Patent Publication Number: US-2006000490-A1

Title: Method and apparatus for cleaning residual material from the dispensing elements of mixing trucks

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The invention relates to a method and apparatus to facilitate cleaning of the dispensing elements of mixing trucks. More specifically, the invention relates to cleaning the hopper and chutes of concrete mixing trucks while retaining the runoff from the cleaning process for proper disposal at a later time.  
      2. Description of the Related Art  
      Conventional concrete mixing trucks include large drum containers for mixing aggregate, sand, and cement slurry together to produce pourable concrete at a job site. Typical operation of a concrete mixing truck begins by loading the truck with the materials, usually by depositing the materials into the drum via one or more loading hoppers at the concrete facility. After loading, the drum rotates to mix the materials, and the truck is driven to a construction site where the delivery chute is positioned at a desired location. The chute is placed at a downward angle so that the concrete mixture may flow down and out of the chute. An auxiliary chute, or chute extension may be attached to the end of the main chute to better direct the flow of concrete. The concrete is discharged from the drum, into a truck hopper, and down the chute to the desired discharge location, such as into a concrete pump, a wheelbarrow, or directly onto the area being coated. A residual amount of concrete or a coating thereof may remain on the truck&#39;s dispensing elements after the concrete is poured. This concrete or concrete coating may harden on the chutes and hopper, thereby impeding use of the dispensing elements at a later time. In addition, the residual concrete may accidentally fall from the truck while the truck is returning from the construction site. This can create a hazard to drivers following behind the truck, and may form undesirable deposits of concrete on roads or other areas.  
      Thus, after concrete has been fully discharged from the truck, the operator must wash away the concrete residue adhering to the truck hopper and outlet chutes before leaving the construction site. In order to remove the concrete residue, the hopper and chutes may be washed off at the construction site using a hose and water. A disadvantage of this method is that a concrete patch is formed on the ground at the site where the washing takes place. For this reason, many localities have laws barring this practice. Accordingly, the contractor must provide a designated location at the construction site where this rinsing operation may occur. This may be inconvenient and inefficient, especially if the rinsing station is located at a site remote from the concrete discharge location.  
      Moreover, concrete truck wash-off can pose serious environmental concerns. Thus, environmentally friendly and cost efficient systems for cleaning the dispensing elements of concrete mixing trucks have become ever more desirable, especially as it becomes increasingly unacceptable to dump the residual concrete outside of a prescribed disposal area. In many cases, precautions must be taken at the construction site to ensure that concrete residue runoff does not contaminate the site or adjoining waterways. Because construction sites are being subjected to ever-increasing environmental regulations, proper disposal of concrete residue will continue to be of concern for the foreseeable future.  
      Various systems for ridding residual concrete material from mixing trucks have been proposed, including emptying the material into portable containers for remote disposal, and washing the material directly into sewage systems. These methods are undesirable in that they pose various environmental and practical problems. For example, emptying the material into portable containers, such as buckets, for remote disposal, is labor intensive and time consuming. Washing the material directly into a sewage system causes environmental and other problems. For example, it can increase the burden on the sewage system and may cause blockage of the system, in addition to being environmentally undesirable. Yet other prior art systems require the use of powered pumps or pressurized containers for returning the runoff material to the drum on the truck. These systems are prohibitive because of the expense in acquiring and maintaining the systems.  
      Consequently, it would be advantageous to provide an environmentally sound and economically practical method and apparatus that would greatly reduce or eliminate the drawbacks of the prior art systems. It would be particularly desirable if such a method and apparatus were able to recycle any residual material so that it may be recovered and reused. The need has therefore arisen for an improved system for cleaning residual material from concrete trucks and disposing of it properly.  
     BRIEF SUMMARY OF THE INVENTION  
      In a first aspect, the invention is directed to a system, method, and apparatus for facilitating the cleaning of residual material from the dispensing elements of a truck, such as from the hopper, main chute, and auxiliary chute of a mixing truck. The apparatus of the invention includes a catch basin that is mounted on and carried by the truck for receiving the runoff from washing the material residue from the dispensing elements of the truck. A funnel assembly may be mounted on the truck&#39;s dispensing chute, and a drain hose is connected between the funnel assembly and the catch basin. The dispensing elements of the truck are then washed using water or other suitable liquid, and the mixture of liquid and residual material passes through the funnel and hose under the force of gravity, and into the catch basin. The apparatus may also include a means for supporting and cleaning an auxiliary chute.  
      In another aspect, the method of the invention includes: providing a concrete mixing truck with a catch basin; attaching a funnel to the main chute of the truck; connecting a hose between the funnel and the catch basin; and washing the chute with water or other liquid, whereby the water washes the concrete residue from the chute, into the funnel, through the hose, and into the catch basin. If an auxiliary chute also requires cleaning, the method may also include the step of mounting the auxiliary chute on the catch basin and washing the concrete residue from the auxiliary chute into the catch basin. The runoff received by the catch basin may be emptied at a later time and properly disposed of or recycled.  
      These and other features and advantages of the present invention will become apparent to those of ordinary skill in the art in view of the following detailed description of the preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The accompanying drawings, in conjunction with the general description given above, and the detailed description of the preferred embodiments given below, serve to illustrate and explain the principles of the preferred embodiments of the best mode of the invention presently contemplated, wherein:  
       FIG. 1  is a perspective view illustrating the system, method, and apparatus of the invention;  
       FIG. 2  illustrates a perspective view of the truck-mounted catch basin and detachable funnel of the invention in transport configuration;  
       FIG. 3  illustrates a perspective view of the catch basin of the invention with one sidewall partially cut away, the lid open, the funnel removed, and further illustrating the insertion of the auxiliary chute support rods;  
       FIG. 4  illustrates a top view of the catch basin of the invention, with the lid open  180  degrees to illustrate the auxiliary-chute support rod storage tubes;  
       FIG. 5  illustrates a side view of the detachable funnel assembly of the invention; and  
       FIG. 6  illustrates an end view of the detachable funnel of  FIG. 5 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      In the following detailed description of the invention, reference is made to the accompanying drawings which form a part of the disclosure, and, in which are shown by way of illustration, and not of limitation, specific embodiments by which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. The embodiments illustrated are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of the invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the invention is defined only by the appended claims, along with the full range of equivalents to which such claims are entitled.  
      As illustrated in  FIG. 1 , the method and apparatus of the invention is directed to a system  10  for cleaning residual concrete material from the dispensing elements of concrete trucks following the pouring of concrete, or the like. The system  10  of the invention is mounted on a truck  12  having a mixing drum  13 . Truck  12  may be any type of truck that uses a chute for dispensing of materials, but in the preferred embodiment of the invention, truck  12  is a conventional concrete mixing truck having dispensing elements  14 , which generally include a hopper  15 , a main chute  16 , and a detachable auxiliary chute  18 . During travel of truck  12  to a job site, auxiliary chute  18  is stored on truck  12  in separate location, detached from main chute  16 . Prior to pouring of concrete, auxiliary chute  18  may be attached to the distal free end  20  of main chute  16  to provide better control for directing the flow of concrete exiting mixing drum  13 . Free end  20  of main chute  16  includes a pair of chute pins  22  that extend outward from main chute  16  at a right angle to the direction of flow of concrete. A first mating end  24  of auxiliary chute  18  is fitted with a pair of chute-attachment hooks  26  which enable auxiliary chute  18  to be hung on free end  20  of main chute  16  by interfitting hooks  26  with chute pins  22 , so that main chute  16  and auxiliary chute  18  form a continuous half-pipe-like surface (not shown) for dispensing of concrete.  
      The apparatus of the invention is advantageously mounted on and carried by truck  12 , and includes an on-board catch basin  30  that may be mounted on the rear of truck  12  behind the rear tires  28 . As also illustrated in  FIGS. 2-4 , catch basin  30  is a water-tight container or box, which is constructed having a front wall  31 , two sidewalls  32 , a rear wall  33 , and a bottom  34 , and is preferably constructed of sheet metal that is folded and welded along mating seams. A lid  36  is attached to basin  30  by hinges  37 , and may be opened for providing access to the interior of basin  30 , or closed for when truck  12  is in motion. Angle reinforcements  38  are included around the lip  40  of basin  30  to provide reinforcement so that basin  30  is able to support the other components of system  10  and auxiliary chute  18 . Angle reinforcements  38  project inward from front wall  31 , sidewalls  32 , and rear wall  33 , and, thereby, help prevent spillage of runoff liquid from within basin  30  while truck  12  is in motion. To further prevent spillage of the runoff during transport, a seal (not shown) may be provided around the upper lip  40  of catch basin  30  for contacting lid  36  when lid  36  is in the closed position, as illustrated in  FIG. 3 . Catch basin  30  may be either permanently attached to truck  12  by welding, or the like, or may be removably secured to truck  12  by mechanical fasteners or other known means.  
      Catch basin  30  includes a pair of funnel mounting brackets  42  located near upper lip  40  on the exterior surface of front wall  31 . Each funnel mounting bracket  42  projects outward from front wall  31 , and includes a horizontally-disposed funnel-support pin  46 . As illustrated in  FIG. 2 , a funnel assembly  50  may be detachably mounted on mounting brackets  42  while the cleaning system  10  of the invention is not in use or ready for transport, so that funnel assembly  50  is supported on the front wall  31  of catch basin  30 . This provides a secure storage location for funnel  50  during travel of truck  12  to and from a job site. In addition, catch basin  30  includes a main latch  48  for securing lid  36  during travel mode. A funnel latch  49  may also be provided for securely latching funnel  50  in place during travel mode so funnel  50  does not come loose of mounting brackets  42  when truck  12  goes over a bump, or the like. Alternatively, lid  36  may be extended in the areas  44  over mounting brackets  42  to perform a similar securing function by trapping funnel  50  within mounting brackets  42  (as illustrated only in  FIG. 4 ), and, in this embodiment, only main latch  48  is required for securing the invention for transport.  
      As illustrated in  FIGS. 5-6 , funnel assembly  50  includes a pair of mounting hooks  52  which enable funnel assembly  50  to be not only detachably mounted on basin  30  during transport, but which also are of a size and configuration similar to chute attachment hooks  26  on auxiliary chute  18 . This enables funnel assembly  50  to be mounted on main chute  16 , by engaging funnel mounting hooks  52  with chute pins  22 , as illustrated in  FIG. 1 . Thus, funnel assembly  50  can be detachably mounted on free end  20  of main chute  16  for receiving waste cleaning liquid resulting from cleaning of main chute  16 .  
      Funnel assembly  50  includes a semi-cylindrical funnel wall  54  having a semi-circular rear funnel wall  56  welded to one end to create a closed end  58  of funnel  50 , and an open, mating end  60  of funnel  50 . Semi-cylindrical funnel wall is shaped in a half-pipe configuration of a similar size and shape to match the size and shape of free end  20  of main chute  16 , so that cleaning water will flow from main chute  16  into funnel  50 . Funnel assembly  50  may be constructed from sheet metal materials, such as stainless steel, steel, aluminum, or other suitable materials.  
      Mating end  60  of funnel  50  includes a funnel lip  62  formed around the perimeter of semi-cylindrical funnel wall  54 , and a gasket  64  is attached around the perimeter of funnel lip  62 . Gasket  64  forms a seal with free end  20  of main chute  16  when funnel  50  is mounted on main chute  16  to help prevent leakage of cleaning water onto the ground. Gasket  64  may be constructed of a suitable polymeric or other material such as silicone, vinyl, rubber compounds, and the like, and may be attached to funnel lip  62  by adhesive, mechanical fasteners, or other suitable means.  
      Funnel mounting hooks  52  are located on opposite sides of semi-cylindrical wall  54 , and are attached by welding or other suitable means. It may be seen from  FIG. 5  that mounting hooks  52  extend outward beyond funnel lip  62  to enable funnel  50  to engage with chute pins  22  (not shown in  FIG. 5 ). A handle  68  may also be included on funnel assembly  50  and may be located on rear funnel wall  56 . Handle  68  is useful for handling funnel  50  when aligning mounting hooks  52  with chute pins  22  on main chute  16  or mounting brackets  42  on catch basin  30 .  
      Funnel assembly  50  includes a drain opening  70  formed in the bottom of semi-cylindrical funnel wall  54 . A drain pipe  72  is attached to drain opening  70  for receiving cleaning water flowing into funnel  50 . Drain pipe  72  preferably includes an elbow  74  for angling the drain pipe exit  76  toward basin  30  when funnel  50  is mounted on main chute  16 . Drain pipe exit  76  includes a hose connector fitting  78 , such as a camlock fitting, threaded hose fitting, or any of the other types of hose fittings commonly known in the art. As illustrated in  FIG. 1 , a drain hose  80  has a first end  82  connectable to drain pipe  72 , and a second end  84  that is disposed within catch basin  30 . It will be apparent that cleaning liquid is able to pass from main chute  16 , into funnel  50 , through drain pipe  72  and drain hose  80 , and into catch basin  30 .  
      The system  10  of the invention also makes provision for the convenient cleaning of auxiliary chute  18  by providing an auxiliary chute support arrangement  88 . As illustrated in  FIGS. 3 and 4 , auxiliary chute support arrangement  88  includes auxiliary chute support rods  90 , which are stored in storage tubes  92  located on the inner surface of lid  36 . Support rods  90  may be retained in storage tubes  92  by frictional fit or by other known means. Support rods  90  are constructed from angle iron or other suitable material having an angle cross-section, and each support rod  90  includes an auxiliary chute support pin  94  located at one end. Support pins  94  extend outward at a right angle from the major axis of support rods  90 , and are attached to support rods  90  by welding or other suitable means.  
      Basin  30  includes two pairs of support rod brackets located at two opposed inner corners of near sidewall  32 . Each pair of support rod brackets includes an upper support rod bracket  96  and a lower support rod bracket  98 . An angle-shaped hole  100  is formed in-line through each support rod bracket  96 ,  98 , so that a support rod  90  can be slid into angle-shaped hole  100  and maintained in an upright position. Because hole  100  is angle-shaped, rather than round, support rods  90  will not rotate when inserted in holes  100 . Support rods  90  are inserted in holes  100  in the configuration illustrated in  FIG. 3 , so that support pins  94  face outward in opposite directions from each other. As illustrated in  FIG. 1 , an auxiliary chute  18  may be hooked-on to support pins  94  and held with its mating end  24  adjacent to basin  30 , so that when auxiliary chute  18  is washed, the runoff will flow directly into basin  30 .  
      In addition, it should be noted that bottom  34  of catch basin  30  has a downward slope from front wall  31  to rear wall  33 , and from far sidewall  32  to near sidewall  32 , so that water will flow toward a drain valve  110  located at a rear corner  112  of catch basin  30 . Drain valve  110  includes a handle  114 , which may be actuated by pulling outward, as indicated by arrow  116  in  FIG. 3  for opening drain valve  110  to empty catch basin  30 . Of course, it is only desirable to drain the liquid from catch basin  30  at a suitable location where the contents can be properly treated. Accordingly, drain valve  110  must be of a type that is suitably secure from opening when truck  12  travels over bumps, or the like, but otherwise, any type of drain valve known in the art may be used as drain valve  110 .  
      In use, truck  12  travels to a job site to deliver an amount of concrete or other material. At this point catch basin  30  should be empty of liquid and secured by main latch  48  and funnel latch  49  (if installed), as illustrated in  FIG. 2 . Following pouring of the concrete, when it is time to clean dispensing elements  14 , such as hopper  15 , main chute  16 , and auxiliary chute  18 , lid  36  of catch basin  30  is opened and auxiliary chute support rods  90  are inserted into holes  100  in support rod brackets  96 ,  98 . Auxiliary chute  18  is then detached from main chute  16 , and mounted on support rods  90  by engaging chute attachment hooks  26  with support pins  94 . Funnel assembly  50  is then lifted off mounting brackets  42  and mated to free end  20  of main chute  16  by engaging mounting hooks  52  with chute pins  22 . First end  82  of drain hose  80  is attached to hose connector fitting  78  on drain pipe  72 , and second end  84  of drain hose  80  is disposed in the interior of catch basin  30 . System  10  is now configured as illustrated in  FIG. 1 .  
      The operator obtains a water hose  120  having an available source of water or other cleaning liquid. The source of water may be city water or well water provided by the contractor at the job site. Alternatively, truck  12  may be fitted with a water tank (not shown) containing a source of water that can be pressurized with a hand pump (not shown), or by other means, as is known in the art. This makes the entire cleaning process self-contained and not reliant on the requirement that there be a nearby source of water. The operator uses the water from water hose  120  to wash the residual concrete from hopper  15  and main chute  16 . The combined mixture of water and concrete residue flows into funnel assembly  50 , down drain pipe  72 , through drain hose  80 , and into catch basin  30 . After hopper  15  and main chute  16  have been cleaned satisfactorily, auxiliary chute  18  is also cleaned using water from water hose  120 . Following cleaning, auxiliary chute  18  is removed from support pins  94  and stowed, drain hose  80  is removed from drain pipe  72 , and funnel assembly  50  is removed from main chute  16 , replaced on mounting brackets  42 , and latched in place using funnel latch  49  (if installed). Support rods  90  are returned to storage tubes  92 , and lid  36  is closed and main latch  48  is latched. Truck  12  then returns to the concrete facility and catch basin  30  is drained by opening drain valve  110  by turning handle  114 . The contents of catch basin  30  are either properly disposed of, or, preferably, recycled, and catch basin  30  is rinsed out and ready for reuse.  
      From the foregoing it should be apparent that the system  10  of the invention sets forth a method and apparatus for cleaning the dispensing elements of mixing trucks that have a number of advantages over the prior art. The present invention does not require pumps for operation, and does not require any heavy lifting or manual carrying of waste runoff, but, instead, merely relies on gravity for transporting the runoff to the catch basin. In addition, the invention provides a simple and efficient system for containing and properly disposing of or recycling the residual material.  
      While specific embodiments have been illustrated and described in this specification, those of ordinary skill in the art appreciate that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments disclosed. This disclosure is intended to cover any and all adaptations or variations of the present invention, and it is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combinations of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the foregoing disclosure. The scope of the invention should properly be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.