Abstract:
A system and method for changing a flow direction of dry bulk material which comprises constructing a steel clad ceramic elbow or pipe or planar flip gate and placing the same in a location where a flow direction change is desired and where abrasion will occur. The inside of the pipe has a steel surface, as does the exterior of the pipe. The ceramic material is disposed in the gap between the steel exterior and interior. The interior steel pipe wears away in portions but the remaining non-worn away portion still provides valuable support for the uncovered ceramic portions.

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to grain and dry bulk material handling, and more particularly relates to changing the direction of and diverting the flow of dry bulk material, and even more particularly relates to methods and systems for extending the service life of elbows, valves and diverters for flowing dry bulk material. 
     BACKGROUND OF THE INVENTION 
     In recent years, certain industries have dramatically increased the amount of grain necessary to meet their operations. For example, ethanol plants utilize a large amount of grain and have grain distribution systems which often handle a higher grain throughput than does a typical grain storage elevator. It also has become increasingly important for such business to remain efficient in their operations and to minimize the duration of any downtime. 
     In the past, grain handling equipment manufacturers have sold ceramic-lined spouts, elbows, and even “Y” valve ceramic-lined directional flow diverters for applications that have very high flow rates. These ceramic-lined systems typically involve gluing or otherwise adhering ceramic tiles to the inside surface of spouts, valves, and diverters, etc. The ceramics tiles are well known to handle abrasion better than grain handling apparatus with a metal-to-grain contact surface. While these ceramic-lined spouts, elbows, and diverters, etc. have enjoyed much success and have been used extensively in the past, they do have some drawbacks. 
     First of all, often non-grain debris which is harder and heavier than grain becomes mixed with the grain; e.g., rocks, metal pieces, screws, nuts, bolts, etc. can find their way into the grain. When this happens, damage to the tiles can be substantial. Impact of a large enough object at a high enough velocity can result in breaking off parts of the ceramic tiles, which may cause still more damage further down the material flow path. It has also been proposed to use a ceramic tile itself as a diverter in a material flow path. In such cases, it is possible for the ceramic tile to break and/or become displaced from its working arrangements, resulting in rapid changes with substantial leakage of material into unwanted pathways. 
     Consequently, there exists a need for improved methods and systems for providing, maintaining, repairing and replacing equipment for diverting dry bulk material in an efficient manner. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a system and method for diverting dry bulk material in an efficient manner. 
     It is a feature of the present invention to utilize a ceramic filled flow-diverting structure. 
     It is a feature of the present invention to utilize material other than ceramic, which also possess superior abrasion-resistance properties, such as urethane and ceramic chip urethane. 
     It is an advantage of the present invention to increase the service life of flow-diverting panels in “Y” style valves. 
     It is another feature of the present invention to provide for a replaceable ceramic filled flow direction changing panel. 
     It is another feature of the present invention to utilize a panel with a single slab of abrasion-resistant material, as well as multiple smaller tiles in combination. 
     It is another advantage of the present invention to reduce the time to replace a failed ceramic flow-diverting panel. 
     The present invention is an apparatus and method for diverting large quantities of flowing dry bulk material in an efficient manner, which are designed to satisfy the aforementioned needs, provide the previously stated objects, include the above-listed features, and achieve the already articulated advantages. The present invention is carried out in a “displaced diverter tile-less” manner in a sense that tendency for an abrasion-resistant diverter tile to break and then become displaced from its operating configuration, has been greatly reduced. 
     Accordingly, the present invention is a system and method including a ceramic or other abrasion-resistant material filled flow-diverting panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be more fully understood by reading the following description of the preferred embodiments of the invention, in conjunction with the appended drawings wherein: 
         FIG. 1  is a top view of a valve embodying the invention. 
         FIG. 2  is a side elevational view of the valve in  FIG. 1 . 
         FIG. 3  is an edge elevational view of the valve of  FIGS. 1 and 2  with a portion of the housing broken away along line  3 - 3  of  FIG. 2 . 
         FIG. 4  is a side elevational view of the valve from the side opposite in  FIG. 2  and showing the spring holding device for the valve member. 
         FIG. 5  is a perspective view of the valve member used in the valve shown in  FIGS. 1-4 . 
         FIG. 6  is a side elevational view of another type of two-way valve housing in which the core filled member may be embodied. 
         FIG. 7  is a perspective view of the diversion panel  16  of  FIGS. 1-5 . 
         FIG. 8  is a cross-sectional view of the diversion panel  16  of  FIG. 7  taken on line  8 - 8 . 
         FIG. 9  is a cross-sectional view of an alternate embodiment of the present invention showing abrasion-resistant material inside a metal housing. 
         FIG. 10  is an enlarged view of a Y valve of the present invention. 
         FIG. 11  is a cross-sectional view of a co-axial double-walled spout or elbow of the present invention showing a ceramic-filled core. 
     
    
    
     DETAILED DESCRIPTION 
     Briefly, my invention comprises a valve for controlling the flow of grain into selected chutes. The valve is designed with a valve operating member to enclose the flow so that the grain cannot be caught between the valve member and the side walls of the valve housing. 
     Now referring to the drawings wherein like numerals refer to like matter throughout, and more specifically referring to the drawings of the first embodiment ( FIGS. 1-5 ), I illustrate a valve body  10  having an inlet  11  into which the grain will flow. A principal outlet  12  is approximately in line vertically with the inlet  11 . A secondary outlet  13  into which grain may be directed extends at an angle away from the vertical. Thus, grain may come into the housing  10  from above through the inlet  11  and be directed into either outlet by a valve member. 
     Customarily, the valve member has been a simple plate which might have been rimmed with a flexible material such as belting. In my improved device, I use a valve member  15  as shown in  FIG. 5 . A diversion panel  16  is retained, but side plates  17  are provided on each lateral edge of the panel  16 . These side plates  17  are formed with an arcuate outer edge  18  adapted to fit into the housing  10  as is apparent in  FIG. 2 . It may be noted that the side walls of the housing  10  are also found in arcuate form. It might also be noted that no internal spout is necessary. The inlet  11  is simply an extension of the entry pipe (not shown). 
     The member  15  is mounted on a shaft  20  journalled in the side walls of the housing  10 . Various means of turning the valve may be provided. The simplest is illustrated. It consists of a plate  21  fixed to the shaft  20 . A cross beam  22  is fastened to the plate. Chains or ropes or the like may be fastened to each end of the cross beam  22 , and these can be pulled selectively to control the position of the valve member  15  within the housing  10 . It will be obvious that chains and sprocket devices or power operated devices such as geared motors may be substituted for the pull-type device. 
     Means for holding the valve member  15  in position is also provided. This consists of a lever  25  fastened to the axle  20  at its end opposite the plate  21 . A spring  26  extends between the free end of that lever  25  and a tab  27  fixed to the housing  10 . The positions of the tab  27  and lever  25  are arranged so that the free end of the lever pulls the spring  26  over the center as the valve member  15  moves from one position to its alternate position. Thus, the spring will tend to pull the valve member into either position and will be stretched longer between those positions. 
     In order to hold the panel  16  in position, stops  28  in the form of metal strips fastened to the upper wall of the housing  10  in position to be engaged by the plate. 
     The use of the device will be obvious from the description thus far. The principal benefit comes from the unique side walls  17 . These walls are proportioned so that in either position of the valve member, they completely cover the walls of the housing  10 . Thus, the grain is completely enclosed in a trough formed by the panel  16  and the sidewalls  17  as it enters the housing  10  through the entry  11  and is directed through either outlet  12  or  13 . Therefore, the grain cannot be leaked between the panel  16  and the walls of the housing  10 . This greatly eliminates leakage of the grain. The side walls are substantially co-extensive with the sides of the housing  10  to avoid leakage. The moving part is also blocked by the strips  28  and can be held positively in place so that the force of the grain does not tend to move the valve member in any direction. 
     A simple alternate is shown in  FIG. 6 . Here the outlets  31  and  32  of the housing  30  are both directed at an angle from the vertical. The inlet  33  is still adapted to receive the grain vertically. The same type of valve member  15  may be used in the housing  30  with the same beneficial results. 
     It should be understood that ceramic is used as an example of a tile, but other abrasion-resistant materials could be used as well, such as urethane. Ceramic should be viewed here as being merely an example of many different suitable materials. 
     Now referring to  FIG. 7 , there is shown an exploded perspective view of a diversion panel  16  having a first outer surface  161  and central abrasion-resistance central core  163 , which may be ceramic and a second outer surface  162 . One type of ceramic that is used is a custom designed 90% alpha alumina oxide ceramic sold under the trade name of Durafrax 2000 by Saint-Gobain, Tour Les Miroirs, 18, avenue d&#39;Alsace 92 096 La Défense cedex France. 
     The outer surfaces often may be metallic, but it should be understood that while metallic surfaces are mentioned as examples, many other suitable materials could be substituted, such as aluminum, steel, cast iron, concrete, PVC, etc. 
     Now referring to  FIG. 8 , there is shown a cross-sectional view of the diversion panel  16 . It shows beveled edges  165  at the top and bottom of the ceramic  163 , which may (but need not) be included to facilitate insertion of the ceramic  163  into a prefabricated gap between the outer metal sheets  161  and  162 . In one method, the ceramic  163  is inserted into the gap and then liquid urethane  167 , or other suitable substitute, is poured around the ceramic tile  163  and allowed to cure and then covered by end cap plates  166 . In another embodiment, the ceramic tile is attached to a steel support plate with epoxy or other suitable adhesive. The steel support plate is then welded in place and capped. An alternative could be that the steel support plate and affixed ceramic could be one side of the diversion panel  16 . 
     Numerous variations of the disclosed ceramic-filled diversion panel  16  could be used as well. For example, now referring to  FIG. 9 , there is shown a ceramic insert which has a metal core  1640  with ceramic tiles  1650  adhered on both sides via epoxy  1680  or the like. This metal core ceramic insert is then put between the outer panels  1610  and  1620  and the space filled with liquid urethane  1670  just as the ceramic tile  163  is put between outer surfaces  161  and  162  in  FIG. 8 . The benefit provided by the variation shown in  FIG. 9  is that if both of the outer surfaces  1610  and  1620  are worn through so that flowing material is contacting the ceramic on both sides, the metal core  1640  helps hold the ceramic in place and prevents a hole completely through the diversion panel  16  if a heavy metal object were to strike the ceramic; i.e., the ceramic  1650  with the interior metal core is more likely to stay in place despite severe cracking than would a single homogenous ceramic tile. Plates  1660  hold the ceramic insert in place. 
     Now referring to  FIG. 10 , there is shown another view of a Y valve of the present invention with a double-walled structure with a ceramic-filled core with an input pipe  1  and an input adapter  2   
     Now referring to  FIG. 11 , there is shown a cross-sectional view of another embodiment of the present invention which shows a double-walled spout or elbow  1000  with an exterior wall  1020  and an interior wall  1040  disposed adjacent to the cavity  1050  for containing flowing bulk material. Disposed between the walls  1020  and  1040  is a ceramic filling which may be a single piece of ceramic pipe or a plurality of ceramic tiles  1030  affixed to either of the walls  1020  or  1040  or affixed to both of the walls via a urethane binder  1032  as discussed above.  FIG. 11  should be understood to be a view of a curved section of a spout; e.g., an elbow (where abrasion is often more of a problem), as well as a straight section of a double-walled ceramic-filled spout. Some of the descriptions and teachings relating to  FIGS. 7-9  are equally applicable to double-walled pipes and elbows with ceramic cores, and it is believed that a person skilled in the art could readily create such a double-walled ceramic-filled elbow. 
     Throughout this description, it has been focused upon the flow diversion panel of a Y valve. However, this is merely one example of a flow diversion panel or structure of the present invention. Indeed, the flow-diverting structures of the present invention could be ceramic-filled spouts, elbows, etc. A key distinction of the present invention is that the prior art ceramic spouts, elbows, valves, etc. have been ceramic lined, meaning a ceramic layer is disposed on the side of the spout adjacent to the flowing bulk material. The present invention brings forth the notion of a ceramic-filled structure where the ceramic material is disposed in a space between substantially parallel structures, such as parallel plates, co-axial tubes and elbows. The ceramic thereby forms at least part of a core between these parallel and/or co-axial structures. As discussed above, the ceramic tiles can be held in place with epoxy or with a liquid urethane. A benefit of this structure is the increased ability to retain ceramic material in the desired location even after it has been cracked. Consequently, it is preferred that the material used in the present invention for the outer walls, i.e. the material containing the ceramic core, have a lower propensity to crack as compared to the ceramic material. 
     Throughout this description, reference is made to grain, grain handling, grain elevators, grain bins and to feed and feed mills, because it is believed that the beneficial aspects of the present invention would be most readily apparent when used in connection with grain and feed; however, it should be understood that the present invention is not intended to be limited to grain and feed handling and should be hereby construed to include other agricultural and non-agricultural applications as well. For example only, and not intended as a limitation, the dry bulk material may be corn, soybeans, wheat, rice, almonds, walnuts, peas, coffee beans, paint pigment, or any free-flowing dry bulk material, such as coal. The term “dry bulk material” is intended to refer to the above-listed materials and other materials having similar properties. 
     Additionally, the present invention is described as having a ceramic inner core in a diverter panel. It should be understood that materials other than ceramic could be substituted so long as they have superior resistance to abrasion from the intended and reasonably expected unwanted dry bulk material, such as urethane, ceramic chip urethane. Also the material may be arranged in multiple tiles, on single slab or other configurations, depending upon the particular application. 
     It is thought that the method and apparatus of the present invention will be understood from the foregoing description and that it will be apparent that various changes may be made in the form, construct steps, and arrangement of the parts and steps thereof, without departing from the spirit and scope of the invention or sacrificing all of their material advantages. The form herein described is merely a preferred exemplary embodiment thereof.