Abstract:
An apparatus for the controlled feeding of concrete strengthening and adhesion material, such as plastic fibers, to a concrete mix. The apparatus includes a set of reciprocating spikes that contract the fibers with a comb-like action that separates the individual fibers and moves them forward to a rotating agitator having a central rotating shaft with spokes extending outwardly to provide a further separation of fibers and a forward movement of the fibers toward a rotating impeller which moves the fibers forward and downward to a duct which exits to a concrete mixing apparatus. The separation of the fibers prior to entry into the concrete mix serves to inhibit or prevent subsequent aggregation or balling of the fibers in the mix.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to concrete mixers and in particular to concrete strengthening and adhesion material feeder apparatus for producing a mix for fibrous concrete i.e. concrete strengthened and improved adhesion by the addition of concrete strengthening and adhesion material. 
     2. Description of the Prior Art 
     Certain problems arise during the production of such a fibrous concrete mix as the fibres have to be evenly distributed throughout the mix in order for the maximum benefits to the concrete to be achieved. In particular the feed of the fibers into the mix has to be such that the fibers are not formed into &#34;balls&#34; rather than being evenly distributed throughout the mix. 
     It is therefore the general object of this invention to provide a concrete strengthening and adhesion material feeding machine which overcomes the above problems and which produces a mix, to add in any desired proportions, of cement, aggregate and fibers. 
     A concrete strengthening and adhesion material feeding machine in accordance with the invention comprises a feed for concrete strengthening and adhesion material and aggregate incorporating a hopper for material, a means to separate and process said material, a metering means and a discharge outlet. 
     The use of a concrete strengthening and adhesion material hopper of this nature ensures that the material are fed evenly to the processing means and the danger of fibres of metal or other types of material being attracted together by self-magnetism or self-sticking and being formed into balls is substantially reduced. 
     Conveniently the hopper is reciprocated over an material combing and separating means. 
     The equipment is suitable for any form of concrete strengthening and adhesion material and the flow of material can be changed so that the size and shape of the material is appropriate to the particular type of material and to the feed desired. Equally, the feed of concrete strengthening and adhesion material may be varied by varying the depth or frequency of reciprocation of the compressor in the hopper, by varying the level of concrete strengthening and adhesion material maintained in the hopper during operation, or by varying the size of the outlet from the hopper. 
     Preferably concrete strengthening and adhesion material is fed to the hopper through a delivery opening and the opening and the compressing means may be vibrated to assist even flow of material. If the delivery opening is disposed over the mouth of the hopper then the level of concrete strengthening and adhesion material contained therein can be maintained substantially constant as the hopper reciprocates beneath the feed end of the processing means. 
     The concrete strengthening and adhesion material feeding apparatus may be mounted on wheels or on slides for reciprocal movement across its outlet port. 
     The concrete strengthening and adhesion material may be made of metal, plastics, glass or any other convenient material and may be made of any desired shape or configuration to suit the desired ultimate concrete mix. 
     The flow of concrete strengthening material may be varied by varying the speed of rotation of the impeller-agitator combination by adjusting the size of the adjustable metering gate. 
     The apparatus may also include a blowing unit into which works in conjunction to the feeding apparatus comprises a venting hopper connected to a source of pressurized air. The mix on entering the hopper is manipulated so that an even flow of material may be discharged from the hopper by the air pressure through an outlet port. This device helps to ensure an even supply of mix to the concrete through the outlet port and thus prevents surging. 
     Recent years have seen an upsurge in the use of fiber reinforced concrete. Structures formed of fiber reinforced concrete have superior strength over unreinforced concrete and, in many instances, can be employed in lieu of concrete reinforced with reinforcing rods or bars (rebars) to provide similar strength at lesser cost. 
     Various fibers have been employed. Most often, steel fibers are used, but in many instances, ceramic fibers, such as glass fibers, have been employed. Typically, the fibers are dispersed randomly within the mix and the structures resulting from a pour of the mix. As a consequence, the maximum reinforcement provided by a given number of fibers cannot be achieved. Those fibers parallel to the direction of a bending force application to the concrete structure provide no reinforcing whatsoever, while those fibers only slightly angled with respect to the direction of the bending force application provide but minimal reinforcement. Consequently, it has been necessary to incorporate in such concrete, a far greater number of fibers than actually necessary to ensure that proper reinforcing will be achieved with such a random distribution. 
     This, in turn, has posed not only an economical problem due to the cost of the increased amount of fibers, but a labor problem as well. When used in the large amounts required, the fibers have a tendency to adhere to each other or &#34;ball.&#34; When balls are left in the poured concrete, a weak spot is formed. Moreover, the presence of such balls impedes finishing operations. Accordingly, it has been necessary to manually retrieve the fiber balls from the concrete as it is being poured and finished. 
     Fine aggregates comprising river or mountain sand or artificial particles are widely used to prepare cement mortar or line stone type hydraulic mortar which is used to construct buildings or many other civil structures. 
     Although the composition and particle size of the sand also influences the quality of the product, so long as sand collected from the same source is used it is easy to utilize the sand having the same composition and particle size and it is rare to admit sands from different sources. When the sand contains particles of different size it is easy to classify them into fine, medium and coarse particles with a sieve and a small difference in the particle size does not result in a great difference in the quality of the product. 
     Numerous innovations for concrete strengthening and adhesion material feeding apparatus have been provided in the prior art that are adapted to be used. Even though these innovations may be suitable for the specific individual purposes to which they address, they would not be suitable for the purposes of the present invention as heretofore described. 
     SUMMARY OF THE INVENTION 
     It is the principal object of the invention to provide a new and improved concrete strengthening and adhesion material feeding apparatus. More specifically it is an object to provide a method of forming a concrete strengthening and adhesion material concrete mix and an apparatus for performing the method. 
     The inventive method achieving the foregoing objects, in its broadest sense, includes the step of forming a composite of concrete strengthening and adhesion material, distributing reinforcing material on or throughout the concrete mix, and applying a further addition of concrete to the first mixture and the concrete strengthening and adhesion material distributed thereon before the first mixture has set. As a consequence, the concrete strengthening and adhesion material will have a substantially two-dimensional orientation so as to all be substantially transverse to the direction of force application to the resulting concrete mix. Consequently, all concrete strengthening and adhesion material are load bearing with the result that the number of concrete strengthening and adhesion material employed may be minimized over prior art methods. 
     According to a preferred embodiment of the invention, the foregoing steps are repeated until a desired thickness of the resulting concrete structure is approached. A final covering mix of concrete is then applied. 
     The amount of concrete strengthening and adhesion material deposited on each mix may be varied in accordance with expected stress characteristics. In some cases, the number of concrete strengthening and adhesion material deposited on each mix will be increased as the method is performed, while in other cases, the opposite will be true. In most cases, during the fabrication of the structure, the number of concrete strengthening and adhesion material deposed on each mix will be progressively decreased until approximately half of the desired thickness of the structure is attained, at which time a progressive increase of the number of concrete strengthening and adhesion material deposited on each sheet may be initiated. 
     The novel features which are considered characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read in connection with the accompanying drawing. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is a perspective view of a concrete strengthening and adhesion material feeding apparatus exhibiting material processing means and first housing as well as material processing mechanical driving means second housing; 
     FIG. 2 is a perspective view of a second housing which encases material processing mechanical driving means; 
     FIG. 3 is a perspective view of a material compressor means exhibiting a material compressor chains, cross members, and cross member end caps; 
     FIG. 4 is a top view of a feeder cam exhibiting rear shaft and front shaft slots formed therein; 
     FIG. 5 is a side view of a feeder cam exhibiting cam cross members in alternating opposite positions to one another; 
     FIG. 6 is a side view of an agitator exhibiting spiral finger-like projections which are individually secured to an agitator half washer that is securely fastened to a agitator shaft; 
     FIG. 7 is a cross-sectional view of a agitator half washer; 
     FIG. 8 is a cross sectional view of an agitator exhibiting omni-directional finger-like projections extending outwardly from a central shaft; 
     FIG. 9 is a top view of a distal end of a bar containing spikes and an end cap; 
     FIG. 10 is a side view of a bar exhibiting spikes extending outwardly on a top edge; 
     FIG. 11 is a top view of a bar exhibiting spikes distributed throughout and terminal distal end caps; 
     FIG. 12 is a top view of a slotted spike guide plate exhibiting a plurality of spike guides; 
     FIG. 13 is a side view of an impeller shaft exhibiting a female key slot on an impeller shaft; 
     FIG. 14 is a cross sectional view of an impeller exhibiting a male key slot; 
     FIG. 15 is a perspective view of one inter-relational configuration of shafts, pulleys, idlers and belts which constitute the material processing mechanical powering means; 
     FIG. 16 is a front view of a material feeding housing exhibiting a line shaft having bearings and pulleys contained therein; 
     FIG. 17 is a cross sectional view of concrete mix with concrete strengthening and adhesion material distributed throughout and extending outwardly on a top layer to facilitate adhesion of a second layer of concrete mix; and 
     FIG. 18 is a cross sectional view of concrete mix with concrete strengthening and adhesion material distributed on a top superficial layer and extending outwardly on said top layer to facilitate adhesion of a second layer of concrete mix. 
    
    
     LIST OF REFERENCE NUMERALS UTILIZED IN THE DRAWING 
     10--A CONCRETE STRENGTHENING AND ADHESION MATERIAL FEEDING APPARATUS 
     12--MATERIAL INGRESS 
     14--ADJUSTABLE METERING GATE 
     16A--MATERIAL COMPRESSOR 
     16B--MATERIAL COMPRESSOR CHAIN 
     16C--MATERIAL COMPRESSOR CROSSMEMBER END CAPS 
     16D--MATERIAL COMPRESSOR CROSSMEMBER 
     18A--EXTENDED SPIKES 
     18B--RETRACTED SPIKES 
     20--PROCESSED MATERIAL EXIT DUCT 
     22A--SLOTTED SPIKE GUIDE PLATE 
     22B--SPIKE GUIDE 
     24--DIRECTION OF MATERIAL FEEDING 
     26A--IMPELLER 
     26B--IMPELLER MAIN BODY 
     26C--IMPELLER LONGITUDINAL OPENING 
     26D--IMPELLER SHAFT 
     26E--IMPELLER MALE KEYWAY 
     26F--IMPELLER FEMALE KEYWAY 
     28A--FEEDER CAM 
     28B--FEEDER CAM REAR CAM PLATE 
     28C--FEEDER CAM CROSS MEMBER 
     28D--FEEDER CAM REAR SHAFT 
     28E--FEEDER CAM FRONT SHAFT 
     28J--FEEDER CAM REAR SHAFT SLOT 
     28K--FEEDER CAM FRONT SHAFT SLOT 
     28L--FEEDER CAM MIDDLE CAM PLATE 
     28M--FEEDER CAM FRONT CAM PLATE 
     30A--AGITATOR 
     30B--AGITATOR SHAFT 
     30C--AGITATOR CABLE TIES 
     30D--AGITATOR HALF WASHERS 
     32--ANGLED BOTTOM PLATE 
     34--DIRECTION OF MATERIAL FEEDING INTO CONCRETE 
     35--MATERIAL FEEDING HOUSING 
     36--HOUSING FOR MOTOR, GEARS AND CHAINS 
     38--CONCRETE STRENGTHENING AND ADHESION MATERIAL 
     40--CONCRETE MIX 
     42A--SPIKE BAR 
     42B--SPIKE 
     42C--SPIKE BAR END CAP 
     42D--SPIKE BAR CROSS MEMBER 
     44A--MATERIAL FEEDER ENCLOSURE 
     44B--MATERIAL FEEDER ENCLOSURE TOP COVER 
     44C--MATERIAL FEEDER ENCLOSURE TOP COVER HANDLE 
     44D--MATERIAL FEEDER ENCLOSURE TOP COVER FASTENER 
     44E--MATERIAL FEEDER ENCLOSURE TOP FRONT SIDE DOOR 
     44F--MATERIAL FEEDER ENCLOSURE FRONT DOOR HINGE 
     44G--MATERIAL FEEDER ENCLOSURE LOWER FRONT SIDE DOOR 
     44H--MATERIAL FEEDER ENCLOSURE LOWER FRONT SIDE DOOR HANDLE 
     44I--MATERIAL FEEDER ENCLOSURE MATERIAL DUCT 
     44J--MATERIAL FEEDER ENCLOSURE LOWER SIDE FRONT BRACKET 
     44K--MATERIAL FEEDER ENCLOSURE LOWER SIDE BOTTOM MIDDLE BRACKET 
     44L--MATERIAL FEEDER ENCLOSURE LOWER SIDE TOP MIDDLE BRACKET 
     44M--MATERIAL FEEDER ENCLOSURE LOWER SIDE REAR BRACKET 
     44N--MATERIAL FEEDER ENCLOSURE LOWER SIDE REAR BRACKET OPENING 
     440--MATERIAL FEEDER ENCLOSURE LOWER SIDE FRONT OPENING 
     44P--MATERIAL FEEDER ENCLOSURE LOWER SIDE MIDDLE BRACKET 
     44Q--MATERIAL FEEDER ENCLOSURE UPPER SIDE MIDDLE BRACKET 
     44R--MATERIAL FEEDER ENCLOSURE UPPER SIDE MIDDLE BRACKET SUPPORT MEMBER 
     44S--MATERIAL FEEDER ENCLOSURE UPPER SIDE FRONT BRACKET 
     44T--MATERIAL FEEDER ENCLOSURE UPPER SIDE FRONT BRACKET OPENING 
     44U--MATERIAL FEEDER ENCLOSURE UPPER SIDE REAR BRACKET 
     44V--MATERIAL FEEDER ENCLOSURE LIMIT SWITCH STOP 
     44W--MATERIAL FEEDER ENCLOSURE BOTTOM PAN 
     44X--MATERIAL FEEDER ENCLOSURE BOTTOM 
     44Y--MATERIAL FEEDER RIGHT AND LEFT HAND PANEL 
     44Z--MATERIAL FEEDER DRIVE - SIDE BEARING PLATE 
     45A--MATERIAL FEEDER TOP HOUSING PANEL 
     46A--MOTOR 
     46B--MOTOR SHAFT 
     46C--MOTOR SHAFT PULLEY 
     48--LINE SHAFT 
     50--MOTOR SHAFT 
     51--DRIVE SHAFT 1 
     52--IMPELLER SHAFT 
     53--AGITATOR SHAFT 
     54--DRIVE SHAFT 2 
     55--DRIVE SHAFT 3 
     56--LINE SHAFT INNER PULLEY 
     58--LINE SHAFT OUTER PULLEY 
     60--LINE SHAFT BELT 
     62--LINE SHAFT IDLER 
     64--MOTOR SHAFT OUTER PULLEY 
     66--MOTOR SHAFT INNER PULLEY 
     68--MOTOR SHAFT IDLER 
     70--DRIVE SHAFT 1 OUTER PULLEY 
     72--DRIVE SHAFT 1 INNER PULLEY 
     74--DRIVE SHAFT 1 IDLER 
     76--DRIVE SHAFT 2 INNER PULLEY 
     78--DRIVE SHAFT 3 IDLER 
     80--DRIVE SHAFT 2 OUTER PULLEY 
     82--DRIVE SHAFT 3 PULLEY 
     84--AGITATOR SHAFT PULLEY 
     86--AGITATOR IDLER 
     88--IMPELLER SHAFT PULLEY 
     90--AGITATOR BELT 
     92--MOTOR SHAFT BELT 
     94--DRIVE SHAFT 1 BELT 
     96--DRIVE SHAFT 3 BELT 
     98--LINE SHAFT BEARING 
     100--LINE SHAFT BRACKET 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference to FIG. 1, a concrete strengthening material feeding apparatus, constructed in accordance with a preferred embodiment of the invention, includes a housing 35, having a n entrance 12 for the introduction of concrete strengthening and adhesion material (hereinafter referred to as &#34;fibrous material&#34;) and a material compressor 16A. As detailed in FIG. 3, a weighted plate that is removably suspended by a plurality of chains 16B and crossmembers 16D having endcaps 16C. In practice, the material compressor is removed while fibrous material is loaded into the apparatus through entrance 12. The material compressor 16A may then be replaced to provide a compressive force on the fibrous material. The fibrous material comes to rest on reciprocating spikes 18A and 18B and spike guide plate 22A and is pushed downward thereto by the weight of material compressor 16A. The reciprocating spikes, shown in extended position 18A and retracted position 18B, move in a reciprocating motion to disperse and separate the fibrous material in a comb-like fashion and move it in a path, shown by arrow 24, toward rotating agitator 30A and impeller 26A. The reciprocating spikes 18A and 18B protrude through a slotted spike plate 22A by virtue of spike guide 22B. The spikes 18A and 18B are mounted on spike bars 42A and rotate in response to the rotation of a plurality of camshafts 28A. A vertically adjustable metering gate 14 functions to regulate the amount of material moving toward agitator 30A and impeller 26A. Angled bottom plate 32 slopes downward toward processed material exit duct 20. This bottom plate serves to catch stray bits of fibrous material that may fall through the spike guide plate 22A and directs them toward the concrete mix. FIG. 2 shows a material enclosure 44A, material top cover 44B, containing a fastener 44D, the top cover 44B which opens manually by a handle 44C to allow addition of the material, a top front side door 44E which is openably attached by a hinge 44F, a lower front side door 44G openable with a handle 44H, a material feeder enclosure duct 44I which introduces the material to the concrete mix, a material feeder enclosure lower side bracket which attaches said housing 35 to a second housing 36 which encases a mechanical powering means, a lower side bottom middle bracket 44K, a lower side top middle bracket 44L, lower side rear bracket 44M, lower side rear bracket opening 44N which corresponds to a front cam feeder shaft lower side front bracket opening 440 which corresponds to an impeller shaft, a lower side middle bracket 44P, upper side middle bracket 44Q, a upper side middle bracket support member 44R, upper side front bracket 44S, upper side front bracket opening 44T which corresponds to an agitator shaft, a upper side rear bracket 44U, a material feeder enclosure limit switch stop 44V, a bottom pan 44W, an enclosure bottom 44X, a right and left had panel 44Y which are securely fastened to the front panel 44E and a top housing panel 45A, and material feeder drive side bearing plate 44Z to which a motor 46A is mounted. Said motor 46A consists of a motor shaft 46B upon which a motor shaft pulley 46C is mounted. 
     Referring to FIG. 16; a line shaft bracket 100 is mounted on the material feeding housing 35. The line shaft bracket 48 secures in a movable configuration, a line shaft 48 upon which is mounted at bearings 98, a line shaft outer pulley 58 and a line shaft inner pulley 56. 
     Referring to FIGS. 4 and 5; the feeder cam 28A contains a sequence of components such as a front shaft 28E which is movably attached to a bar containing spikes 42D, a front cam plate 28M, a plurality of middle cam plates 28L, a plurality of cross members 28C which are arranged in unparrallel configuration to one another, thus, allowing spikes 18A and 18B to extend and retract, respectively upon rotation of the shaft 28E, the front shaft 28E has a slot 28K contained therein which securely but movably attaches the spike bar 42D, a feeder cam rear plate 28B which is securely attached to a feeder cam rear shaft 28D having a slot 28J which securely mounts pulleys 54 and 55. 
     The agitator 30A, shown in FIG. 1 and further detailed in FIGS. 6, 7, and 8, comprises a rotatable agitator shaft 30B having loosely connected thereto a plurality of spoke-like cable ties 30C held loosely, but securely, in place by half washers 30D. As the agitator is rotated, the cable ties act to separate and disperse the fibers and push the fibrous material toward the impeller and exit duct 20. 
     Referring to FIGS. 9, 10 and 11; the spike bar 42A contains multiple spikes 42B and end caps 42C located at opposite distal ends of the spike bar 42A. The end caps 42C in conjunction with the spike bar 42B movably attached said component to shafts 54 and 55 which rotate in unison to extend said spikes 42 in an extended 18A and retracted 18B fashion. 
     Referring to FIGS. 13 and 14; the impeller 26A contains a cylindrical main body 26B having a longitudinal opening 26C which allows mounting said unit on a rotatable impeller shaft 26D. The main body 26B and the shaft 26D are securely attached by male 26E and female 26F keyways, respectively. 
     Referring to FIG. 15; an inter-relational configuration comprising in direct relationship as described herein or in combination thereof; an inner pulley 66 firmly affixed to a motor shaft 50 of said powering motor 46A which is directly connected to a drive shaft 1, 51 by a belt 92 and drive shaft outer pulley 70, said belt 92 has an idler 68 interspersed functioning to engage or disengage both pulleys; said drive shaft 1, 51, is also directly connected to a second inner pulley 72 mounted thereon, said second shaft 1 inner pulley 72 is connected to another inner pulley 76 directly mounted on drive shaft 2, 54, thereon, both drive shaft inner pulley 1, 72 and drive shaft 2 inner pulley 76 are connected by a belt 94 with an idler 74 interspersed functioning to engage or disengage both pulleys; said drive shaft 2, 54, is also directly connected to a second outer pulley 80 mounted thereon, said second shaft outer pulley 80 is connected to another pulley 82 directly mounted on drive shaft 3, 55, and drive shaft pulley 2 and drive shaft 3 pulley 82 are connected by a belt 96 with an idler 78 interspersed functioning to engage or disengage both pulleys; said motor shaft 50 also has a second outer pulley 64 directly mounted thereon, said second motor pulley 64 is connected to a line shaft inner pulley 56 which is directly mounted on a line shaft 48, said line shaft inner pulley 56 and said second motor outer pulley 64 are connected by a belt 60 with an idler 62 interspersed functioning to engage or disengage both pulleys; and said line shaft 48 has a second outer pulley 58 directly mounted thereon which is connected by a belt 90 to at least two additional pulleys, 84 and 88, at least one which is directly mounted on said agitator shaft 53 and at least one other which is directly mounted on at least one said impeller shaft 52, said line, agitator and impeller shaft pulley connecting belt 90 has an idler 86 interspersed functioning to engage or disengage said pulleys. 
     Referring to FIG. 17; concrete mix 40 has concrete strengthening and adhesion material 38 mixed throughout to add omni-directional strength to concrete, and increased adhesion material at the top outer portion of the concrete layer. 
     Referring to FIG. 18; concrete mix 40 has concrete strengthening and adhesion material 38 located on the top portion only to add omni-directional strength to concrete, and increased adhesion material at the top outer portion of the concrete layer. 
     It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the type described above. 
     While the invention has been illustrated and described as embodied in a concrete strengthening and adhesion material feeding device, it is not intended to be limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. 
     Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. 
     What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims.