Hydroseeders having integrated bale grinders and methods

In one embodiment, a hydroseeder has an integrated bale grinder. The hydroseeder includes a tank, an agitator, a plurality of grinding flights, and a basket. The tank includes an opening and is configured to hold a material slurry. The agitator is positioned below the opening and is configured to agitate the material slurry. The plurality of grinding flights extends from the agitator and is configured to grind a material bale as it is introduced into the tank. The basket extends from the opening of the tank and is configured to direct the material bale toward the plurality of grinding flights.

TECHNICAL FIELD

The present specification generally relates to hydroseeders and, more specifically, hydroseeders with integrated bale grinders.

BACKGROUND

Hydroseeding (or hydraulic mulch seeding, hydro-mulching, hydraseeding) is a planting process that generally uses a material slurry of water, seed, hydro-mulch, and fertilizer. The material slurry is produced within a mixing tank by mixing the various ingredients with an agitator. The material slurry is then drawn out by a material pump and spraying unit for application to prepared ground. The seed, hydro-mulch, and fertilizer may be provided in pressed/dry 50 lb. material bales. Most current systems require a user to lift and drop the full 50 lb. bale into the mixing tank where it is soaked by the water and gets broken up by the agitator. Such processes may leave large clumps of the material bale still intact, which may clog the material pump or spraying unit.

Accordingly, a need exists for alternative hydroseeders with integrated bale grinders for breaking up material bales.

SUMMARY

In one embodiment, a hydroseeder has an integrated bale grinder. The hydroseeder includes a tank, an agitator, a plurality of grinding flights, and a basket. The tank includes an opening and is configured to hold a material slurry. The agitator is positioned below the opening and is configured to agitate the material slurry. The plurality of grinding flights extends from the agitator and is configured to grind a material bale as it is introduced into the tank. The basket extends from the opening of the tank and is configured to direct the material bale toward the plurality of grinding flights.

In another embodiment, a hydroseeder has an integrated bale grinder. The hydroseeder includes a tank and an agitator. The tank includes an opening and is configured to hold a material slurry. The agitator is positioned below the opening and is configured to agitate the material slurry. The agitator includes a rotatable shaft, a plurality of mixing paddles, and a plurality of grinding flights. The plurality of mixing paddles extends from the rotatable shaft along a first segment. The plurality of grinding flights extends from the rotatable shaft along a second segment and is configured to grind a material bale as it is introduced into the tank.

In yet another embodiment, a method of preparing a material slurry for a hydroseeding operation includes providing a hydroseeder. The hydroseeder includes a tank, an agitator, a plurality of grinding flights, and a basket. The tank includes an opening and is configured to hold the material slurry. The agitator is positioned below of the opening. The plurality of grinding flights extends from the agitator. The basket extends from the opening of the tank. The method further includes adding a liquid to the tank of the hydroseeder, directing a material bale through the opening of the tank, wherein the basket directs the material bale toward the plurality of grinding flights, grinding the material bale with the plurality of grinding flights, wherein in particles of the material bale are directed around the plurality of grinding flights and into the liquid, and agitating the liquid and the particles of the material bale with the agitator to form the material slurry.

DETAILED DESCRIPTION

Embodiments described herein are directed to hydroseeders and methods of preparing a material slurry for a hydroseeding operation. In particular, hydroseeders as will be described herein include an integrated bale grinder. The bale grinder may be incorporated into an agitator of the hydroseeder and configured to grind up material bales as they are introduced into a tank of the hydroseeder. This allows for the bales to be more finely integrated into the material slurry produced within the tank of the hydroseeder. By finely grinding material bales, clogs in a material sprayer/pump of the hydroseeder during application seeding/mulching processes may be prevented. These and other features will be described in greater detail below.

Referring now toFIG. 1, a hydroseeder10is generally depicted. Though not shown, the hydroseeder10may be positioned or integrated into a vehicle or trailer to aid in transporting the hydroseeder10to a location for performing a hydroseeding operation. As noted above, hydroseeding is a planting process that uses a material slurry of seed, mulch, fertilizer, and liquid (e.g., water) that is sprayed onto prepared earth. However, hydroseeders may be useful in applications beyond hydroseeding. In particular, hydroseeders may also be used for, for example, application of alternate daily cover (ADC) for landfills. Moreover hydroseeders may also be used for applying mulch and water to a location without seed. Accordingly, hydroseeders as described herein are not limited to hydroseeding applications. Accordingly, it is contemplated that the material slurry may include a fewer or greater number of components (e.g., water, seed, mulch, fertilizer, or any combination thereof) without departing from the scope of the present disclosure. As will be described in greater detail herein, the hydroseeder10is configured to produce the material slurry to be used in the hydroseeding operation. It is noted that the term “hydroseeding operation” may refer to any use of the hydroseeder wherein a material slurry is prepared for application at a location irrespective of whether or not “seed” is a component of the material slurry. That is, the term hydroseeding is not limited to seeding applications but may be inclusive of non-seeding applications (e.g., mulching applications, fertilizing applications, and ADC applications).

To accommodate production of the material slurry, the hydroseeder10includes a tank12. In operation the tank holds the material slurry therein. Referring also toFIG. 2, a sectional view of the hydroseeder10illustrating an interior18of the tank12is depicted. The tank12may include an opening14that allows access to the interior18of the tank12. Material bales may be passed through the opening14and into the interior18of the tank12. The material bales may then be broken up and mixed with water (or other carrier liquid) to create the material slurry. Water may be supplied to the tank12through the opening14. In some embodiments, a water inlet (now shown) may be fluidly coupled to a water source such as a lake, pond, fire hydrant, or the like to provide water to the tank12. As will be described in greater detail herein, the material bales may be broken up with a bale grinder (e.g., grinding flights130) incorporated in an agitator100. As described above, material bales may include a mixture of seed, hydro-mulch, and fertilizer that has been compressed into a bale. However, as discussed above, hyrdroseeders may be used for non-seeding operations. Accordingly, it is contemplated that material bales may include a fewer or greater number of components (e.g., seed, mulch, fertilizer, or any combination thereof) without departing from the scope of the present disclosure.

In some embodiments, and as illustrated inFIGS. 1 and 2the tank12may include a top wall16through which the opening14is formed and sidewalls extending from the top wall16. The top wall16may define a platform. The platform may be supported by the sidewall(s) of the tank12and may support a weight of a user standing thereon. In the illustrated embodiment, the tank12includes first and second lateral sidewalls20,22that are positioned opposite one another and are connected by longitudinal sidewalls24and a base wall26to enclose the interior18of the tank12.

Referring to the embodiment ofFIG. 2, a loading hatch28may be positioned over the opening14to provide a material chute for material bales to be passed through. The loading hatch28may include a lid or similar structure to allow and/or prevent access to the opening14of the tank12.

In some embodiments, a railing29may be coupled to the top wall16to provide at least a partial enclosure to the platform as defined by the top wall16. For example, the railing29may be coupled through any conventional coupling techniques including, but not limited to, the use of fasteners (e.g., bolts) or welding. In use, an operator may stand on the platform and using a spraying system (e.g., a sprayer and a material pump, not shown) fluidly coupled to the interior18of the tank12to discharge the material slurry within the tank12to a desired planting location. While hydroseeders are generally described in relation to the figures, it is noted that hydroseeders may have various shapes and constructions without departing from the scope of the present disclosure.

Referring again toFIG. 2, positioned within the tank12of the hydroseeder10is an agitator100. The agitator100is positioned below the opening14of the tank12and is positioned to agitate the material slurry within the tank12. The agitator100may include a rotatable shaft110that extends between the first lateral sidewall20and the second lateral sidewall22of the tank12. The agitator100may be rotatively coupled to the first and second lateral sidewalls20,22at either end of the rotatable shaft110. Accordingly, the agitator100may rotate about an axis defined by the rotatable shaft110within the tank12.

FIG. 3illustrates an perspective view of the agitator100in isolation from the rest of the hydroseeder10illustrated inFIGS. 1 and 2. Extending from the rotatable shaft110of the agitator100may be a plurality of mixing paddles120. The plurality of mixing paddles120may be arranged in pairs wherein the mixing paddles120of each pair are positioned opposite one another across a diameter of the rotatable shaft110. Each paddle may include a paddle base122coupled to the rotatable shaft110and a paddle body124extending from the paddle base122to a free end126of the paddle. The paddle body124may have a maximum width, as illustrated inFIG. 4Athat is greater than a diameter of rotatable shaft110. Each paddle of a pair of paddles may be angled with respect to the other paddle of the pair of paddles. For example, each paddle of each pair may be angled at a non-zero angle with respect to the other paddle. In some embodiments, the pairs of mixing paddles120may be helically arranged along a length rotatable shaft110. That is each pair of mixing paddles120may be angled at some non-zero angle with respect to the subsequent mixing paddle pair such the mixing paddles120appear to wind around the rotatable shaft110in a corkscrew-like manner. For example, a second mixing paddle pair may be angled from a first mixing paddle pair about 30% about an axis defined by the rotatable shaft110, and a third mixing paddle pair may be angled from the second mixing paddle pair about 30% about the axis defined by the rotatable shaft110and so on and so forth. In embodiments, a greater or lesser angle may be used without departing from the scope of the present disclosure. As illustrated, the plurality of mixing paddles120may extend along a first segment154of the rotatable shaft110.

As noted hereinabove, a bale grinder may be incorporated into the agitator100. Referring toFIG. 3, the bale grinder may comprise a plurality of grinding flights130may extend from the agitator100disposed proximate at least on edge of the rotatable shaft110. For example, the plurality of grinding flights130may extend along a second segment152of the rotatable shaft110. That is, illustrated inFIGS. 3 and 4A, the plurality of mixing paddles120may extend along the first segment154and the plurality of grinding flights130may extend along a second segment152that is separate from the first segment154. Accordingly, the plurality of mixing paddles120are separate from the plurality of grinding flights130. The plurality of grinding flights130are positioned to grind a material bale as it is introduced into the tank12of the hydroseeder10. To this end and with reference toFIG. 2, the plurality of grinding flights130may be positioned directly beneath the opening14of the tank12to receive the material bale as it is passed through the opening14.

Referring again toFIGS. 3-4B, each grinding flight of the plurality of grinding flights130may include a base132coupled to the rotatable shaft110and a body134extending from the base132. The body134may define a first edge136, a second edge138, and a distal end140. The first and second edges136,138of the body134may be serrated edges. The distal end140of the grinding flight may define a notch142. The notch142and serrated edges may grab onto material bales to help perform the grinding operation. In some embodiments, the first edge136and the second edge138may be staggered from one another along the axis defined by the rotatable shaft110(e.g., the X-axis of the depicted coordinate axes) such that the first edge136and the second edge138do not share a common plane. The body134of the grinding flight may be angled between the first edge136and the second edge138, as illustrated inFIG. 4A.

Still referring toFIG. 4A, the grinding flights of the plurality of grinding flights130may be linearly staggered from one another along a length of the rotatable shaft110. In some embodiments, the plurality of grinding flights130may be arranged in a first grouping143and a second grouping144. The first grouping143and the second grouping144may mirror a position of the respective grinding flights130of each grouping about a centerline, c. For example, each grouping may include a first grinding flight146a,146b, a second grinding flight148A,148B, and a third grinding flight150a,150b. The first grinding flights146a,146bmay be positioned next to one another without any intervening grinding flights positioned there between. The second grinding flights148A,148B may positioned to an outside of the first grinding flights146a,146b, followed by the third grinding flights150a,150b. Each of the grinding flights130may be coupled to the rotatable shaft110at consistent orientations relative to one another. That is, each grinding flight may be coupled to the rotatable shaft110such that the first edge136leads the second edge138in the X direction of the depicted coordinate axes. Such orientation of the two groupings143,144may aid in directing material bales and portions thereof toward centerline, c. This may improve grinding efficiency and effectiveness.

FIG. 4Billustrates a front view of the first grouping143coupled to the rotatable shaft110of the agitator100. In the illustrated embodiment, a centerline of each of the grinding flights (146a,146b, and146c) is positioned circumferentially around the rotatable shaft. That is the centerline of each grinding flight is angled from the subsequent grinding flight in the Y-Z plane an angle θ. The angle between each subsequent grinding flight may be equal to the previous angle. That is the angle between the centerline of the first grinding flight146aand the second grinding flight148A may be equal to the angle between the centerline of the second grinding flight148A and the centerline of the third grinding flight150a, and so one and so forth. In the given example, wherein there are three grinding flights in the first grouping143, the centerlines of each subsequent grinding flight may be angled about 120° from one another. In embodiments wherein a greater number of grinding flights are utilized in a grouping, the angle between grinding flights may be smaller. It is contemplated, however, that various uniform and non-uniform angles between grinding flights are contemplated and possible without departing from the scope of the present disclosure.

Referring again toFIG. 2, the hydroseeder10may include a basket200that extends from the opening14of the tank12and directs a material bale toward the plurality of grinding flights130. Referring also toFIGS. 5A and 5B, a perspective view and a side view of the basket in isolation from the hydroseeder10ofFIG. 2are respectively illustrated. The basket200includes a frame202. The frame202may include an attachment portion203for coupling the basket200to a surface of the top wall16of the tank12around the opening14. The basket200may be coupled to the tank12through a variety of means including, but not limited to fasteners, welding, and the like. In some embodiments, the basket200may be removable from the tank12so as to provide access to the interior18of the tank12, such as when maintenance needs to be performed inside of the tank12.

The frame202of the basket200may include sloped sidewalls204positioned opposite one another. The sloped sidewalls204may aid in directing material bales toward the grinding flights130. The sloped sidewalls204may be oriented parallel to the rotatable shaft110of the agitator100. In some embodiments, and as illustrated inFIGS. 5A and 5B, the sloped sidewalls204may be have open-celled construction, such that openings extend through the sloped sidewalls204. In other embodiments, the sloped sidewalls204may be of a solid construction without openings extending therethrough.

Referring briefly toFIGS. 8A and 8B, the frame202of the basket200may define flight paths212that allow the plurality of grinding flights130to rotate through a portion of the basket200. For example, with reference again toFIGS. 5A and 5B, extending from the sloped sidewalls204may be a plurality of rungs210that define a base208of the basket200. The plurality of rungs210may be coupled to both sloped sidewalls204and extend therebetween. The plurality of rungs210may be curved to continue to guide material bales into the base132of the basket200for grinding by the grinding flights130as illustrated inFIGS. 8A and 8B. In the present embodiments, three parallel rungs211,212, and213are depicted spaced apart from one another. However, it is contemplated that any number of rungs210may be used. The spaces around the rungs211,212, and213may define the flight paths212for the grinding flights130to rotate through. In some embodiments, the plurality of rungs210may have serrated edges that contact the material bales so as the encourage contact between the material bales and the plurality of grinding flights130. That is, the serrations of the plurality of rungs210may grab onto the material bale204to better hold the material bale402for the grinding operation of the grinding flights130.

One or more cross bars214may extend between and connect the plurality of rungs210. The one or more cross bars214may provide additional support to the structure. In some embodiments, the one or more cross bars214may also include serrated edges to aid in guiding and holding material bales in contact with the plurality of grinding flights130. As the plurality of grinding flights130grind up material bales, the basket200may prevent particles of the material bale from being added to the material slurry that are greater than a predetermined size. Accordingly the frame202of the basket100may exclude particles of a material bale above a predetermined size from entering the material slurry. For example, particles of material bale which may clog a material pump or sprayer unit. In some embodiments, particles of material bale which are greater than a distance between adjacent rungs (e.g.,211and212) may be excluded from entering the material slurry.

Referring toFIG. 6, the interior18of the hydroseeder10is schematically depicted. As illustrated, the basket200is coupled to the tank12around the opening14. The agitator100is positioned directly below the basket200such that at least some of the grinding flights130are positioned to pass through the basket200(e.g., through the flight paths defined by the basket200) when performing a grinding operation.

FIG. 7illustrates a flow chart300illustrating a method of preparing a material slurry for a hydroseeding operation.FIG. 7is best understood when described in conjunction withFIGS. 8A and 8B, which schematically illustrate a grinding operation by the plurality of grinding flights130of the agitator100.

At step302a hydroseeder100, such as that described in conjunction withFIGS. 1-6is provided. A liquid400, illustrated inFIGS. 8A and 8Bis added to the tank12at step304. The liquid400for example may include water or other suitable liquid for performing a hydroseeding operation. At step306a material bale402is directed through the opening14of the tank12. The basket200guides the material bale402into contact with the grinding flights130. As the material bale402is guided by the basket200toward the grinding flights130of the agitator100the grinding flights130may grind the material bale402into a particulate (step308), shown inFIG. 8B. The mixing paddles120(shown inFIG. 2) rotate with the grinding flights130, since they are connected to the same rotatable shaft110, to agitate and mix the ground particulate404of the material bale402to provide the material slurry of liquid, seed, mulch, and fertilizer, for example (step310). Once mixed, the material slurry may be ready for a hydroseeding operation (step312). That is the material slurry may be pumped out of the tank12using a material pump, and sprayed onto prepared earth to seed the prepared earth.

Accordingly, aspects of the present disclosure are directed to hydroseeders that include an integrated bale grinder. In particular, the bale grinder is incorporated into an agitator of the hydroseeder and is configured to grind up material bales as they are introduced into a tank of the hydroseeder. In the embodiments described herein, grinding flights are coupled to an agitator of the hydroseeder and positioned beneath an opening in the hydroseeder, which allows the grinding flights to grind material bales as they are dropped into the opening of the hydroseeder. This allows for the material bales to be more finely broken apart and integrated into the material slurry, which may prevent clogs in the sprayer/pump of the hydroseeder. Accordingly, a more efficient hydroseeder may be provided.