BACKGROUND

Field

[0001] Embodiments described generally relate to aggregate spreader systems. More particularly, such embodiments relate to forward moving aggregate spreaders.

Description of the Related Art

[0002] A bitumen sprayer applies bitumen onto the road surface with aggregate spreading trucks reversing down the road behind the sprayer to tip aggregate particles onto the freshly laid bitumen. These trucks are required to reverse to avoid driving onto the exposed bitumen and spread the aggregates through fixed spreader boxes which are filled by the elevated tipper body. When both the bitumen and aggregates have been placed, surface rollers then re-orientate the aggregates to provide a robust seal. This is a slow process with low work efficiency. Furthermore, whilst the roads are being prepared, sprayed seal sites are an inherently dangerous place to be, with a combination of hot bitumen being sprayed under pressure and loose aggregates being applied to the road - all under live conditions. In addition to the combined risks of reversing trucks and road crew on the ground, there are associated risks with the use of tipper trucks, including the potential to hit overhead utilities and overhanging trees and rollover accidents that are a result of high center of gravity and shifting load during material discharge.

SUMMARY

[0003] Vehicles for spreading aggregate material are provided herein. In some examples, the vehicles can include front and rear ends that are opposed, a chassis, an aggregate material dispensing system that is at the front end of the vehicles, a hopper that holds the aggregate material, and a single conveying belt that moves the aggregate material from the hopper to the aggregate material dispensing system.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The present disclosure is best understood from the following detailed description when read with the accompanying Figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. [0005] Figure 1 depicts a left perspective view of the exemplary forward moving aggregate spreader with the conveying system in the driving position.

[0006] Figure 2 depicts a right perspective view of the exemplary forward moving aggregate spreader with the conveying system in the dispensing position.

[0007] Figure 3 depicts a left perspective view of the exemplary forward moving aggregate spreader with the conveying system in the dispensing position.

[0008] Figure 4 depicts a top view of the exemplary forward moving aggregate spreader with the conveying system in the dispensing position.

DETAILED DESCRIPTION

[0009] It is to be understood that the following disclosure describes several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the present disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention. Additionally, the present disclosure may repeat reference numerals and/or letters in the various exemplary embodiments and across the Figures provided herein. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various exemplary embodiments and/or configurations discussed in the Figures. Moreover, the formation of a first feature over or on a second feature in the description that follows may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features may be formed interposing the first and second features, such that the first and second features may not be in direct contact. Finally, the exemplary embodiments presented below may be combined in any combination of ways, i.e., any element from one exemplary embodiment may be used in any other exemplary embodiment, without departing from the scope of the disclosure.

[0010] Additionally, certain terms are used throughout the following description and claims to refer to particular components. As one skilled in the art will appreciate, various entities may refer to the same component by different names, and as such, the naming convention for the elements described herein is not intended to limit the scope of the invention, unless otherwise specifically defined herein. Further, the naming convention used herein is not intended to distinguish between components that differ in name but not function. Additionally, in the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to." All numerical values in this disclosure may be exact or approximate values unless otherwise specifically stated. Accordingly, various embodiments of the disclosure may deviate from the numbers, values, and ranges disclosed herein without departing from the intended scope. Furthermore, as it is used in the claims or specification, the term "or" is intended to encompass both exclusive and inclusive cases, i.e., "A or B" is intended to be synonymous with "at least one of A and B," unless otherwise expressly specified herein.

[0011] The terms "up" and "down"; "upward" and "downward"; "upper" and "lower"; "upwardly" and "downwardly"; "above" and "below"; and other like terms as used herein refer to relative positions to one another and are not intended to denote a particular spatial orientation since the apparatus and methods of using the same may be equally effective at various angles or orientations.

[0012] A bitumen spraying vehicle (not shown) applies asphalt binder material. As used herein,“asphalt binder material” and“bitumen” refer to a liquid asphalt, emulsified asphalt, molten bituminous material, asphalt binder material, binder containing asphalt components, asphalt containing binder, or any combination thereof. The bitumen spraying vehicle can be followed by a forward moving aggregate spreader 10 that can dispense aggregate material. As used herein,“aggregate material” refers to gravel, sand, crushed stone, recycled glass, shell, recycled materials, slag, any particulate matter, or any combination thereof. The aggregate material can be combined with the asphalt binder over an existing paved road or could be used to create a new paved surface. It will be understood by those skilled in the art that many forms of asphalt binder materials or aggregate materials 20 can be used.

[0013] The forward moving aggregate spreader 10 can be used to chipseal an existing paved surface by combining a previously dispensed asphalt binder layer and an aggregate layer spread on the top of the asphalt binder layer. The layers combine to create a new surface over the roadway.

[0014] Referring to FIGS . 1 -4, the forward moving aggregate spreader 10 can comprise a frame or chassis 12 supported on wheels 14, an engine 16, an operator cab 30, a storage hopper 40, a conveying system 50 and an aggregate material dispensing system 60. As used herein“chassis” refers to any vehicle body that can be configured to include any of the components of the forward moving aggregate spreader 10 described herein (e.g., a vehicle body with or without a trailer). For purposes of reference, the forward moving aggregate spreader 10 includes front and rear ends generally indicated at 22, 24.

[0015] The forward moving aggregate spreader 10 can include a chassis 12 supported on wheels 14 and extending longitudinally between front and rear ends 22, 24. The chassis 12 can supports a storage hopper 40 for holding aggregate material. The forward moving aggregate spreader 10 can apply the aggregate material at a maximum sustainable speed of between about 1 and about 15 miles per hour, or between about 1 and about 15 miles per hour.

[0016] The operator cab 30 can be modified to allow the conveying system 50 to pass by or through the operator cab 30. The operator cab 30 can be modified to remove a portion of the operator cab 30 such that the conveying system 50 can be adjacent to a first portion 32 of the operator cab and on top of a second portion 34 of the operator cab. The operator cab can be further be modified such that the conveying system 50 passes through the operator cab 30. The operator cab 30 can include a channel (not shown) such that the conveying system 50 passes through the channel. In this embodiment, operators in the operator cab 30 are not directly exposed to the aggregate material. The forward moving aggregate spreader 10 can be operated without a driver. In this embodiment, the forward moving aggregate spreader 10 can not have an operator cab 30.

[0017] The aggregate material dispensing system 60 comprises a front hopper 70 at the front end 22 of the forward moving aggregate spreader 10 and can be part of the aggregate dispensing system 60. The storage hopper 40 can be at the rear end 24 of the forward moving aggregate spreader 10 and behind the operator cab 30. The conveying system 50 can extend diagonally for transporting aggregate material from the storage hopper 40 to the front hopper 70 of the aggregate material dispensing system 60. In alternative embodiments (not illustrated), the conveying system can extend in other directions (e.g., longitudinally along the central axis of the chassis 12, in a zig-zag formation, parallel to side walls 43, 44, etc.) for transporting aggregate material within or under the storage hopper 40 from the storage hopper 40 to the front hopper 70.

[0018] The hoppers 40,70 are sized large enough to provide a sufficient holding capacity for dispensing aggregate material on a continuous basis. The storage hopper 40 can be located on chassis 12 of the forward moving aggregate spreader 10. The storage hopper 40 can extend diagonally such that the sides of the storage hopper 40 slope toward the conveying system 50. A portion of the rear wall 42 of the storage hopper 40 can have a slope between 5 degrees and 20 degrees from the vertical plane. A portion of the side walls 43, 44 of the storage hopper 40 can have a slope between 5 degrees and 60 degrees from the vertical plane. A portion of the front wall 46 of the storage hopper 40 can have a slope between 5 degrees and 60 degrees from the vertical plane. As used herein,“slope” refers to the angle from the vertical plane. The storage hopper 40 can have fixed and/or flexible baffles 80, or a similar structure that separate the storage hopper 40 into separate compartments. There can be 0, 1, 2, 3, 4, or 5 baffles 80 in the storage hopper 40. There can be less than 6, less than 5, less than 4, less than 3, or less than 2 baffles 80. The baffles 80 can be perpendicular to the conveying system 50. In alternative embodiments (not illustrated), the baffles can be at an angle to the conveying system. In alternative embodiments (not shown), the storage hopper can have any other or additional partitioning element or aggregate material handling element. The baffles 80 or partitioning element or aggregate material handling element can prevent crushing weights on the aggregate material when loading onto the conveying system 50. The storage hopper 40 can have a gate 48 that in an open position is configured to allow the aggregate material to move from the storage hopper 40 on the conveying system 50 and in a closed position is configured to retains the aggregate material within the storage hopper. The gate 48 can be spring loaded such that it is biased in the closed position. In alternative embodiments, (not illustrated), the gate can be controlled by other mechanisms (e.g., magnetic locks, electronic locks, etc.). Storage hopper 40 can have a camera 49. Camera 49 can monitor the level of aggregate material in the storage hopper 40 and can be integrated into the electronic control module. Camera 49 can be place on rear wall 42, front wall 46, or side walls 43, 44. Additional cameras (not shown) can be placed on the forward moving aggregate spreader 10 to monitor the system, including but not limited to, cameras outside or inside the operator cab 30, cameras proximate to the front hopper 70, aggregate material dispensing system, or the conveying system 50. The additional cameras also can be integrated into the electronic control system. Storage hopper 40 can also include a retractable cover 41. The retractable cover 41 can be a rigid, flexible, or screen material. The retractable cover 41 can include an open position in which the retractable cover is retracted to either the front or rear portion of the storage hopper 40, and a closed position when the retractable cover 41 is extended to a position where it covers the storage hopper 40. [0019] The front hopper 70 can discharge aggregate material through a discharge port. The discharge port can be divided into separate adjacent sections by a plurality of gates. The gates can have open and closed states for allowing and preventing discharge of aggregate material. The overall span or width of the applied layer of aggregate material can be determined by the gates which can be opened and closed. More gates can be opened to expand the span of discharged aggregate material or closed to decrease the span of discharged aggregate material. Thus, the length or span of the discharge port can be selectively variable to accommodate different application widths and changes in the width of the roadway surface. The width of the discharged aggregate material can be equal to or just greater than the width of the discharged asphalt binder material. The discharge port can also be divided into multiple horizontally parallel sections with certain sections having a fixed output and other sections having a variable output.

[0020] The conveying system 50 can be endless belt conveyors and can be controlled by motors. Additionally, the conveying system can be other conveying mechanisms such as gravity conveyors, gravity skatewheel conveyors, belt conveyors, wire mesh conveyors, plastic belt conveyors, bucket conveyors, flexible conveyors, vertical conveyors, spiral conveyors, vibrating conveyors, pneumatic conveyors, electric track vehicle systems, belt driven live roller conveyors, lineshaft roller conveyor, chain conveyor, screw conveyor or auger conveyor, chain driven live roller conveyor, overhead i-beam conveyors, dust proof conveyors, overland conveyor, or drag conveyors. The conveying system 50 can feed aggregate material from the storage hopper 40 to into the aggregate material dispensing system 60. The aggregate material dispensing system 60 can include extendable portions 62, 64. The extendable portions 62, 64 can extend to varying widths to account for different road widths. The extendable portions 62, 64 can include a retracted position in which the extendable portions 62, 64 do not extend beyond the perimeter of the chassis 12. At the rear end 52, the conveying system can have a relatively low vertical height. The conveying system 50 can extend frontward and upward, such that at the front end 54, the conveying system 50 can be above the aggregate material dispensing system 50. The conveying system 50 can have two sections 56, 58. The first section 56 can be fixed and extend diagonally from the rear bottom corner of the storage hopper 40 to the front of the storage hopper 40. The second section 58 of the conveying system 50 can be pivotally connected to the first section 56. The conveying system 50 can have a driving position wherein the second section 58 of the conveying system does not extend beyond a width of the chassis 12. The conveying system 50 can have a dispensing position such that a portion of the second section 58 is outside the width of the chassis 12. The motors can have a variable speed such that the discharge rate of aggregate material is controllable. The speed of motor and therefore the speed of the conveying system 50 can be controlled by an electronic control module. The control module can be in electrical communication with the motor. In this manner, the rate of aggregate material that is delivered to the front hopper 70 can be controlled by the forward moving aggregate spreader 10. The operator of the forward moving aggregate spreader 10 can control the dispensing of the aggregate material and determine adjustments that are needed by viewing the aggregate material dispensing system 40 in front of the operator cab 30.

[0021] To adjust for varying vehicle speeds, varying application rates, and varying widths and thickness of the layers of aggregate material, the forward moving aggregate spreader 10 can include an electronic controller (either an integral controller or separate controllers) in electrical communication with the conveying system 50, the aggregate material dispensing systems, gates, or the hoppers 40, 70. The electronic controller can be responsive to vehicle speed determined by a speed sensor and other operator input. The electronic controller 84 can control these components to set an application rate and width for the aggregate material from one of many of the various application rates and widths available. As the vehicle speed changes, the electronic controller can automatically compensate accordingly for uniform application.

[0022] The electronic control module can be part of the forward moving aggregate spreader 10. During operation, various control valves and gates can be selectively closed or opened in order to set the width or change the width of the chipsealing operation. This can be done without stopping the forward moving aggregate spreader 10. In the event that the forward moving aggregate spreader 10 incurs a change in speed, the electronic controller can proportionally control the application flow rates of the aggregate material to maintain uniform thickness of the layers. The flow rate of aggregate material can be controlled by adjusting the degree of opening of the gates.

[0023] The forward moving aggregate spreader 10 can include driverless technology (not shown) that can either assist or replace an actual operator. When the forward moving aggregate spreader 10 utilizes driverless technology, the operator cab 30 can be removed. The driverless technology can be integrated with the electronic control system.

[0024] Embodiments of the present disclosure further relate to any one or more of the following paragraphs. [0025] A vehicle for spreading an aggregate material, the vehicle comprising, opposed vehicle front and rear ends, a chassis, an aggregate material dispensing system at a front end of the vehicle, a hopper configured to hold the aggregate material, and a single conveyor belt configured to move the aggregate material from the hopper to the aggregate material dispensing system.

[0026] A vehicle for spreading an aggregate material, the vehicle comprising, opposed vehicle front and rear ends, a chassis, an aggregate material dispensing system at a front end of the vehicle, an operator cab, a hopper located behind the operator cab configured to hold the aggregate material, and a single conveyor belt configured to move the aggregate material from the hopper to the aggregate material dispensing system.

[0027] A vehicle for spreading an aggregate material, the vehicle comprising, opposed vehicle front and rear ends, a chassis, an aggregate material dispensing system at a front end of the vehicle, a hopper configured to hold the aggregate material, and a single conveying system configured to move the aggregate material from the hopper to the aggregate material dispensing system.

[0028] A vehicle for spreading an aggregate material, the vehicle comprising, opposed vehicle front and rear ends, a chassis, an aggregate material dispensing system at a front end of the vehicle, an operator cab, a hopper located behind the operator cab configured to hold the aggregate material, and a single conveying system configured to move the aggregate material from the hopper to the aggregate material dispensing system.

[0029] A vehicle for spreading an aggregate material, the vehicle comprising, opposed vehicle front and rear ends, a chassis, an aggregate material dispensing system at the vehicle front end, an operator cab, a hopper located behind the operator cab configured to hold the aggregate material, and a single conveyor belt configured to move the aggregate material from the hopper to the aggregate material dispensing system, wherein the conveyor belt is adjacent to the operator cab, wherein the conveyor belt has a first section that is fixed running diagonally from a rear corner of the hopper toward the operator cab and a second section that is pivotally connected to the first section, and wherein the conveyor belt has a driving position where the second section of the conveyor belt is pivoted toward the operator cab such that the second section does not extend beyond a width of the chassis and a dispensing position where the first section and second section of the conveyor belt are aligned and a portion of the second section extends outside the width of the chassis.

[0030] The vehicle of any of the preceding paragraphs, wherein the conveyor belt has a first section running diagonally from a rear corner of the hopper toward the operator cab and a second section that is pivotally connected to the first section.

[0031] The vehicle of any of the preceding paragraphs, wherein the conveyor belt is adjacent to the operator cab.

[0032] The vehicle of any of the preceding paragraphs, wherein the conveyor belt consists essentially of a single conveyor belt.

[0033] The vehicle of any of the preceding paragraphs, wherein the conveying system consists essentially of a single conveyor belt.

[0034] The vehicle of claim any of the preceding paragraphs, wherein the conveyor belt passes through the operator cab.

[0035] The vehicle of any of the preceding paragraphs, wherein the hopper has at least two compartments separated by at least one baffle.

[0036] The vehicle of any of the preceding paragraphs, wherein a floor of the hopper slopes toward the rear end of the vehicle.

[0037] The vehicle of any of the preceding paragraphs, wherein a first end of the conveyor belt is lower than a second end of the conveyor belt.

[0038] The vehicle of any of the preceding paragraphs, wherein the conveyor belt has a driving position where the second section of the conveyor belt is pivoted toward the operator cab such that the second section does not extend beyond a width of the chassis.

[0039] The vehicle of any of the preceding paragraphs, wherein the conveyor belt has a dispensing position where the first section and second section of the conveyor belt are aligned and a portion of the second section extends outside the width of the chassis.

[0040] Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and/or the combination of any two upper values are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are "about" or "approximately" the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.

[0041] Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.

[0042] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.