Method and apparatus for installing barrier material

A farm implement for guiding a barrier material into a layered material comprises a turntable for holding the barrier material, a guide apparatus for guiding the barrier material into the layered material, and a crossbar to which is attached the turntable and a hitch portion for attaching the crossbar to a vehicle. The guide apparatus comprises a vertical support post that attaches the guide apparatus to the crossbar, a guide slot hingedly attached to the vertical support post, a platform and at least one roller attached to the guide slot, and at least one cap hingedly attached to and positioned above the guide slot.

CROSS-REFERENCE TO RELATED APPLICATIONS

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to farm implements and methods in general and in particular to a method and apparatus for installing fencing or other barrier or confinement materials below the surface of, for example a litter pile, for raising animals therein.

Large scale poultry farming requires large enclosures for containing the hatchlings in order to keep them confined, which at early stages is important for keeping them near a source of heat and at all stages is important for the birds' protection. Typically these enclosures are placed in a fresh bed of litter, which must be replaced after each batch of birds has been raised.

The litter can be comprised of a variety of materials and arranged in various ways. Often the bottom layer of litter is composed of a water-absorbent material, which is important for containing wastes and keeping the birds dry and clean. This absorbent material may be a natural material which is relatively inexpensive to obtain and relatively harmless to the birds.

Many growers use waste material from a variety of natural sources, for example hulls generated during the production of white rice, as a base for their litter. While rice hulls have many other beneficial properties such as water absorbency, they are nonetheless potentially dangerous to the health of the birds. If a chicken or turkey poult swallows a piece of hull the material can get stuck in the bird's crop and if not dislodged can lead to the bird's death. Therefore, the bottom layer of rice hulls (or other base material) is overlaid with layers of other, less harmful materials such as wood chips, wood shavings, or straw.

When barriers are installed in the barn or pen to create discrete brooding pens for the poults, care must be taken not to disturb the layers of material so as avoid turning up to the surface any materials (such as rice hulls) from lower layers that could be a danger to the birds. The extra care that must be taken during installation of temporary barriers for confining the birds (or other animals) while they are being raised makes manual installation of the barriers difficult and time-consuming. Even where no dangerous materials are used, manually installing a barrier in the litter pile is still a laborious process that can consume a great deal of time.

More generally, installing a barrier material into a layered material can be cumbersome and time-consuming, especially when care must be taken not to mix or disturb the various layers involved. One such example is the installation of lawn or garden edging materials, wherein one must avoid spilling dirt onto the adjoining grass or pavement.

SUMMARY OF THE INVENTION

The object of this invention, therefore, is to provide a method and apparatus for installing a barrier in a litter pile or any other layered surface.

In one embodiment the invention is a guide apparatus for guiding a barrier material into a layered material, where the guide apparatus comprises a guide slot having solid walls; and at least one cap, positioned over the guide slot and arranged to generate downward force on the barrier material as the barrier material is guided through the guide slot.

In another embodiment the invention is a method of inserting a barrier material into a layered material, comprising the steps of providing a guide apparatus comprising a guide slot having solid walls and an open rear portion and at least one cap, the cap being positioned over the guide slot and arranged to generate downward force on the barrier material as the barrier material is guided through the guide slot; advancing the guide apparatus through the layered material; guiding the barrier material through the guide slot; and extruding the barrier material through the open rear portion of the guide apparatus into the layered material.

In yet another embodiment the invention is a farm implement for guiding a barrier material into a layered material, the farm implement comprising a turntable for holding the barrier material; a guide apparatus for guiding the barrier material into the layered material, the guide apparatus comprising a vertical support post, a guide slot hingedly attached to the vertical support post, a platform and at least one roller attached to the guide slot, and at least one cap hingedly attached to and positioned above the guide slot, and a crossbar to which is attached the turntable and the vertical support post of the guide apparatus, the crossbar further comprising a hitch portion for attaching the crossbar to a vehicle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1shows a tractor10pulling one embodiment of a brooder guard plow20while installing barrier material30. This embodiment, and the device in general, is referred to as a “brooder guard plow” to reflect the fact that this particular embodiment of the invention has been developed for installation of cardboard barriers referred to as “brooder guards” into layers of litter60, wherein the device “plows” through the litter layers as it guides the barrier material into place. Nonetheless the general principles described herein may be used in a variety of settings to install fencing or other barriers into layered material which might also include earth. In still another embodiment the base surface is a layer of relatively loose material such as sand or silt. Brooder guard plow20collectively refers to a guide apparatus40for guiding barrier material30into layered litter60, a turntable70for holding and dispensing barrier material30, a crossbar100for supporting the various parts and attaching to tractor10, and an adjustable stand120for supporting brooder guard plow20when it is not attached to tractor10or other vehicle.

Brooder guard plow20is designed to create a narrow furrow as it moves along, into which the desired barrier material30is inserted from the back end of a guide apparatus40. Guide apparatus40consists of an elongated slot through which barrier material30is fed as barrier material30is gradually bent, so that it ends up parallel to a base surface50(FIG. 4) on which it is laid. Base surface50in one embodiment is a concrete barn floor on which litter material60is layered, and in other embodiments base surface50is earth. Barrier material30is preferably carried along with guide apparatus40, preferably on a rotating turntable70that permits smooth feeding of barrier material30through guide apparatus40.

Arrows inFIG. 1suggest the forward movement (straight arrow) of tractor10and the concomitant rotational movement (curved arrow) of a roll80of barrier material30on turntable70. As barrier material30moves through guide apparatus40, barrier material30is bent slightly in a vertical direction as it makes a transition from being above litter60and tilted relative to the level of base surface50to being below litter60and parallel to base surface50. This transition generally induces ruffles90in barrier material30, with these ruffles90being greater near the upper edge of barrier material30. Guide apparatus40must be long enough for barrier material30to make a sufficiently gradual transition before coming to rest on base surface50. In one embodiment using eighteen inch wide corrugated cardboard, the guide slot portion (described below) of guide apparatus40is approximately five and a half feet long.

Guide apparatus40and turntable70, in one embodiment, are mounted on a crossbar100that is adapted to be attached to tractor10, e.g. using a standard three-point tractor hitch110(FIG. 2). However, this is only one embodiment and other means of driving guide apparatus40and turntable70are encompassed within this invention, including mounting guide apparatus on the front or side of a vehicle. Furthermore, in the case where tractor10is the means by which guide apparatus40and turntable70are driven, other types of hitches and coupling mechanisms may be used without deviating from the invention. In a preferred embodiment, crossbar100has a non-circular cross-section such as a square to allow more secure attachment of the various components, without the clamps holding the components inadvertently rotating and thus misaligning the components.

In a preferred embodiment guide apparatus40and turntable70are attached to crossbar100as shown inFIG. 1. Crossbar100, in turn, can be moved up and down, e.g. by a hydraulic system that is part of tractor10or other vehicle to which brooder guard plow20is attached, to permit the height of guide apparatus40to be adjusted relative to base surface50. Other means of carrying barrier material30and feeding it into guide apparatus40, such as from an adjoining vehicle, are also encompassed within this invention.

In one embodiment, shown in the foreground on the right ofFIG. 2, crossbar100includes an adjustable stand120, which is useful for allowing brooder guard plow20to stand on its own in a relatively level orientation when it is not attached to tractor10or other vehicle. Adjustable stand120is preferably freed and locked back into place by a quick-release mechanism that does not require tools, such as a thumbscrew or a knob with a threaded shaft (not shown), to permit ease of operation. During operation adjustable stand120is moved upwards high enough to keep the bottom portion from contacting the layered material. Adjustable stand120preferably has a wide base130to distribute the weight of brooder guard plow20over a wider area, to avoid its sinking, e.g. into soft earth or sand, or damaging surfaces such as concrete or asphalt.

The lateral positions of turntable70, guide apparatus40, and adjustable stand120along the width of crossbar100can be adjusted by loosening the clamps140that hold these respective parts onto the crossbar. Alternatively, these parts can be permanently fixed into place, for example by welding, as shown for adjustable stand120inFIG. 2.

Shown inFIG. 3is a preferred embodiment of turntable70, which supports roll80of barrier material30to be installed. In this embodiment turntable70consists of a flat, circular table surface150with a spindle160projecting from an upper surface and a stem170protruding from the opposite surface and an optional plurality of gussets180on the underside to strengthen table surface150. Table surface150is preferably wide and strong enough to hold a complete roll80of barrier material30without having the outer portions of roll80slip off the sides. Thus the diameter of table surface150is preferably at least several inches larger than the diameter of a full roll80of barrier material30. In one embodiment table surface150is thirty inches in diameter, which is sufficiently wide to hold a full roll of corrugated cardboard which initially contains 250 feet of material and is at least twenty-seven inches in diameter. The top of table surface150of turntable70is preferably smooth with no lip at the edge, in order to permit smooth feeding of barrier material30off turntable70and into guide apparatus40.

Stem170fits into a hole190on a support arm200, which in turn is attached to crossbar100. To promote smoother turning of turntable70and hence smoother feeding of the material, the interface between stem170and hole190is greased. Smooth movement may also be obtained by installing ball bearings at this point of rotation. In other embodiments turntable70can also be stationary, provided that roll80of barrier material30is able to turn about the spindle smoothly enough to permit feeding of barrier material30into guide apparatus40as it is installed. Furthermore and as mentioned previously, barrier material30can be stored and fed into guide apparatus40by other means besides turntable70attached to the crossbar100. For example another vehicle that contains barrier material30might move alongside the vehicle, e.g. tractor10, that is driving guide apparatus40.

The height of turntable70can be adjusted at a collar210. Ideally the height of turntable70is high enough to ride above litter60while tractor10moves, without disturbing the layers of litter60. Preferably the height of turntable70is adjusted so that barrier material30moves from roll80to guide apparatus40while remaining relatively flat and unruffled.

In a preferred embodiment turntable70is tilted relative to base surface50to reduce or eliminate the angle of bending that barrier material30must make before entering guide apparatus40. In a preferred embodiment turntable70is tilted backwards (relative to tractor10) as well as towards guide apparatus40. The angle of tilt in one embodiment is between approximately 15° and 20° (relative to horizontal—seeFIG. 3) and in a preferred embodiment is approximately 18°, both in the backwards direction (angle α inFIG. 3, which represents the 90° right angle of support arm200plus the 15°–20° of backwards tilt) as well as towards the side containing the guide apparatus (angle β inFIG. 3represents the 15°–20° tilt relative to a reference point that is approximately normal to base surface50). In general the backward angle of tilt of turntable70should approximately match the angle of the downward slope of barrier material30as it moves through guide apparatus40. The angle and length of guide apparatus40, in turn, depend on the width and flexibility of the barrier material being installed, such that barrier material that is wider or less flexible will need a shallower, more gradual angle as it makes the transition from above to inside of or below the layered material.

The angle of tilt on turntable70can be set at a number of points, e.g. where the adjustable vertical portion of support arm200meets the horizontal part having hole190which holds stem170(angle α inFIG. 3) or by adjusting the clamp that holds the turntable assembly onto crossbar100, if the cross-section of crossbar100permits such rotational movement. The backward tilt angle of turntable70can also be made to be adjustable by making the joint labeled with angle α inFIG. 3a pivoting joint that can be adjusted and locked down. In a preferred embodiment the backward tilt angle is permanently set at the position labeled as angle α (FIG. 3) and the side tilt angle labeled β is set by twisting the material to which turntable support hole190is attached (FIG. 3).

In one embodiment there is an optional tension bar220attached to the turntable which puts sufficient force on roll80of barrier material30to keep it from ‘freewheeling’, i.e. spinning faster than is warranted by the rate of material feeding and thus unwinding excess material (FIG. 6B). Tension bar220in one embodiment is pivotably attached to the vertically adjustable support bar of turntable70and consists of tension bar220with an optional flap230at the end that contacts the roll of barrier material. Flap230helps to more evenly distribute the force of tension bar220to avoid having the end of tension bar220tear barrier material30. Tension bar220is held against roll80in one embodiment by action of a simple spring240attached to crossbar100(FIG. 6B). Tension bar220can be set on the left or right side of roll80, depending on which direction roll80is mounted on turntable70, with the attachment of spring240to crossbar100being switched to the opposite side.

FIG. 4shows a cross-section of barrier material30after installation. In this view part of layered material60has been omitted to permit clear viewing of the installed barrier material30along its full height. At the bottom is base surface50upon which barrier material30rests; in one embodiment this is a concrete floor of a barn while in other embodiments this is a hard-packed earth surface. Above this base surface50in one embodiment is a layer of water-absorbent material62, which in a preferred embodiment consists of a layer of rice hulls about two inches deep. This material is then overlaid with an upper layer of material64such as wood chips, wood shavings, straw, or some combination of materials in one or more layers. Upper layer64is generally deeper than lower layer62and in one embodiment upper layer64is six inches deep.

When barrier material30has been installed, the support generated by the surrounding layered material is usually sufficient to keep barrier material30upright. However, if necessary (and as appropriate given the nature of the base surface) stakes or posts may be added to keep the barrier material from falling or sagging.

FIG. 5shows the installation of barrier material30. Before installing barrier material30, guide apparatus40is pulled by tractor10or other device as guide apparatus40is lowered, until guide apparatus40is at a desired height relative to base surface50. Usually guide apparatus40is lowed until its bottom portion is resting on base surface50. By driving guide apparatus40forward as it is lowered this minimizes disruption of layered material60as guide apparatus40is inserted therein. Also, in the case of denser layered materials it may be necessary to drive guide apparatus40forward while lowering in order to be able to penetrate layered material60. By running guide apparatus40through layered material60for a short distance this creates a furrow into which the beginning portion of barrier material30may be fed when starting a new row.

In one embodiment a skid plate250is attached to the underside of guide apparatus40, preferably at or near the front end, to keep guide apparatus40resting on base surface50(and to prevent guide apparatus40from digging deeper, in the case of a base surface consisting of a softer material such as earth) and to prevent damage to the underside of the remainder of guide apparatus40(FIG. 7).

To install, barrier material30is manually fed through guide apparatus40until barrier material30protrudes from the back end of guide apparatus40. In one embodiment a furrow is made in layered material60by hand, or other means besides movement of guide apparatus40, to permit the beginning of barrier material30to be inserted. In another embodiment, as described above, guide apparatus40is run through layered material60for a short distance to create an initial furrow into which barrier material30may be manually inserted during initial setup.

The end of barrier material30is then held firmly in place while guide apparatus40is moved forward through layered material60(FIG. 5). Barrier material30may be held in place by hand (FIG. 5), or it may be staked, clamped, or weighted in place to allow a single person to install barrier material30without assistance. Guide apparatus40is then driven forward, guide apparatus40digging a narrow furrow or channel through layered material60as it advances and inserting barrier material30with minimal disruption of layered material60. If barrier material30is fragile, as, for example, in one embodiment where it is corrugated cardboard, then guide apparatus40must be moved forward slowly so as to permit barrier material30to feed through guide apparatus40without tearing. After guide apparatus40passes a given point, layered material60generally falls back into place around the newly-inserted barrier material30. In regions where two separate pieces of barrier material30meet such as where barrier material30has torn or a roll of material has ended, tape, clips, clothespins, or other fastening techniques may be used to join the barrier material pieces together.

The roll80of barrier material30may be placed on turntable70in one of two orientations (FIGS. 6A and 6B). Changing the orientation may be desirable if barrier material30has two different faces, so that a particular face (smooth or ridged, for example, in the case of corrugated cardboard) faces to the left or right as it is installed.

FIGS. 7 and 8show different views of a preferred embodiment of guide apparatus40either with (FIG. 7) or without (FIG. 8) barrier material30present. At the front end guide apparatus40includes a vertical post260for attaching guide apparatus40to crossbar100. In a preferred embodiment the bottom of vertical post260has attached to it skid plate250, to keep guide apparatus40resting on base surface50(and to prevent the guide apparatus from digging deeper, in the case of a base surface consisting of a soft material such as earth) and to prevent damage to the underside of the remainder of guide apparatus40(FIG. 7). In one embodiment the front edge of vertical post260is rounded or has a triangular ‘knife’ edge to allow vertical post260to ‘cut’ through layered material60with a minimum of disruption of the layers.

Attached to vertical post260are one or more flat plates270, preferably at least several inches higher than the anticipated level of layered material60, which create a wall that prevents layered material60from falling into the path of the advancing guide apparatus40(FIG. 7). The front portion of guide apparatus40consisting of vertical post260and flat plates270is preferably attached by a hinge280to the rearward portion of guide apparatus40, which rearward portion consists of a guide slot290and related components. This connection between the front and rear portions of guide apparatus40is preferably hinged so as to allow the rear portion to move up and down with the contours of base surface50on which barrier material30is being laid, even if tractor10or other vehicle moves up and down during installation. This allows the rear exit portion of guide slot290to remain in close contact with base surface50at all times, insuring that barrier material30is always inserted as close as is practical to base surface50. Flat plates270attached to vertical post260are arranged with enough clearance to permit pivoting movement of the rear portion of guide apparatus40relative to the front portion without binding or other interference (FIGS. 7 and 8).

To limit the range of movement of the rear portion of guide apparatus40, especially when the entire brooder guard plow20is lifted off base surface50, one end of a chain300is attached to the vertical post and the other end of the chain is attached to part of the rear portion of the guide apparatus (seeFIGS. 2,7). The length of chain300is adjusted so that it becomes taut when vertical post260is lifted, such that the rear portion of guide apparatus40is lifted off of base surface50and not allowed to drag. In an embodiment wherein the bottom edge of flat plates270are approximately parallel to base surface50, the rear portion of guide apparatus40angles downward slightly when the entire guide apparatus40has been lifted, chain300is taut, and no part of the rear portion is resting on base surface50.

The rear portion of guide apparatus40consists of guide slot290, one or more top caps310, and optional rollers320and other guides to ensure smooth feeding of barrier material30(FIGS. 7 and 8). Guide slot290is preferably tapered with a solid bottom and solid walls (FIG. 8). The solid bottom and walls prevent layered material60from entering into and potentially clogging guide slot290. The width and degree of taper of guide slot290depends on, among other factors, the width and flexibility of barrier material30and thus the degree of bending or ruffling needed to transition barrier material30to base surface50, as well as relative density of layered material60(such as litter) through which guide apparatus40is driven. If the litter or other layered material60is relatively dense, then a narrower profile may be desired for the entire guide apparatus40, in order to reduce the amount of force required to drive guide apparatus40through layered material60. If guide slot290is made narrower, however, guide slot290may be made longer to give a greater transition length, so as to permit barrier material30to make the transition with smaller ruffles90and thus be able to fit in the narrower guide slot290.

The inside portion of guide slot290is preferably relatively smooth and free of rough edges to prevent barrier material30from catching and possibly tearing as it is fed through. The walls are preferably at least several inches higher than the highest anticipated level of layered material60, to prevent layered material60from falling into guide slot290. In one embodiment at least some part of the upper portion above guide slot290is left open to permit manual feeding and unjamming of barrier material30in guide slot290(FIGS. 7 & 8).

The base of guide slot290in one embodiment is approximately two inches wide, and the walls are tapered outward towards the top so that the distance between the walls at the top is several inches wider (FIGS. 7 and 8). Guide slot290is tapered so that the bottom portion has a smaller profile, to reduce disruption of layered material60, while still allowing the upper portion of barrier material30to bend or ruffle as it is fed through guide slot290. In one embodiment the front edge of the outer wall of guide slot290has an inward curve330, preferably just near the top, to help guide barrier material30into guide slot290(FIG. 8).

Near the front end of guide slot290is preferably a platform340and one or more rollers320that help smoothly guide barrier material30into guide slot290(FIG. 1). Rollers320may be simply smooth and rounded but stationary surfaces, or rollers320may rotate with bearings to permit ease of rotation. To help push and guide barrier material30downward there are preferably one or more hinged and weighted caps310above guide slot290. Caps310are preferably hinged at the front end (dashed line images of caps310A inFIG. 7indicate direction of motion and point of pivot), to allow a steady pushing force to be applied to barrier material30as it undergoes the bending that is necessary during the transition into layered material60. In one embodiment caps310are made of steel, such that the weight of the material itself provides sufficient downward force on barrier material30. In other embodiments caps310are spring-loaded, using methods that are well known in the art, to generate downward force. Caps310are preferably elongated channels with a lip on either side, so that cap310helps to guide and stabilize the upper edge of barrier material30as it passes through guide slot290inducing ruffles90(FIG. 7).

The hinged ends of caps310are supported at heights sufficiently high above guide slot290to permit barrier material30to make a gradual transition from where barrier material30enters guide apparatus40, roughly at the level of turntable70, until barrier material30reaches the rear end of guide slot290and is deposited with its lower surface at approximately the level of base surface50. The posts312that support caps310, as well as any other portion of guide apparatus40, are designed to have a relatively flat profile so as to prevent disruption of layered material60that might occur if any parts of guide apparatus40protruded from the sides.

As barrier material30leaves roll80the bottom edge contacts platform340of guide apparatus40and the entire width of barrier material30contacts rollers320(FIG. 1). As barrier material30moves through guide apparatus40, barrier material30is only supported on its bottom edge by the small platform340near the front of guide apparatus40(FIG. 1). After moving past platform340, barrier material30is no longer supported on its bottom edge until barrier material30nears the rear end of guide slot290. In the intervening space the lower edge of barrier material30is unsupported. The lack of support on the lower edge, plus the downward-pushing force of the cap(s), forces barrier material30downward, generating ruffles90, and thus aids in forcing barrier material30to be parallel to and at the level of base surface50(FIGS. 1,5, and7).