Patent No. 5,725,716, which in turn is a continuation-in-part of U. S. application Serial No. 239,540, filed May 9,1994, now U. S.

Patent No. 5,496,434, which in turn is a continuation-in-part of U. S. application Serial No. 870,927, filed April 20,1992, now U. S. Patent No. 5,330,603, which in turn is a continuation-in-part of U. S. application Serial No. 753,344, filed August 30,1991, now U. S. Patent No. 5,145,282, which in turn is a continuation-in-part of U. S. application Serial No. 521,442, filed May 10,1990, now U. S. Patent No. 5,049,006, which in turn is a continuation-in-part of U. S. application Serial No. 417,501, filed October 5,1989, now U. S. Patent No. 4,955,760, which in turn is a continuation-in-part of U. S. application Serial No. 235,205, filed August 23,1988, now U. S. Patent No. 4,872,784.

This invention relates to a novel continuous structure forming apparatus and method.

The present invention provides a novel apparatus and method which overcomes the shortcomings of previous expedients. In addition, the apparatus and method provide features and advantages not found in earlier technology.

The apparatus of the present invention may be employed by individuals with only limited mechanical skills and experience.

Structures can be produced by such individuals safely and efficiently without supervision utilizing the apparatus of the invention. The apparatus and method of the invention can be modified to form a variety of different structures.

Benefits and advantages of the novel apparatus of the present invention will be apparent from the following description of the accompanying drawings in which: Figure 1 is a view in perspective of one form of mobile continuous structure forming apparatus of the present invention; Figure 2 is an enlarged side view of the structure forming apparatus of the invention shown in Figure 1; Figures 3,4 and 5 are schematic illustrations of the structure forming apparatus of the invention during succeeding steps in the operation thereof; Figure 6 is a fragmentary view of a turntable assembly of the structure forming apparatus of the invention; and Figure 7 is a fragmentary cross-sectional view of the turntable assembly shown in Figure 6 taken along line 7-7 thereof.

As shown in the drawings, one form of novel mobile continuous structure forming apparatus 11 of the present invention includes a supporting portion 12, a material supplying portion 13, a mixing portion 14, a matrix forming portion 15 and a control portion 16.

The supporting portion 12 of the structure forming apparatus of the invention includes a plurality of spaced upstanding frame members 20,21,22,23. A plurality of generally horizontally disposed frame members 25,26,27,28 join adjacent upper ends of the upstanding frame members, and horizontal frame members 30,31,32,33 join lower ends thereof.

Components of the material supplying portion 13, as well as other components such as an operator's seat 29 or electrical generators, air compressors, hydraulic pumps and the like (not shown) also can be mounted on and/or suspended from the frame members.

The material supplying portion 13 of the apparatus 11 includes a plurality of reservoirs 36 operatively connected with the supporting portion 12. The reservoirs are connected independently with the mixing portion 14, preferably through flexible conduit means 37. The material supplying portion also may include hoppers 38 adjacent the mixing portion.

The mixing portion 14 of the structure forming apparatus 11 of the invention includes an elongated mixing chamber 39 adjustably disposed on the supporting portion 12.

The matrix forming portion 15 of the apparatus 11 includes first mixture distributing means 40 adjacent an outlet 41 of the mixing chamber 39 and adjustable downwardly therefrom. The first mixture distributing means 40 as shown in the drawings includes a pair of spaced elongated transversely disposed arcuate members 42,43 with generally horizontal lower edges adjustably oriented closer together than upper edges thereof.

The matrix forming portion also includes second mixture distributing means 44 adjacent the first mixture distributing means 40. The second mixture distributing means advantageously is disposed in a generally horizontal orientation. Preferably, the second mixture distributing means includes a tubular member 45 with a narrow slot 46 along its length disposed generally transversely of the movement of a blanket 34 through the apparatus 11. Alternatively, the second mixture distributing means may include an orifice 47 mounted on a reciprocating cutter mechanism 48.

Positioning means 50 is disposed adjacent the second mixture distributing means 44 for placement of a structure 49 in a preselected final configuration while the structure is flexible and adhesive. The positioning means extends outwardly from the supporting portion 12. As shown in the drawings, the positioning means includes a cantilevered frame assembly 51 extending from horizontal cross frame member 31 in a generally horizontal orientation.

The frame assembly 51 is movable from a generally horizontal structure positioning orientation to a storage position. The positioning means 50 also includes frame assembly lifting means 52 mounted on the supporting portion 12 including an extendable rm member 53 that is pivotally connected along the length of lower horizontal frame member 30. The arm member 53 also has a free end 54 that is selectively engageable with the frame assembly 51 along the length thereof. As shown in Figure 1, the free end

54 of the arm member is engageable with rod member 65 extending from the side of the frame assembly.

The frame assembly lifting means 52 includes drive means 55 operatively connected with the arm member 53 adjacent frame assembly 51. The drive means 55 lifts the connected end 56 of the frame assembly over an upper cross frame member 26 of the supporting portion 12. Advantageously, the drive means 55 is mounted on the supporting portion remote from the frame assembly 51. The drive means 55 may be a hand crank 57 or an electric, hydraulic or air motor (not shown).

The drive means 55 as shown preferably includes endless flexible connecting means such as chain 58 and sprocket/roller means 59 along the length of the chain. Advantageously, a pair of lifting means 52 may be utilized with one lifting means along each side of the supporting portion 12. Preferably, the operation of the two lifting means is coordinated such as with a jack shaft 60.

Positioning means 50 advantageously includes elongated structure grasping means 62 translatably movable along the cantilevered frame assembly 51 extending from the supporting portion 12. Preferably, the elongated structure grasping means 62 extends between and travels along spaced parallel side rails 63 of the frame assembly 51.

The elongated structure grasping means 62 advantageously includes a pair of cooperating hinged sections 64. The travel of the grasping means 62 preferably is coordinated to equalize the tension across a structure 49 being placed into a preselected final configuration.

The positioning means 50 also may include pressure applying means 66. The pressure applying means advantageously includes roller means 67 which as shown may be disposed along one edge of the cantilevered frame assembly 51. Preferably, the pressure applying means 66 includes spaced roller assemblies independently movable in a generally vertical plane.

The pressure applying means 66 advantageously are disposed above the coated matrix/blanket 61 being advanced along the frame assembly 51. The operation of the pressure applying means

preferably is coordinated with the travel of the elongated structure grasping means 62.

The supporting portion 12 of the mobile continuous structure forming apparatus 11 advantageuously includes a rotatable turntable assembly 70. Preferably, the turntable assembly includes an upper deck portion 71 and a lower base plate portion 72 spaced therefrom. Rotation between the two portions advantageously is achieved with a plurality of roller bearing members 73 arranged radially in a circular pattern 74 (Figure 6).

Most preferably, the turntable assembly 70 includes two offset circular bearing patterns 74 and 75 as shown in Figure 7.

An intermediate horizontal guide section 76 is disposed between the upper and lower bearing patterns. The turntable assembly also includes automatic orienting and locking means 77.

Advantageously, the structure forming apparatus 11 includes outer shell sections 78 selectively hung from the apparatus to enclose the apparatus during storage and to control wind, temperature, other weather conditions, etc. during operation. The outer shell sections preferably include quick access openings 79.

In the operation of the mobile continuous composite structure forming apparatus 11 of the invention as shown in the drawings, the apparatus disposed on a trailer or truck bed 10 is transferred to a job site and positioned therealong. At this point, frame assembly 51 of positioning means 50 is in a tied-down storage position along the top of supporting portion 12 as shown in Figure 3.

After freeing the frame assembly 51, drive means 55 is activated advancing endless chain 58 around sprocket/rollers 59 in a clockwise direction thereby pivoting the arm member 53 toward the front of the apparatus 11.

This movement of the the arm member causes the frame assembly 51 attached thereto to pivot about upper cross frame member 26 (Figure 4) so that the free end 80 of the frame assembly moves downwardly until it contacts the ground (Figure 5). As the arm member pivots downwardly into a generally horizontal orientation, the trailing end 56 of the frame assembly moves downwardly and engages yoke members 82 adjacent lower cross member 31 (Figure 2).

The free end 54 of the extendable arm member which has been in engagement with rod 65 extending from the frame assembly then withdraws therefrom.

A crane 83 which has been folded horizontally for storage is raised so a cable 84 wound thereon can be be extended for connection adjacent to the free end 80 of the frame assembly 51 to support it in an operating position. The pressure applying means 66 then is pivoted into place along the edge of frame assembly 51.

At this point, the supporting portion 12 is rotated on turntable assembly 70 to precisely orient the cantilevered frame assembly with respect to the ditch being lined.

Operation of the structure forming apparatus 11 is begun by preselecting a liquid reactive resin forming material, a catalyst, an inhibitor, particulate solid additive material and a porous blanket. The ambient temperature is measured. From this information, the relative proportions of the resin forming material, catalyst and inhibitor are determined based on the ambient temperature and the constuction of the porous blanket.

With the relative proportions determined, the liquid reactive resin forming material is advanced from a reservoir 36 through a conduit 37 into mixing chamber 39. Simultaneously, other ingredients e. g. particulate solid additive materials, catalysts, inhibitors, etc. from other reservoirs (not shown) advance through conduits into the mixing chamber. During this continuous mixing operation, substantially all of the additive particles are encapsulated with the catalyzed and inhibited resin forming materia The resulting mixture being delivered from outlet 41 of the mixing chamber 39 passes downwardly between arcuate members 42,43 into contact with a porous blanket or blankets 34 moving therethrough. The mixture is delivered at a rate sufficient to form a residual pool 35 between the arcuate members. As the blanket exits the liquid pool, part of the mixture migrates through the blanket substantially uniformly to form a continuous resin matrix within the blanket with the outer surfaces being adhesive.

The matrix/blanket structure 49 is coated with a second mixture at second distributing means 44 and then advanced by grasping means 62 along the length of frame assembly 51. The resulting structure 61 is placed into a preselected final configuration such as a path or ditch liner while it is flexible and has an adhesive outer surface. Preferably, the adhesive lower surface is placed in contact with a firm base surface such as concrete or packed soil or gravel.

As each length of the coated matrix/blanket structure 61 is positioned to partially overlap the previously positioned length, pressure may be applied to the overlapped area. Advantageously, this is accomplished with a plurality of rollers 67 spaced along one edge of the cantilevered frame assembly 51. During the operation of the grasping means 62, the rollers 67 are located above the matrix/blanket being advanced along the frame assembly.

When the matrix/blanket 61 is properly positioned in its preselected final configuration such as over a ditch, each of the independently movable rollers 67 is moved downwardly to engage the edge of the matrix/blanket and push the unsupported center of the blanket against the sidewalls and bottom of the ditch. Additional lengths of the coated matrix/blanket are individually positioned in succession into an overlapping orientation with each length tightly affixed to each previously positioned length to form a substantially continuous composite structure with high strength and exceptional durability.

To produce high quality continuous composite structures of the invention, it is important that all of the steps be carefully coordinated by control portion 16.

The control portion 16 of the structure forming apparatus 11 of the invention includes programmable memory means 85 and actuating means 86 responsive thereto in combination with coordinating means 87 to control the operation of the various components of apparatus 11. Preferably, the coordinating means includes a process controller 88 that initiates changes in the flows of materials and speeds of drives to bring variations therein back to the rates specified by programs present in the memory 85.

This coordination commonly is achieved through the transmission of information such as digital pulses from monitors and/or sensors at the control components (not shown) to the process controller 88. The operating information is compared with the preselected programming parameters stored in the memory 85.

If differences are detected, instructions from the controller change the operation of the components to restore the various operations to the preselected processing specifications.

Normal maneuvering of the continuous structure forming apparatus of the invention to maintain it close to a preselected path ordinarily can be accomplished by advancing the truck or trailer on which the forming apparatus 11 is located along the edge of the ditch or path being covered. If obstacles such as bridges, trees, head gates, etc. are encountered, minor changes in the placement of the composite structure can be achieved by utilizing the turntable assembly 70.

Major changes of direction may be accomplished by returning the frame assembly 51 into its storage position on top of the supporting portion 12 and shifting the position of the trailer or truck on which the apparatus 11 is mounted. The steps of moving the frame assembly 51 from its working position to its storage position are in the reverse order to the steps described in detail above for initiating the operation of the apparatus.

The pressure applying means 66 is pivoted to a stored position along the supporting portion 12. The tension in cable 84 is eased so the free end 80 of the frame assembly rests on the ground. The cable and crane are stored and drive means 55 extends arm member 53 so the free end 54 thereof is connected with rod member 65 located along the side of the frame assembly 51.

Then, the chain 58 is advanced in a counterclockwise direction by drive means 55 which pivots the arm member in the same direction which pulls the connected end 56 of the frame assembly over upper cross frame member 26 and advances it toward the rear of the apparatus. Continuing movement of chain 58 raises the frame assembly into a generally horizontal orientation on top of the apparatus, its normal storage position. In this orientation, the apparatus on the truck or trailer can be moved

as a normal load to a new location and the frame assembly repositioned to resume operation of the structure forming apparatus of the invention.

The above description and the accompanying drawings show that the present invention provides a novel apparatus which overcomes the shortcomings of previous expedients and in addition, provides features and advantages not found in earlier technology.

The apparatus of the invention may be operated by individuals with only limited mechanical skills and experience to produce high quality structures safely and efficiently. The apparatus and method can be modified to form a variety of different structures.

It will be apparent that various modifications can be made in the particular apparatus and method described in detail above and shown in the drawings within the scope of the present invention. Components employed in the apparatus and method can be changed to meet specific process and structural requirements.

These and other changes can be made in the apparatus and method of the invention provided the functioning and operation thereof are not adversely affected. Therefore, the scope of the present invention is to be limited only by the following claims.