. The proportional mixing of the soil and the fluid make it difficult to maintain the desired proportions because the diameter is unpredictable. In order to prevent this problem, the nozzles  533  should not be positioned outside of the barrel section  101 .  FIG. 5  illustrates a cross section of a soil processing tool  500  in another embodiment of the present invention which may include a core barrel or barrel section  101  which may be substantially cylindrical in shape and may have a substantially open top and an open bottom. The barrel section  101  may include an outer surface  103  and an inner surface  105  and may include an upper edge  107  and a lower edge  109 . A first support member  111  may extend across the barrel section  101  and connect opposing interior surfaces  105  to provide support and stability to the barrel section  101 . A second support member  111  may extend across the barrel section  101  substantially perpendicular to the first support member  111 . The soil processing tool  100  may include a core section  113  which may be substantially centrally positioned with respect to the barrel section  101  and the first and second support members  111  may be radially positioned to the core section  113 . The core section  113  may include a pocket member  115  which may extend axially in the top surface  117  of the core section  113  to accept a hollow kelly bar of the drilling rig (not shown). The bottom surface  119  of the core section  113  may be a truncated cone shaped and may include cutting tips  131  or teeth. 
         [0039]      FIG. 5  additionally illustrates nozzles  533  positioned in the middle section of the core section  113  and illustrates that the nozzles  533  may be positioned at an angled relationship to the core section  113 . In this embodiment, the nozzles  553  may be positioned only within the barrel section  101 .  FIG. 1  additionally illustrates a first and second flight member  137  which may extend between the core section  113  and the barrel inner surface  105  of the barrel section  107  and may be positioned at an angled relationship to the core section  113 . The first and second flight member  137  may include cutting tip  139  which may have a sharpened edge in order to cut through debris and irregularities in the underlying soil. The cutting tip  139  may be positioned on a leading edge of the first and second flight member  137 . 
         [0040]      FIG. 5  illustrates that cutting tips  139  may be positioned along the lower edge  109  of the barrel section  101 . The soil processing tool  500  may achieve a well defined and narrow gap between the outer surface of the soil processing tool  500  and the inner surface of the drill column  501 . 
         [0041]    While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular forms disclosed.