Patent ID: 12214361

DETAILED DESCRIPTION

The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments, which are also referred to herein as “examples,” are described in enough detail to enable those skilled in the art to practice the invention. The embodiments may be combined, other embodiments may be utilized, or structural, and logical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

Before the present invention is described in such detail, however, it is to be understood that this invention is not limited to particular variations set forth and may, of course, vary. Various changes may be made to the invention described and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process act(s) or step(s), to the objective(s), spirit or scope of the present invention. All such modifications are intended to be within the scope of the claims made herein.

Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as the recited order of events. Furthermore, where a range of values is provided, it is understood that every intervening value, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the invention. Also, it is contemplated that any optional feature of the inventive variations described may be set forth and claimed independently, or in combination with any one or more of the features described herein.

The referenced items are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such material by virtue of prior invention.

Unless otherwise indicated, the words and phrases presented in this document have their ordinary meanings to one of skill in the art. Such ordinary meanings can be obtained by reference to their use in the art and by reference to general and scientific dictionaries, for example, Webster's Third New International Dictionary, Merriam-Webster Inc., Springfield, M A, 1993 and The American Heritage Dictionary of the English Language, Houghton Mifflin, Boston Mass., 1981.

FIGS.1and2provide complementary cross-sectional views of one embodiment of a fragmenting machine10, also known as a horizontal grinder. The machine10is designed to splinter and/or fragment materials using high impact forces. The fragmenting machine10includes a frame12structurally sufficient to withstand the vigorous mechanical workings of machine10. One embodiment of the machine10may be powered by several electrical motors generally prefixed by M, namely MR, MD, MP, and MF. These electric motors are illustrated as equipped with suitable drive means for powering the various working components, namely the feeding, fragmenting and discharging means of machine10. It will be obvious to the skilled artisan, however, that the machine10may be powered by a variety of different power sources, e.g., internal combustion engines, diesel engines, hydraulic motors, industrial and tractor driven power take-off, etc.

In basic operational use in various embodiments, waste materials W may be power fed by a conveyer system to a fragmenting or grinding chamber14by a powered feed system16powered by a feed motor MF in cooperative association with a power feed rotor drum16D powered by power feed motor MP.

Thus, one embodiment of the machine10may include a hopper18for receiving waste materials W and a continuously moving infeed conveyer20for feeding wastes W to the waste fragmenting or grinding chamber14. An infeed conveyer20may be suitably constructed of rigid apron sections hinged together and continuously driven about drive pulley20D and an idler pulley20E disposed at an opposing end of the conveyer20. The conveyer20may be operated at an apron speed of about 10 to about 30 feet per minute, depending upon the type of waste material W. The travel rate or speed of infeed conveyer20may be appropriately regulated through control of gearbox20G. Feed motor MF in cooperative association with gear box20G, apron drive pulley20P, chain20F, and apron drive sprocket20D driven about feed shaft20S serves to drive continuous infeed conveyer20about feed drive pulley20D and idler pulley20E.

Power feed system16is driven by motor MP and in cooperative association with the infeed conveyer20, driven by motor MF, uniformly feeds and distributes bulk materials, W, such as cellulose-based materials to the fragmenting or grinding chamber14. Power feed system16positions and aligns the materials W for effective fragmentation by the fragmenting rotor40. The power feed system16comprises, in one embodiment and as illustrated, a power feed wheel or rotor drum16D equipped with projecting feeding teeth16A positioned for counterclockwise rotational movement about power feed wheel16D. Power feed wheel16D may be driven by power feed shaft16S which in turn is driven by chain16B, drive sprocket16P and motor MP. The illustrated embodiment further comprises arm16F which holds power feed wheel16D in position.

A rotary motor MR serves as a power source for powering a fragmenting rotor40that operates within the fragmenting or grinding chamber14. The fragmenting and grinding are accomplished, in part, by shearing or breaking teeth500which rotate about a cylindrical drum42and exert a downwardly and radially outward, pulling and shearing action upon the waste material, W, as it is fed onto a striking bar43and sheared thereupon by the teeth500. Within some machines, the rotor may rotate upward into the feed material. The shearing teeth500project generally outwardly from the cylindrical drum42, which is typically rotated at an operational speed of about 1800-2500 r.p.m, though, as discussed above, other r.p.m. ranges are well within the scope of the present invention. The fragmenting rotor40is driven about a power shaft42S, which is in turn powered by a suitable power source such as motor MR. Motor MR is drivingly connected to power shaft pulley42P which drivingly rotates power shaft42S within power shaft bearing42B. The rotating teeth500thus create a turbulent flow of the fragmenting wastes W within the fragmenting chamber14.

Initial fragmentation of the material, W is, in one embodiment, accomplished within the dynamics of a fragmenting or grinding chamber14which may comprise a striking bar43and a cylindrical drum42equipped with a dynamically balanced arrangement of the shearing or breaker teeth500. The striking bar43serves as a supportive anvil for shearing material W fed to the fragmenting zone4. Teeth500are staggered upon cylindrical drum42to facilitate dynamic balancing of rotor40. Rotor40, generally operated at an operational rotational speed of about 1800-2500 r.p.m., rotates about shaft42S. Material fragmented by the impacting teeth500is then radially propelled along the curvature of the screen44. Screen44, in cooperation with the impacting teeth500, serves to refine the material W into a desired particle size until ultimately fragmented to a sufficient particle size so as to pass through screen44for collection and discharge by discharging conveyor50. A discharging motor MD serves as a power source for powering a discharger52, illustrated as a conveyor belt and pulley system, wherein the discharger52conveys processed products D from the machine10.

The power feed system16helps to maintain a substantially consistent feed rate to the fragmenting chamber and rotor therein. Stabilization of the feed material prior to entry into the fragmenting chamber is essential to fragmentation speed and efficiency. The need for feed stability in a fragmenting machine is relative to the size and consistency of the feed material, as well as the rotor r.p.m. and torque. Thus, the power feed system16, also referred to as a pre-crusher, power feeder, power feed drum, power feed roll or roller, or powerfeed, is an integral component of an efficient horizontal grinder.

A typical power feed wheel16D usually comprises serrated plates, cleats or other elements, represented inFIG.2as power feed teeth16A, that function to grip the feed material as it is delivered to the fragmenting chamber and rotor therein.

Maintenance of a certain downward pressure of the power feed wheel16D on the feed material will help regulate the speed with which the material enters the fragmenting chamber and encounters the rotor. This downward pressure assists, inter alia, in preventing the fragmenting rotor40from pulling the feed material in too quickly. The downward pressure of the power feed wheel16D stabilizes the feed material by providing a level of compression and lateral movement of the feed material prior to encountering the rotor, thus improving the efficacy of fragmentation within the fragmenting chamber14. power feed device described is not a required element.

FIGS.3and4illustrate an example embodiment of a rotating fragmentation system100, according to an example embodiment. The rotating fragmentation system100includes a plurality of spaced apart cutouts102in the outer surface S of cylindrical drum42, a holder110is attached to an associated cutout102, a mount120attached to an associated holder110, and a tooth500attached to each mount120.

FIG.3provides a perspective view of the fragmenting rotor40with a plurality of teeth500mounted in a spaced apart configuration upon cylindrical drum42to facilitate dynamic balancing of rotor40and to provide full coverage on the rotor40. It should be noted that many variations of tooth500positioning and spacing on cylindrical drum42are possible, and that each such variation is within the scope of the present invention. The rotational direction of the drum42is shown by the arrow inFIG.3.

Cylindrical drum42has an outer surface S with a plurality of spaced apart cutouts102. Within each cutout102, a holder110is attached to the drum42. The holder110comprises an upper surface111, a lower surface (major surface substantially parallel to upper surface111but not shown) and a central mount aperture113. Holder110further comprises a leading threaded opening114and a trailing threaded opening116. Threaded fasteners, such as bolts, engage the leading threaded opening114and a trailing threaded opening116. As illustrated, the cutouts102and holders110are rectangularly shaped. Other cutout shapes could be used and are within the scope of the present invention.

As best illustrated in the exploded view ofFIG.4, mount120is removably attached to holder110. The mount includes a central body121. The central body121includes a lower arm122and an upper arm124. The lower arm122includes an upper surface126and a lower surface128, with an aperture130therethrough. Upper surface126may be flat as illustrated. The upper arm124comprises an upper surface132and a lower flat surface134, with an aperture136therethrough. The central body121further comprises a leading surface138and a trailing surface140, with an aperture142therethrough. As shown, leading surface138comprises a central raised section144with flat step sections146on each side of the central raised section144. The raised section serves as a key to ensure proper alignment of the tooth500which has a groove therein for alignment and attachment to the central raised section144of the mount120. Other alignment geometries can be employed.

Each tooth500is attached to the leading surface138of a mount120. Exemplary tooth500comprises a body having a generally flat leading middle surface150with an upper angled grinding surface152adjacent the middle surface150and a lower angled grinding surface154adjacent the middle surface150, with the leading middle surface150therebetween as illustrated and a back surface148having a geometry. The flat leading middle surface150of each tooth500comprises an aperture156therethrough which is aligned with mount120aperture142when properly positioned for attachment to the mount120.

As described above, leading surface of the mount138may comprise a geometry that is complementary to the raised central section144with adjacent side-stepped sections146. Each tooth500may comprise complementary structure on its back surface148. Thus, the back surface148of the illustrated embodiment of tooth500comprises a central groove160disposed vertically along the back surface148, with adjacent side surfaces162. This central groove160may engage and receive the complementary raised central section144of the mount120, and the adjacent side surfaces162may engage the respective and complementary adjacent side stepped sections146of the illustrated embodiment of mount120, thus ensuring proper alignment and assisting in keeping the tooth500in proper position during fragmenting. As illustrated, a bolt is threaded through aligned apertures156and142, tightened against the trailing surface140of mount120with nut N to attach tooth500to mount120. With some tooth styles, the tooth500may be threaded to accept a bolt inserted from the back of the mount120.

FIG.5is a perspective view of a tooth500, according to an example embodiment.FIG.6is a cross sectional view of a tooth500along line6-6inFIG.5. The tooth500will now be discussed in more detail by referring to bothFIGS.5and6, Tooth500includes a main body510having at least one opening512therein. The main body510further includes an attachment surface538and a working surface520. The attachment surface538is for attaching the tooth500to the mount120. More specifically, the attachment surface538is for attaching the tooth500to the leading surface138of the mount120. The attachment surface538has a footprint501. The footprint501is bounded by the outer perimeter of the attachment surface538. The working surface520is formed as part of the main body510. The working surface520includes a first edge521having at least three cutting claws,522,523,524and a second edge526having at least three cutting claws527,528,529. Each of the cutting claws522,523,524,527,528,529extends beyond the footprint501of the attachment surface538. The main body510and the cutting claws522,523,524,527,528,529are formed integrally. In other words, the tooth500can be formed from one casting, in one example embodiment. The first edge521having at least three cutting claws522,523,524, and the second edge526having at least three cutting claws527,528,529are all one casting. The main body510and the at least three claws on the first edge522,523,524and the at least three claws527,528,529on the second edge526are formed of the same material. The material is generally a metal. In the example embodiment discussed above, the tooth500is formed by casting. It should be noted that the tooth500can also be forged, machined or formed by any other means in other example embodiments.

Now looking atFIGS.4-6, the at least one opening512in the main body510is shaped to receive a fastener (shown as element B inFIG.4). The fastener B is for removably attaching the tooth500to the mount120. In the embodiment shown, the opening is shaped to receive a large hex head bolt as the fastener B. The opening includes a hex shaped cavity514which captures the hex head of the bolt or fastener B. The opening512also includes a cylindrical opening516for the shaft of the bolt or fastener B. If the opening512is sufficiently large, the tooth500can be cast with the opening512in the casting. As a result, manufacturing does not require machining of the opening512. In some embodiments, machining may be required on the attachment surface538of the tooth500to make sure it mates properly to the corresponding surface138on the holder.

A metallic coating is placed on at least a portion of the working surface520. In one embodiment, the portion provided with the metallic coating includes at least three claws522,523,524on the first edge521and the at least three claws527,528,529on the second edge526. In another embodiment, the working surface520is provided with the metallic coating. In one example embodiment, substantially the entire exterior of the tooth500is provided with the metallic coating, except the attachment surface538.

In one embodiment, the metallic coating is a welded overlay. Weld overlays are metallic coatings welded directly onto the substrate. The high-heat welding process forms a molecular-level bond with the base metal, essentially alloying the coating to the substrate at the interface. The result is a durable, almost completely nonporous and impenetrable coating with excellent resistance to high-stress gouging wear.

Weld overlays are typically applied in greater thicknesses than thermal sprayed coatings. As such, substantial amounts of material may be applied in a comparatively short time. The weld alloying process makes the applied material an integral part of a component's physical structure. By nature of the process, highly customized surfaces may be developed by layering and alloying several different materials. Once a coating has been welded onto a substrate, it is virtually impervious to the problems of coating separation, lifting, and peeling that can sometimes occur in thermal sprayed coatings under high stress. The alloyed material also combines the high resistance to sliding abrasion offered by thermal sprayed coatings with an equally exemplary resistance to gouging and plowing wear.

During weld overlaying, the parts are exposed to high surface temperatures (in excess of 2,300° F.) and must be resistant to thermal deformation. Consideration needs to be given to any prior heat treatment of the substrate material and the thermal effects of the welding process on substrate metallurgy. Careful control of preheat, interpass and post-weld heat treat temperatures may be required for certain substrate alloys in order for the weld overlay process to be successful. Coefficients of expansion for the base metal and applied coating should be similar. Dissimilar coefficients can lead to cracking in the coating and possible damage to the component as the material and substrate cool.

In one embodiment, the metallic coating is a hardfaced weld overlay. The tooth500inFIG.5has a hardfaced overlay. Hardfaced weld overlays are applied in substantial thicknesses (typically >0.100″). A hardfaced overlay has significant resistance to gouging and plowing wear.

A tooth made from a casting of one material and then provided with a welded overlay or a hardfaced welded overlay is not as sharp as a tooth with added carbide inserts. However, the claw type tooth is able to fragment materials and last longer in a fragmentation device or a fragmentation environment. The claws522,523,524,527,528,529present a larger surface area or working area for fragmenting materials. The tooth500with a metal overlay or a hardfaced metal overlay is less costly to manufacture. The cast tooth500does not have to be machined so that it can receive an insert, such as a carbide insert. The tooth500is, therefore, easier and less costly to manufacture. It also wears longer so that the teeth500on a fragmentation device do not have to be replaced as often. The result is less downtime for a fragmentation device.

Of course, adding the tooth or teeth500to holders on a drum forms a rotational fragmenting device, such as the fragmenting rotor40. Additionally, adding a feed chute and other chambers and screens also forms a more extensive fragmentation device10.

The present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification.