Hopper Auger for Uniform Paste Distribution in Mat Forming
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Solution Overview
Problem
Existing methods for forming flexible erosion control mats, such as those described in U.S. Pat. No. 6,793,858, face inefficiencies in manufacturing and require improvements to enhance the quality and production efficiency of tied block mats used for erosion control in areas like airport runways, roadbeds, and waterways.
Innovation Solution
A hopper system with a rotating auger is used to distribute a hardenable paste into mold cavities on a drum, where the paste is embedded with a geogrid mesh, allowing for the formation of tied block mats that can function as a drivable surface and effectively control erosion, with features like radially extending protrusions or paddles to ensure uniform distribution and minimize waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a rotating drum with mold cavities is used to form flexible mats, then the mats can be produced with interconnected concrete panels, but the manufacturing process lacks efficiency and quality consistency
Solution Approach 1:
The hopper is divided into multiple independent mold cavities arranged in a linear array, with each cavity receiving material through its own dedicated opening. This segmentation allows for precise control of material distribution to each individual block while maintaining continuous production across all cavities simultaneously.
Solution Approach 2:
A vibratory mechanism serves as an intermediary between material deposition and block formation. The vibration actively facilitates uniform material distribution and consolidation within each mold cavity, ensuring consistent block quality while maintaining high production speed.
2Manufacturing precision
If material is deposited into mold cavities on a rotating drum, then flexible mats are formed, but material distribution uniformity and product quality are compromised
Solution Approach 1:
The hopper system incorporates a vibratory mechanism that dynamically adjusts material flow and distribution during the forming process. This dynamic vibration ensures uniform material consolidation in each mold cavity while the hopper itself remains structurally simple and stationary.
Solution Approach 2:
The vibratory function is extracted as a separate, independent mechanism rather than being integrated into the hopper structure itself. This allows the hopper to remain simple in design while the added vibration component provides the necessary material distribution control.
3Productivity
If conventional methods are used to form tied block mats, then erosion control is provided, but the production process is time-consuming and less efficient
Solution Approach 1:
The system maintains continuous production by having multiple mold cavities arranged in a linear array that can be continuously fed and formed. The vibratory mechanism operates continuously during material deposition to ensure consistent block formation, enabling high-speed production without sacrificing erosion control effectiveness.
Solution Approach 2:
The vibratory mechanism changes the physical state and distribution parameters of the deposited material through vibration, ensuring proper consolidation and uniformity. This parameter control maintains block quality and erosion control reliability while enabling faster production rates.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system increases the quality and efficiency of flexible mat production, enabling the creation of sturdy tied block mats that can be used as drivable surfaces for erosion control, reducing soil loss until vegetation matures and providing a durable erosion barrier.
Implementation Method 1
The auger is rotatably mounted in the interior chamber and includes a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including surfaces angled relative to a central rotational axis of the auger to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening.
Data Source
AI summary
In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.