This application claims priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 12/535,036 filed on Aug. 4, 2009, the entire contents of which are incorporated herein by this reference.
1. Field of the Invention
This invention is generally directed to cleaning devices and more specifically relates to washing devices.
2. Background Information
Mats are known in the art for use in construction sites. Often times, wooden mats are used at constructions sites. Wooden mats may be utilized for any purpose, but are often used to support loads or as structural protection.
Mats are often assembled from a group of heavy duty elongated wooden members placed parallel and joined by a joining mechanism. Mats range in sizes from a thickness of between eight to twelve inches, a width of four to five feet, and a length of eight to fifty two feet. Thus, mats may be extremely large, heavy and difficult to handle. Although wood mats are discussed, any material may be used to make the mats used at construction sites. Further, it is known that the mats may be constructed and then transported to a construction site or other site, or the mats may be constructed at a specific site.
Although mat structures may be well known in the art, the inventor has realized that mats used at construction sites, often known as swamp mats, and other sites become dirty during use. Also, the inventor has realized that up until this invention mats used at construction sites and other sites are not easily cleaned by known methods of cleaning. Further, the inventor has realized deficiencies in known cleaning methods and has developed a novel device and method to clean mats.
Generally, an embodiment of the invention includes a portable structure that may have adjustable height. The invention may include a first conveyor that receives mats and is capable of transporting the mat from a first end of the conveyor to a second end of the conveyor. A primary brush system may be located toward the second end of the first conveyor and may receive the transported mat. Once the mat has passed through the primary brush system, the mat may engage a second conveyor. The second conveyor may transport the mat from a first end of the second conveyor to a second end of the second conveyor where a secondary brush system may be located. The mat may then be inserted into the secondary brush system. Once the mat may have passed through the secondary brush system, the mat may engage a third conveyor that transports the mat out of the secondary brush system to an exit from the portable structure.
The portable structure may be elevated off the ground with adjustable legs and feet. If included, there may be any number of legs and/or feet, but preferably at least two sets of legs and feet are utilized. The legs may be secured to a main frame, along with a rail system. The rail system may be utilized for guiding mat structures through the transportable structure/system. Further, there may be a conveyor or conveyors attached to the main frame.
An objective of the invention is to provide a system that may include a water recycling system that allows for utilizing a limited quantity of water at remote work sites or any other work sites.
An objective of the invention is to provide a system to which additional features may be easily attached as needed. For example, additional conveyors may be attached to the portable system to assist in removing mats from the system after the mats have been washed or additional conveyors may be attached at angles perpendicular to the direction of mat transport of a mat for any purpose, particularly including assisting in the removal of debris from the washing system.
An objective of the invention is to provide a device that may be used in a method for cleaning mats. The method may include conveying a mat along a conveying path to a first brush system; engaging the mat with the first brush system; conveying the mat from the first brush system to a second brush system; engaging the mat with the second brush system; and conveying the mat away from the second brush system in a direction opposite a direction of the first brush system.
An objective of the invention is to provide a system for cleaning swamp mats that may be transportable to and from different locations, including remote work sites. An aspect of the invention is an apparatus transportable on a flat bed trailer, and that is highway portable; that is, transportable on a trailer down a roadway and in compliance with all Department of Transportation regulations.
Further, an objective of the invention is to provide a system for cleaning mats that is automated and that may save time over conventional mat washing systems. In recent times, different jurisdictions (e.g., from state to state) have started to closely regulate what is brought into their regulated boundary in order to curb any transfer of hazardous or non-native substance. Thus, as it is necessary to clean mats prior to transporting the mats, any time savings in cleaning mats may be appreciated for at least the reason that it may allow for mats to be more efficiently transported from one jurisdiction to another jurisdiction.
The above summary of the present invention is not intended to describe each illustrated embodiment, aspect, or every implementation or object of the present invention. The figures and detailed description that follow more particularly exemplify these and other embodiments and further aspects of the invention.
The invention may be more completely understood in consideration of the following description of various embodiments of the invention in connection with the accompanying drawings, in which:
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not necessarily to limit the invention to the particular embodiments described. On the contrary, the intention is to cover preferred embodiments, modifications, equivalents, and alternatives falling within the spirit and scope of the invention and as defined by the appended claims.
The subject inventive transportable system and methods of using the transportable system may take on numerous physical and methodical embodiments within the spirit of the invention and only preferred embodiments have been described in detail below, which are not meant to limit the scope and/or spirit of the invention.
A mat washer 10 of the invention may take many forms. Generally, mat washer 10, as seen in
Mat washer 10 may include more conveyor systems than just the first conveyor system 30, as seen in
Main frame 20, as depicted in
Mat washer 10 may have a rail system 60, as in
As depicted in FIGS. 1 and 17-20, conveyor systems 30, 40, 50 may be made from essentially the same parts or different parts and may convey along a conveying line CL. Conveyor systems 30, 40, 50 may convey in a single direction or multiple directions. In one aspect, conveyor systems 30, 40, 50 may comprise at least one spring roller assembly 120. Typically, however, a spring roller assembly 120 is most useful with conveyor system 30 which will receive the greatest wear due to mats being initially placed, or dropped, upon the conveyor 30. Spring roller assembly 120 may generally comprise a roller 122, a roller shaft 124, and a spring take up assembly 130. Roller shaft 124 may extend through roller 122 or may comprise multiple shafts that are attached to roller 122. Roller shaft 124 may extend through holes 126 (See
In one aspect, spring take up assembly 130, as shown in
Further, spring take up assembly 130 creates an independent suspension for each roller 122 and roller shaft 124 assembly in conveyor systems 30, 40, 50, and may create an independent suspension for each side of a roller 122 and roller shaft 124 assembly. Independent suspension of each roller 122 allows washer 10 increased durability. The weight of a mat dropped upon a roller 122 or rollers 122 is absorbed by springs 144, at least partially, to lessen the impacting force upon roller 122 that would occur absent such absorption. Holes 126 are somewhat elongated to accommodate for vertical motion of roller shafts 124. Seals are used to cover exposed gaps in holes 126 or take up assembly 130.
As depicted in
Spring roller assemblies 120 of conveyors 30, 40, 50 may be covered by guards 152, 154 and a third guard (not shown). Roller 122 may be attached to roller shaft(s) 124 at a position between main frame first side 22 and main frame second side 24. Roller shaft(s) 124 may extend through main frame holes 26 and engage take up shaft receivers 134 at ends of roller shaft(s) 124 and at positions outside main frame first side 22 and main frame second side 24 (See
As shown in
As seen in
As seen in
As seen in
Upper bearing assembly 206 and lower bearing assembly 204 may engage actuators 210. Actuators 210 may be any type of actuator; for example, a hydraulic actuator. Such actuators may assist in sliding movement of lower bearing assembly 204 and upper bearing assembly 206. Further, brush drum upper hub assembly 216 extends through upper bearing assembly 206, and is slidably engaged therewith. When upper bearing assembly 206 or lower bearing assembly 204 slide, cable brush drum assembly 202 may angle. Brush drum assembly 202 may also maintain a generally vertical orientation where assembly 204 and assembly 204 are vertically aligned. A pair of drums 212 may also be drawn closer or farther from each other to achieve a desired gap through which a mat is conveyed. Since each bearing assembly 206, 204 is independently adjustable, a variety of angles, gaps and configurations can be achieved in order to accommodate cleaning of a variety of types, sizes and styles of mats.
Brush driver assembly 240 (
Within primary frame assembly 200, brush drum upper hub assembly 216 engages upper bearing assembly 206 and brush drum lower hub assembly 218 engages lower bearing assembly 204. Each bearing assembly 216, 218 is in communication with an actuator 210. Further, brush drive assembly 240 engages brush drum upper hub assembly 216. Yet further, primary brush system 70 may utilize splash shield assemblies 250 for any purpose; for example, for the purpose of blocking debris from flying off mats as cable brushes 214 contact a mat's surface.
As seen in
Secondary brush system 80 may utilize many of the same parts or different parts as primary brush system 70 utilizes. Secondary brush system 80 and primary brush system 70 may be differentiated by at least having different drum assemblies 302, 202, respectively. The independently driven drum assemblies may be rotated clockwise or counter-clockwise as desired. Further, secondary brush system 80 may utilize splash shield assemblies 250 for any purpose; for example, for the purpose of blocking debris or water from flying off mats or out of the washer as brush wafers 306 contact a mat's surface.
Brush wafers 306 may be made from a ring having fibers extending therefrom. The fibers may be made from a natural or unnatural resilient material. Generally, brush wafers 306 may be stacked on top of one another so as to extend from second end of fiber drum body 310 to first end of fiber drum body 308. For at least the purposes of stiffening the fiber brushes and prolonging the life of the brush wafers 306, brush wafers 306 comprising metal fiber or other rigid material may be inserted between brush wafers 306 having fibers made of an unnatural mater (e.g., plastic).
As seen in
Dry discharge conveyor 320 may be generally located from a front end of mat washer 10 and may extend toward and to at least primary brush system 70. Dry discharge conveyor 320 may have many purposes, and one of those many purposes may include the purpose of catching dirt and other material released from mats and caused by primary brush system 70. Dry discharge conveyor 320 may move in any direction, including a direction opposite the direction the mats are conveyed through mat washer 10. As brush system 70 operates, debris, such as dirt or mud or other material is beat from or brushed from a mat and falls downward onto conveyor 320 for removal.
Wet discharge conveyor 330 may be generally located from secondary brush system 80 and may extend toward and to at least a back end of mat washer 10. Wet discharge conveyor 330 may have many purposes, and one of those many purposes may include the purpose of catching dirt and water and other material released from mats caused by the mats interacting with secondary brush system 80. Wet discharge conveyor also catches liquid that is introduced onto a mat during a washing event, such as liquid sprayed upon a mat at the secondary brush system 80. Wet discharge conveyor 330 may move in any direction, including the same direction the mats are conveyed through mat washer 10.
Mat washer 10 may be used with many methods to clean mats of any type. For example, mat washer 10 may be transported, via a tractor trailer for instance, to a remote location or any other location where mats may be used for a construction purpose. Mat washer 10 preferably has proportions which allow for transportation on a trailer. In one aspect, washer 10 is approximately 40 feet in length, approximately eight feet in width, and approximately eleven to twelve feet in height. The height is adjustable due to the leg support assemblies 110. In one aspect washer 10 is placed on a 48 foot step-deck trailer; the lower deck portion of the trailer measures approximately 40 feet to accommodate support of washer 10. As such a common trailer may be used for transport, without the need for special permits or wide load hauling, etc. and complies with department of transportation regulations. Mat washer 10 may be lifted onto a flat bed by any known means, which may include the use of a crane system.
Once mat washer 10 is at a location where mats are in need of washing, mats may be inserted onto spring roller assemblies 120 at a front or first end of mat washer. A mats located at these locations is commonly known as a swamp mat 350 (as depicted in
Rail system 60 may be utilized to keep mats 350 in an upright position on its edge 360 and help direct mats 350 into primary brush system 70. Mats 350 may be conveyed along mat washer 10 via the driven spring roller assemblies 120. Due to the weight of a mat 350, the friction between mat 350 and rollers 122 and the drive of the rollers 122, mat 350 may be conveyed through mat washer 10. The weight of a mat 350 may vary, however, a mat 350 weighing several hundred pounds is typical. Mats having weights of several hundreds of pounds, and sometimes even into the thousands of pounds, may be expected to be washed in the present apparatus. Heavy equipment such as cranes and end-loaders are used to lift and transport the mats on to and/or off from the apparatus (trailers are contemplated for use to transport the mats to the location of the portable apparatus for washing.
In operation of one aspect, mat 350 is placed on conveying system 30 conveying along a conveying line, generally shown as line CL (
A mat 350 may then be conveyed to secondary brush system 80. Secondary brush system 80 is positioned downstream from primary brush system 70. Brush system 80 may work to remove remaining foreign material that was not removed by the primary brush system 70. Secondary brush system 80 may spray water on the mats 350 and may contact the mats 350 with brush wafer 306. Generally, brush wafers 306 are spun in any direction, for example, a direction opposite the direction the mats 350 are moving, and the brush wafers 306 and water may contact the mats 350 to remove pieces of foreign material. A further conveying system (i.e., a discharge conveying system), such as comprising wet discharge conveyor 330 may then collect released foreign material, water, mud and other material that has been released from the mats 350 and convey that material and water out of mat washer 10.
Brush systems 70, 80 may have many unique features. For example, the brush drums 220, 304 of brush system may be adjusted in directions perpendicular to the direction of mat transport so as to tilt in and out and may form different shapes including V-shapes and A-shapes, or angled/slanted parallel shapes. Further, brush systems 70, 80 may be capable of moving closer together for purpose of creating greater tension against mat. Yet further, brush systems 70, 80 may spin in any direction. All functions of brush systems 70, 80 may be controlled by a control system that may be located remotely with respect to main frame 20.
After mat 350 is conveyed through secondary brush system 80 the mat 350 is generally conveyed to an end of mat washer 10 and removed from the transportable device. Further, generally, while at rest and while in use, all systems of mat washer 10 may maintain their in-line position with respect to main frame 20 of mat washer 10 and the mats 350 are conveyed through the systems.
Multiple primary brush systems 70 or secondary systems 80 may be utilized on washer 10 in order to provide additional brushing if needed. Further, the direction of travel of a mat may be reversed such that it travels upstream on the conveyors in order to be re-brushed or rewashed. Yet preferably a mat is removed from washer 10 and replaced for rewashing if needed or desired in order to maintain a steady flow of movement in a single conveying direction as possible.
A separate brush system or systems may be included to wash mat edge or edges 360. Such separate system may utilize similar brush system as described herein.
The methods of use described heretofore are only examples of methods of use. It is clear that one skilled in the art may develop other methods of use as suggested by the description that are in the spirit of the invention and are not intended to be excluded from the scope of the invention by not being specifically recited.
The terms and descriptions used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the invention as defined in the following claims, and their equivalents, in which all terms are to be understood in their broadest possible sense unless otherwise specifically indicated. While the particular MAT WASHING MACHINE AND METHOD OF USING as herein shown and described in detail is fully capable of attaining the above-described aspects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and thus, is representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”
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