Screening Hopper Tine Separation for Soil Particle-Size Control

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Solution Overview

Problem

The re-use of soil and clay materials removed during construction is challenging due to varying particle sizes, moisture content, and contaminants, leading to instability and high energy costs for transportation and treatment.

Innovation Solution

A screening hopper apparatus with a grinding array and separation array, featuring elongate tines and vibrating grinding elements, is used to break down and separate particulate material, allowing on-site processing and mixing with a binder to create a homogenous construction material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soil material is removed and disposed of in landfill sites, then the site can be prepared for foundation construction, but high energy costs are incurred for transporting materials to and from remote locations

Engineering Contradiction:
Improvefoundation stabilityVSAvoidtransportation energy
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent applies preliminary action by processing the soil material on-site before disposal or reuse. The screening hopper breaks down and separates the excavated material immediately at the construction site, eliminating the need to transport bulky, unprocessed material to remote landfill sites. This preliminary processing reduces transportation energy while ensuring the site is properly prepared for foundation construction.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The screening hopper acts as an intermediary device between the excavated soil and the final disposal or reuse destination. By introducing this on-site processing equipment, the patent creates an intermediate step that reduces material volume and prepares it for efficient disposal or reuse, thereby reducing the energy required for subsequent transportation operations.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Use of energy by moving object

If soil material with varying particle sizes and high moisture content is reused directly, then transportation costs are reduced, but the material is unsuitable for construction due to instability and contamination

Engineering Contradiction:
Improvetransportation energyVSAvoidsoil stability
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The patent applies segmentation by dividing the soil processing into distinct functional stages within the screening hopper: initial breakdown by impact, secondary grinding by rotating elements, and separation by screening. This segmented approach systematically addresses particle size variation and contamination issues, transforming unsuitable excavated material into stable, construction-ready fill material that can be reused on-site without extensive transportation.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The screening hopper implements parameter changes by physically altering the soil material's particle size distribution and moisture content through mechanical breakdown and screening processes. These parameter transformations convert the original unsuitable material characteristics into acceptable construction parameters, enabling on-site reuse and eliminating the need for energy-intensive transportation to remote processing facilities.

Inventive Principle:
Principle #35Parameter changes

3Manufacturing precision

If the soil material is screened to achieve correct average particle size, then the material becomes suitable for construction use, but the process becomes complex due to moisture content control requirements

Engineering Contradiction:
Improveparticle size controlVSAvoidmoisture control system
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The screening hopper applies self-service by using the material's own weight and the mechanical energy from the rotating impactor and grinding elements to drive the screening process. The design eliminates the need for external moisture control systems by relying on gravitational force and mechanical impact to achieve particle size separation, thereby achieving manufacturing precision without adding device complexity.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent employs mechanical vibration through the rotating impactor and grinding elements to enhance the screening process. This vibration helps separate particles by size more efficiently and prevents moisture-related clumping, achieving precise particle size control without requiring complex moisture control systems. The mechanical energy from vibration naturally addresses both particle size distribution and moisture management.

Inventive Principle:
Principle #18Mechanical vibration

4Reliability

If large quantities of soil material are transported to landfill sites, then proper foundation construction can proceed, but the energy requirements for transporting materials between locations increase significantly

Engineering Contradiction:
Improvefoundation construction qualityVSAvoidtransportation energy
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The screening hopper performs preliminary action by processing and reducing the volume of excavated soil material on-site before disposal or reuse. This preliminary size reduction and separation eliminates the need to transport full volumes of unprocessed material to remote landfill sites, thereby maintaining foundation construction quality while significantly reducing the energy lost in transportation operations.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent converts the harmful aspect of large-volume material transportation into a benefit by using the excavated material itself as the processing medium. The screening hopper uses the material's own weight and composition to drive the screening and separation processes, transforming what would be a transportation burden into an on-site resource that eliminates the need for energy-intensive long-distance hauling.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

Enables the reuse of soil and clay materials, reducing energy consumption and transportation costs by processing materials on-site, ensuring stability and homogeneity for construction applications.

Implementation Method 1

The tines act to filter out oversized material from entering the hopper and so potentially damaging the grinding array, and also to break down large particulate or agglomerate material.

Methodology Applied
Scientific EffectMechanical impact: Impact Force

Implementation Method 2

a base section of the hopper including a grinding array

Methodology Applied
Scientific EffectGrinding: Abrasion

Implementation Method 3

The tines act to filter out oversized material from entering the hopper

Methodology Applied
Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS12427545B2Screening hopper
Publication Date: 2025.09.30 ECOFILL GRP LTD
  • US12427545B2 patent drawing
  • US12427545B2 patent drawing
  • US12427545B2 patent drawing

AI summary

An apparatus for producing a construction material for use in the building industry is disclosed. The apparatus comprises a hopper (10) which includes a trough (11) having a base section and an open top to allow material to be added to the hopper. The base section of the hopper includes a grinding array (24). A separation array (152) is deployed above the open top with the separation array comprising a plurality of elongate tines (151), each having a first end and a second end, mounted parallel to each other, and secured at least at one end to a support means.