Patent Description:
Systems for the makedown of powder material such as dry polymers may include a plurality of units or stations. These stations may include a material storage station, a material supply station in which material is supplied from the storage station, and a mixing station at which the dry polymer is mixed with a liquid such as water. In some instances, a holding station including one or more holding tanks may be provided at which the wetted solution may be held until use.

Powder material used with the makedown process may be stored within containers that are manually manipulated to fill a storage unit at the material storage station. Depending upon the weight of a container and the physical abilities of an operator, lifting and positioning the container at a loading location may be physically challenging.

Document D1 (<CIT>) is an example of a solid chemical feeder for water treatment according to the prior art, which aims to prevent any cavity forming in a chemical layer. Document D2 (<CIT>) is an example of a lose-in-weigh continuous feeding system according to the prior art, which aims to prevent the 'bridging' phenomenon of powder materials. Document D3 (<CIT>) is an example of a micro-nano powder feeder according to the prior art, which aims to provide a stable powder feeding rate. Document D4 (<CIT>) is an example of a method of mixing drilling fluids according to the prior art, which aims to discourage the entry of moisture into the dry product. Document D2 (see <FIG>) discloses a hopper system with the features of the preamble of claim <NUM>.

The invention provides a hopper system according to claim <NUM>.

Referring to <FIG>, a system <NUM> for processing a powder material, such as a dry polymer, to form a homogeneous aqueous liquid substance is depicted. The system <NUM> comprises a container <NUM>, a material feed system <NUM>, a material wetting system <NUM>, and a tank <NUM>.

The container <NUM> is configured to contain and deliver a solid flowable powder material such as a dry polymer. The container <NUM> may have any desired configuration and, as depicted, includes a closed body section <NUM> and a tapered section <NUM> with an opening (not shown) at the bottom through which the material within the container may be discharged.

A fitment or valve assembly <NUM> (<FIG>) may be secured to the lower end of the tapered section <NUM> of the container <NUM> to control the flow of material from the container. The valve assembly <NUM> may interact with a docking station or base <NUM> mounted on the material feed system <NUM> as desired to open and close the valve assembly.

The material feed system <NUM> includes a housing <NUM> that supports a hopper <NUM>. As depicted, the hopper <NUM> is formed of a lower portion or lower hopper <NUM> (<FIG>) and an upper portion or hopper extension <NUM>. Forming the hopper <NUM> of multiple components may simplify the manufacture thereof, and also permit the lower hopper <NUM> and the hopper extension <NUM> to be formed with different configurations (e.g., sidewalls having different slopes). However, if desired, the hopper <NUM> may be formed without a definitive transition between the lower portion and the upper portion without departing from the spirit of the disclosure.

Referring to <FIG>, the lower hopper <NUM> includes a front or loading edge <NUM>, a rear edge <NUM>, opposite the front edge, and spaced apart side edges <NUM> extending between the front edge and the rear edge. A sloped sidewall <NUM> extends downwardly from each edge and is configured to direct material passing through the hopper extension <NUM> to the bottom of the lower hopper <NUM>. As depicted, each of the sidewalls <NUM> slopes downward in a constant or uniform manner and each of the sidewalls is identically configured so that the lower hopper <NUM> has a symmetrical shape. If desired, the sidewalls <NUM> may not have a constant or uniform slope and each of the sidewalls may not be identically shaped or configured.

The lower hopper <NUM> may have a reduced area feed section <NUM> at the bottom of the lower hopper and extending between the side edges <NUM>. As depicted in <FIG>, the reduced area feed section <NUM> may be configured as a semi-cylindrical portion (i.e., a semi-circular cross section). The sidewalls <NUM> of the lower hopper <NUM> are configured so that each of the sidewalls directs material to the feed section <NUM> in a uniform manner.

The hopper extension <NUM> includes a front or loading edge <NUM>, a rear edge <NUM>, opposite the front edge, and spaced apart lateral edges <NUM> extending between the front edge and the rear edge. The hopper extension <NUM> defines an upper rectangular section <NUM> and a lower sloped or tapered section <NUM>. As depicted, the hopper extension <NUM> is formed of four sidewalls or sections with each extending along one of the edges. More specifically, a front or loading sidewall <NUM> includes a vertical rectangular section <NUM> extending downward from the loading edge <NUM> and a trapezoidal sloped section <NUM> that extends downwardly at an angle relative to the rectangular section <NUM>. Similarly, a rear sidewall <NUM> includes a vertical rectangular section <NUM> extending downward from the rear edge <NUM> and a trapezoidal sloped section <NUM> that extends downwardly at an angle relative to the rectangular section <NUM>. A pair of lateral sidewalls <NUM> each includes a vertical rectangular section <NUM> extending downward from one of the lateral edges <NUM> and a trapezoidal sloped section <NUM> that extends downwardly at an angle relative to the rectangular section <NUM>.

Once assembled, the rectangular sections <NUM>, <NUM>, <NUM> define the upper rectangular section <NUM> and the trapezoidal sloped sections <NUM>, <NUM>, <NUM> define the lower tapered section <NUM>. The lower tapered section <NUM> is configured to store powder material therein and direct material from the container <NUM> into the lower hopper <NUM>. As with the lower hopper <NUM>, each of the trapezoidal sloped sections <NUM>, <NUM>, <NUM> of the hopper extension <NUM> slopes downward in a constant or uniform manner and each of the trapezoidal sections is identically configured so that the tapered section <NUM> has a symmetrical shape. If desired, the trapezoidal sloped sections <NUM>, <NUM>, <NUM> may not have a constant or uniform slope and each of the trapezoidal sloped sections may not be identically shaped or configured.

The upper rectangular section <NUM> operates to store powder material therein and supply the powder material to the lower tapered section <NUM>. Each of the rectangular sections <NUM>, <NUM>, <NUM> is identically configured so that the rectangular section <NUM> has a symmetrical shape. If desired, the rectangular sections <NUM>, <NUM>, <NUM> may not be identically shaped or configured.

The hopper <NUM> may be formed in different manners and may have different configurations. In some embodiments, the hopper <NUM> may include distinct upper and lower components such as lower hopper <NUM> and hopper extension <NUM>. In some embodiments, the sloped sidewalls <NUM> of the lower hopper <NUM> may have a constant slope or inclination that is the same as those of the trapezoidal sloped sections <NUM>, <NUM>, <NUM> of the hopper extension <NUM>. In other embodiments, the sloped sidewalls <NUM> of the lower hopper <NUM> may have a constant slope or inclination but be different from those of the trapezoidal sloped sections <NUM>, <NUM>, <NUM> of the hopper extension <NUM>. Still further, in some embodiments, the slopes or inclinations of the sidewalls <NUM> and the trapezoidal sloped sections <NUM>, <NUM>, <NUM> may vary along their length and/or may be different from each other. Regardless of the configuration, the hopper <NUM> defines a material holding or storage capacity of the material feed system <NUM>.

The hopper <NUM> includes a hopper axis <NUM> that extends vertically through the hopper and defines an axis about which powder material should be poured into the hopper to fill it to its maximum extent. In the hopper depicted in <FIG>, the hopper axis <NUM> extends through the horizontal center of the hopper in both an "x" direction and a "y" direction. In other words, the hopper axis <NUM> extends vertically halfway between the loading edge <NUM> and the rear edge <NUM> of the lower hopper <NUM> and halfway between its side edges <NUM>. Still further, the hopper axis <NUM> extends vertically halfway between the loading edge <NUM> and the rear edge <NUM> of the hopper extension <NUM> and halfway between its lateral edges <NUM>. If the lower hopper <NUM> and the hopper extension <NUM> were not symmetrical, the hopper axis <NUM> may not extend through the horizontal center of both the lower hopper and the hopper extension.

The material feed system <NUM> may further include a feed assembly <NUM> disposed at the feed section <NUM> of the lower hopper <NUM>. As depicted, the feed assembly <NUM> is configured as an auger (not shown) that feeds powder material out of a material feed tube <NUM> and the feed section of the lower hopper <NUM> is configured in a complimentary manner (i.e., semi-cylindrical in shape) with a portion of the auger positioned therein. The material feed tube <NUM> may extend outward from or through a side wall <NUM> of housing <NUM>.

The hopper extension <NUM> is sealed with a cover <NUM> such as a transparent sheet of acrylic material. The cover <NUM> includes a front edge <NUM>, a rear edge <NUM>, opposite the front edge, and a pair of spaced apart side edges <NUM> extending between the front edge and the rear edge. An opening or hole <NUM> extends through the cover <NUM> and is offset from front to back so as to be positioned closer to the front edge <NUM> than the rear edge <NUM>. The hole <NUM> may be centered between the side edges <NUM>.

The docking station or base <NUM> is mounted or disposed on the cover <NUM> in any desired manner with the base <NUM> and hole <NUM> aligned. The hole <NUM> may be configured to correspond in shape (e.g., circular) and size to the opening within the base <NUM>. The base <NUM> and hole <NUM> define a vertical mating or material loading axis <NUM> along which the container <NUM> is positioned during the process of loading material from the container into the hopper <NUM>. As best seen in <FIG>, the hopper axis <NUM> extending vertically through the hopper <NUM> and the material loading axis <NUM> extending vertically through the cover <NUM> are offset or spaced apart from front to rear of the material feed system <NUM> with the material loading axis closer to the front edge than the rear edge.

In some embodiments, a mesh <NUM> may be disposed on the cover <NUM> aligned with the hole <NUM> and is configured with openings large enough to permit powder material to flow unimpeded from the container <NUM> but small enough to prevent foreign objects from falling into the hopper <NUM> if a container is not positioned on the base <NUM>.

Referring back to <FIG>, the material wetting system <NUM> includes a liquid supply system, generally indicated at <NUM>, for supplying liquid such as water to a material wetting unit (not shown) at which the powder material is mixed with the liquid. The liquid supply system <NUM> includes a supply line or pipe <NUM> that feeds a liquid such as water to a booster pump <NUM>. As depicted, the booster pump <NUM> is located below the housing <NUM> of the material feed system <NUM>. The liquid is discharged from the booster pump <NUM> into an outlet pipe <NUM> which feeds the liquid to the material wetting unit. Powder material exits the material feed tube <NUM> and enters the material wetting unit where it is mixed with the liquid from the liquid supply system <NUM> to begin the wetting process. The mixture of powder material and liquid flows into tank <NUM> through line or pipe <NUM> extending between the material wetting unit <NUM> and the tank.

As best seen in <FIG>, the base <NUM> and the hole <NUM> in the cover <NUM> (and thus the material loading axis <NUM>) are shifted towards the loading edge <NUM> of the hopper extension <NUM> relative to the center point between the loading edge and the rear edge <NUM> to reduce the distance that an operator must extend their arms when loading a container <NUM> onto the base <NUM>. As a result, the material loading axis <NUM> is offset front to back relative to the hopper axis <NUM>, which is centered relative to the hopper <NUM> as a result of the symmetrical nature of the hopper. In one example, the material loading axis <NUM> may be no more than approximately <NUM> (<NUM> inches) from the loading edge <NUM>. In another example, the material loading axis <NUM> may be no more than <NUM> (<NUM> inches) from the loading edge <NUM>.

As a result of the offset between the hopper axis <NUM> and the material loading axis <NUM>, powder material may not completely and/efficiently filling the hopper extension <NUM>, depending upon the characteristics (e.g., angle of repose) of the material. In order to improve the ability to fill the lower hopper <NUM> and hopper extension <NUM> as a result of the offset between the hopper axis <NUM> and the material loading axis <NUM>, a diverter plate <NUM> is provided or disposed below the hole <NUM> in the cover <NUM> to alter or divert the flow of material as it enters the hopper extension. In other words, without the diverter plate <NUM>, the offset between the hopper axis <NUM> and the material loading axis <NUM> may result in uneven filling of the hopper extension <NUM> as material flows through the hole <NUM> in the cover <NUM>. When attempting to fill the depicted lower hopper <NUM> and hopper extension <NUM> with powder material, the powder material will fill the lower hopper <NUM> and may fill the lower tapered section <NUM> of the hopper extension <NUM> in a uniform manner. However, the upper rectangular section <NUM> may not be uniformly filled. As a result, without the diverter plate <NUM>, the hopper extension <NUM> would need to be taller for a specified capacity of the hopper <NUM> (i.e., the combined capacity of the lower hopper <NUM> and the hopper extension <NUM>) if other dimensions or angles are maintained.

Referring to <FIG>, the depicted diverter plate <NUM> includes a central section <NUM> and a pair of side sections <NUM>, with one extending laterally from each side of the central section. Each of the central section <NUM> and the side sections <NUM> are generally planar and have diverging side edges. More specifically, central section <NUM> has an inward edge or tip <NUM>, an oppositely facing outward edge <NUM>, and a pair of oppositely facing side edges <NUM>. The outward edge <NUM> is wider than the inward edge <NUM> and the side edges <NUM> extend between and diverge from the inward edge <NUM> to the outward edge <NUM>.

Each side section <NUM> has an inward edge <NUM>, an oppositely facing outward edge <NUM>, and an inner side edge <NUM> and an oppositely facing outer side edge <NUM>. The outward edge <NUM> is wider than the inward edge <NUM> and the side edges <NUM>, <NUM> extend between and diverge from the inward edge <NUM> to the outward edge <NUM>. The inner side edge <NUM> of each side section <NUM> extends from or is collinear with one of the side edges <NUM> of the central section <NUM>.

The central section <NUM> extends downward at an angle <NUM> relative to a horizontal plane <NUM> as best seen in <FIG>. The angle <NUM> of the central section <NUM> may be set based upon any of a plurality of factors. For example, the angle <NUM> may be set based upon the angle of repose of the powder material as well as the dimensions and/or angles of the hopper extension <NUM> and the diverter plate <NUM>. In the depicted embodiment, the angle <NUM> is approximately <NUM> degrees. In other embodiments, the angle <NUM> may be formed at an angle between <NUM> and <NUM> degrees. In still other embodiments, the angle <NUM> may be formed at an angle between <NUM> and <NUM> degrees. Still other angles may be utilized.

Each side section <NUM> is bent downward at an angle <NUM> relative to the plane <NUM> of the center section <NUM> along the intersection of outward edge <NUM> of center section and inner side edge <NUM> of each side section. The angle <NUM> of the side section <NUM> may be set based upon any of a plurality of factors. For example, the angle <NUM> may be set based upon the angle of repose of the powder material as well as the dimensions and/or angles of the hopper extension <NUM> and the diverter plate <NUM> including the center section <NUM>. In other embodiments, the angle <NUM> may be formed at an angle between <NUM> and <NUM> degrees. In still other embodiments, the angle <NUM> may be formed at an angle between <NUM> and <NUM> degrees. Still other angles may be utilized.

The diverter plate <NUM> is depicted with three distinct sections or regions (center section <NUM> and the two side sections <NUM>) that are formed by bending the diverter plate along the outward edges <NUM> of the center section. However, the diverter plate <NUM> may be formed in other manners and with other configurations. For example, the diverter plate <NUM> may be formed with a continuous curve rather than the relatively abrupt changes in direction at each of the outward edges <NUM> of the center section <NUM>.

The diverter plate <NUM> may be mounted relative to the material feed system <NUM> in different manners. In the depicted embodiment, the diverter plate <NUM> includes a pair of mounting legs <NUM> that extend upward from the side sections <NUM> adjacent the inward edge <NUM>. A mounting flange <NUM> extends generally perpendicularly from each leg <NUM>. The mounting flanges have a pair of bores <NUM> through which a fastener (not shown) such as a bolt may extend to secure the diverter plate <NUM> to the cover <NUM> with one mounting flange disposed on each side of the opening or hole <NUM>. Other manners of securing the diverter plate <NUM> to the cover <NUM> or within the hopper extension <NUM> are contemplated.

The diverter plate <NUM> and the mounting flanges <NUM> are configured and disposed relative to the cover <NUM> so that the inward edge <NUM> of the central section <NUM> and the inward edges <NUM> of the side sections <NUM> are disposed below the hole <NUM> in the cover. Referring to <FIG>, in the depicted embodiment, the inward edge <NUM> of the central section <NUM> generally coincides with or is disposed along the material loading axis <NUM>. The inward edges <NUM> of the side sections <NUM> taper or extend at an angle away from the outward edge <NUM> of the central section <NUM>.

As depicted, the diverter plate <NUM> occludes or blocks approximately <NUM> percent of the hole <NUM> in order to divert the flow of powder material along the diverter plate. Thus, as depicted in <FIG>, a first portion of the flow of powder material from the container <NUM> depicted by arrow "<NUM>" can pass directly through the hole <NUM> and into the upper rectangular portion of the hopper extension <NUM> while a second portion of the flow of powder material will be diverted outward by the diverter plate <NUM> away from the hole. The second portion of the flow of powder material engages or contacts the diverter plate <NUM> so that a first fraction of the second portion of the flow is directed or travels along the center section <NUM>, as depicted by arrow "<NUM>" (<FIG>, <FIG>) and the rest of the second portion of the flow is directed or travels along the side sections <NUM>, as depicted by arrows "<NUM>. " By diverting the flow of powder material along the diverter plate <NUM>, the powder material may fill the hopper <NUM> in a symmetrical (or more symmetrical) manner, which will permit the maximum (or a greater) amount of material to be loaded into the hopper.

In another embodiment, the diverter plate <NUM> may be positioned to block approximately <NUM> percent of the flow of material. In still another embodiment, the diverter plate may be positioned to block between approximately <NUM> and <NUM> percent of the flow of material. Other percentages of occlusion are contemplated.

In one example utilizing the hopper <NUM> and diverter plate <NUM> as depicted, the hopper with the diverter plate was capable of holding approximately seven percent more powder material than the hopper without the diverter plate. In order to increase the capacity of a new hopper without a diverter plate so that the same amount of powder material could be loaded therein as may be stored within the hopper <NUM> with the diverter plate <NUM>, the new hopper would either need to be taller or wider. In some applications, increasing the height of the hopper <NUM> would be undesirable as it would require an operator to lift the containers <NUM> higher when loading the system <NUM>. Further, in some applications, increasing the width of the hopper would be undesirable as it would result in an increase in the footprint of the system <NUM>.

As will be appreciated, for a given configuration of the hopper <NUM> and a powder material having certain characteristics (e.g., the angle of repose), the manner in which the hopper is filled may be adjusted by adjusting the dimensions and angles of the sections of the diverter plate <NUM> and/or by adjusting the position of the diverter plate relative to the hole <NUM> in the cover <NUM>.

As depicted, while the upper portion or hopper extension <NUM> of hopper <NUM> is depicted as being symmetrical, the concepts disclosed herein are applicable to systems utilizing asymmetrical upper portions or hopper extensions. In such case, the hopper <NUM> would fill in manner that may not maximize the amount of powder material it can store. Through the use of a diverter plate below the hole in the cover <NUM>, the manner in which the hopper is filled can be modified.

Any ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.

Claim 1:
A hopper system (<NUM>) for powder material, comprising:
a hopper (<NUM>), the hopper (<NUM>) having an upper end (<NUM>), a lower end (<NUM>), a plurality of hopper sidewalls (<NUM>, <NUM>, <NUM>, <NUM>) and a hopper axis (<NUM>), the hopper sidewalls extending downward from the upper end (<NUM>), at least one of the hopper sidewalls (<NUM>) being sloped along a portion thereof, and the hopper axis (<NUM>) extending vertically between at least some of the hopper sidewalls;
a cover (<NUM>) disposed at the upper end (<NUM>) of the hopper (<NUM>), the cover (<NUM>) including an opening (<NUM>) configured for the powder material to flow through the opening (<NUM>) and into the hopper (<NUM>), the opening defining a vertical material loading axis (<NUM>), the material loading axis (<NUM>) being offset relative to the hopper axis (<NUM>);
characterised in that the hopper system (<NUM>) comprises a diverter plate (<NUM>), the diverter plate (<NUM>) comprising an inward edge (<NUM>) extending across the opening (<NUM>) of the cover (<NUM>) to partially occlude the opening (<NUM>), so that the diverter plate (<NUM>) is partially positioned along the material loading axis (<NUM>) and configured to let pass a first portion of the flow of powder material and to divert a second portion of the flow of powder material as it enters the hopper (<NUM>) through the opening (<NUM>).