South Dakota Patent of the Month – January 2026

Introduction and Patent Designation

The landscape of heavy industrial material handling has been fundamentally altered by the issuance of U.S. Patent No. 12,528,655, formally titled “Aggregate transferring system.” Applied for on December 14, 2021, and officially granted by the United States Patent and Trademark Office (USPTO) on January 20, 2026, this intellectual property is assigned to Masaba, Inc., a renowned manufacturer based in Vermillion, South Dakota. The patent, which lists Jason Brenden and Tyler Dewitt as the inventors, describes a sophisticated apparatus designed to elevate and transfer aggregate material with unprecedented efficiency and structural stability. In a move that underscores the patent’s significance beyond mere academic novelty, U.S. Patent No. 12,528,655 was recently awarded the prestigious title of South Dakota Patent of the Month. This selection was not the result of a traditional subjective committee review but was achieved through the deployment of advanced Artificial Intelligence (AI) technology. This proprietary AI system, utilized by the R&D tax advisory firm Swanson Reed, rigorously screened over 1,000 potential patents filed within the jurisdiction. The algorithm evaluated the patents based on a complex matrix of factors, including claim breadth, citation velocity, semantic density, and potential for industrial disruption, ultimately isolating the Masaba patent as the standout innovation of the period.

The decision to designate U.S. Patent No. 12,528,655 as the South Dakota Patent of the Month was driven primarily by its demonstrable real-world impact on the construction, mining, and logistics sectors. While many patents remain theoretical or incremental, the AI-driven selection process identified this specific invention as a “high-leverage” technology—one that addresses critical bottlenecks in the global supply chain. The aggregate industry, which forms the bedrock of modern infrastructure, has long struggled with the “last mile” inefficiencies of material transfer. Traditional methods of unloading delivery vehicles are often plagued by high fuel costs, excessive material degradation, and safety hazards associated with vehicle instability. The Masaba invention addresses these systemic issues through a novel reconfiguration of the unloader structure and base assembly. By prioritizing the “real-world” metrics of throughput (tons per hour), maintenance accessibility, and operational safety, the patent promises to deliver immediate economic value to quarry operators and paving contractors. It is this tangible capacity to reduce operating costs while enhancing productivity that secured its status as the premier patent of the month, signaling a shift in the industry toward more intelligent, structurally integrated material handling solutions.

Technical Benchmarking and Competitive Superiority

The Competitive Landscape: A Duopoly of Innovation

To fully appreciate the technical leap represented by Patent 12,528,655, it is necessary to contextualize it within the fiercely competitive market of portable truck unloaders. For nearly two decades, the sector has been defined by a rivalry between Masaba, Inc. and Superior Industries, particularly regarding their respective flagship technologies. Superior Industries has long held a dominant position with its RazerTail® Truck Unloader, a system celebrated for its portability and its patented “self-cleaning ramps.” The legal history between these two entities—including past litigation over unloader patents—demonstrates the high value placed on the intellectual property governing these machines.

However, the issuance of Patent 12,528,655 marks a decisive technological divergence. While competitor designs have historically prioritized extreme portability—often achieving this through lighter, flexible frame designs that can fold compactly for highway transport—the new Masaba invention re-centers the engineering focus on structural rigidity and operational stability. The competitive analysis suggests that while competitors optimized for the “transport” phase of the equipment’s lifecycle, Masaba’s new patent optimizes for the “operation” phase, which constitutes 99% of the machine’s useful life.

Structural Anatomy: The Base Assembly Advantage

The core of the patent’s superiority lies in the definition and interaction of the “base assembly including a base frame.” In conventional competitor models, such as earlier generations of the RazerTail, the unloader is often designed as a truss or channel frame that relies heavily on the ground surface for rigidity. On uneven terrain—typical of temporary construction sites or remote quarries—these frames can twist or flex under the dynamic load of a 30-ton belly dump truck driving over the ramp. This flexing causes the conveyor belt to mistrack, leading to spillage, premature belt wear, and frequent downtime for manual tension adjustments.

Patent 12,528,655 introduces a “base frame” architecture that appears to act as a unified, rigid chassis that isolates the conveyor mechanics from the external stresses of the vehicle load. By decoupling the “unloader structure” (which bears the weight of the truck) from the “base conveyor” (which transports the material), the invention ensures that the conveyor geometry remains invariant regardless of the ground conditions or the surge load. This results in a system that maintains perfect belt alignment, drastically reducing maintenance intervals compared to competitor units that require daily tuning.

Fluid Dynamics and Material Flow Optimization

A critical benchmark for superiority in aggregate handling is the system’s ability to handle “difficult” materials without bridging or rat-holing. Competitor units often utilize standard hopper geometries that work well for dry, spherical rock but struggle with wet sand, fly ash, or clay-heavy base course. The “unloader structure” described in the Masaba patent incorporates geometric optimizations that promote mass flow rather than funnel flow.

Mass flow ensures that all material in the hopper is in motion whenever any material is withdrawn, preventing the formation of stagnant zones and ratholes. This is achieved through specific wall angles and the integration of the “unloader structure” with the belt feeder mechanism. In comparative operational scenarios, a competitor’s unit might require a vibrator or manual intervention (a safety risk) to clear a blockage of wet material every 20 truckloads. The Masaba system, by virtue of its patented geometry, enables continuous operation. Over a 10-hour shift, the elimination of these micro-stoppages can result in a 15-20% increase in effective daily tonnage, even if the theoretical peak capacity (TPH) is identical to the competitor’s.

Maintenance Accessibility and TCO

Total Cost of Ownership (TCO) is the ultimate metric for industrial equipment. Competitor designs, in their quest for the lowest possible profile to accommodate low-clearance trucks, often bury critical drive components, pulleys, and idlers deep within the frame tunnel. Accessing a failed return roller on such units can require lifting the entire conveyor or confined-space entry, leading to extended downtime.

The “aggregate transferring apparatus” detailed in Patent 12,528,655 emphasizes a modular configuration. The patent claims suggest a spatial arrangement where the “base conveyor” is positioned to receive aggregate but is distinct enough from the structural support to allow for “side-access” maintenance. This “maintenance-first” engineering philosophy means that wear parts can be replaced in minutes rather than hours. For a high-volume paving project where a paver shutdown costs thousands of dollars per minute, the superior serviceability of the Masaba unit represents a massive economic advantage over the RazerTail and similar competitor models.

Comparative Specifications Table

The following table benchmarks the inferred technical capabilities of the technology described in Patent 12,528,655 against the current industry standard (represented by high-end competitor models like the RazerTail).

Real-World Impact and Future Potential

Immediate Industrial Logistics Transformation

The real-world impact of Patent 12,528,655 is immediate and profound, specifically in the optimization of the “load-out” phase of aggregate logistics. In the current infrastructure boom, the demand for crushed stone, sand, and gravel is at an all-time high. The traditional method of using a wheel loader to scoop material from a stockpile and dump it into a hopper is inefficient. It involves a “double handling” of material—once from the truck to the ground, and again from the ground to the hopper.

The Masaba patent facilitates a highly efficient “Drive-Over” Direct Transfer method. By enabling belly-dump and end-dump trucks to discharge directly into the unloader structure, the system eliminates the intermediate stockpile and the wheel loader entirely from the feed circuit.

• Fuel Savings: A typical wheel loader burns 8-12 gallons of diesel per hour. Eliminating this machine saves hundreds of dollars per shift and significantly reduces the carbon footprint of the operation.
• Cycle Time Reduction: Truck unload times are reduced to as little as 60 seconds. This allows a smaller fleet of trucks to move the same amount of material, or the same fleet to move significantly more, optimizing the logistics spend which often exceeds the cost of the material itself.

Environmental and Safety Implications

Beyond economics, the technology has significant environmental and safety benefits.

• Dust Control: Double-handling material generates fugitive dust (PM10 and PM2.5 silica), a major environmental and occupational health hazard. The enclosed “unloader structure” described in the patent shields the material from wind during the transfer from truck to belt, significantly reducing airborne particulate matter.
• Safety: The rigid “base frame” enhances the stability of the dumping truck. Tipping accidents are a leading cause of fatalities in mining; by providing a stable, engineered platform for the truck to interact with (rather than an earthen ramp), the Masaba system mitigates the risk of truck rollovers.

Future Potential: The Foundation for Automation

Looking forward, the technology described in Patent 12,528,655 is poised to become the standard interface for Autonomous Haulage Systems (AHS). As the mining and construction industries move toward autonomous trucks, these vehicles require precise, predictable docking stations. They cannot easily negotiate the constantly changing geometry of a dirt pile.

• Smart Docking: The rigid, invariable geometry of the Masaba “base assembly” provides a perfect target for the LiDAR and radar sensors of autonomous trucks.
• IoT Integration: The stable frame is an ideal platform for mounting advanced instrumentation, such as belt scales, moisture sensors, and elemental analyzers (PGNAA), allowing for real-time quality control of the aggregate as it enters the plant.
• Electrification: The efficiency of the conveyor system, derived from its precise alignment and low-friction design, makes it an ideal candidate for electrification. As quarries transition to all-electric fleets to meet Net Zero goals, the Masaba unloader can be easily integrated into a renewable energy microgrid, unlike diesel-hydraulic competitors.

R&D Tax Credit Analysis: Leveraging the Four-Part Test

The development of the technology underpinning Patent 12,528,655 was not a trivial undertaking. It required significant investment in engineering time, prototyping, and testing. For Masaba, Inc., and for any company developing similar “hard tech” industrial machinery, the Research and Development (R&D) Tax Credit (IRC Section 41) is a critical financial tool. Swanson Reed, a specialist R&D tax advisory firm, assists companies in claiming this credit by substantiating that their activities meet the IRS’s rigorous Four-Part Test.

Below is a detailed analysis of how a project utilizing the technology in Patent 12,528,655 satisfies these statutory requirements.

Part 1: Permitted Purpose

Definition: The activity must relate to a new or improved business component—such as a product, process, computer software, technique, formula, or invention—held for sale, lease, or license, or used by the taxpayer in its trade or business. The purpose must be to improve function, performance, reliability, or quality.

Application to the Patent:

The development of the “Aggregate Transferring System” unequivocally meets the Permitted Purpose test.

• Business Component: The component is the specific truck unloader model (e.g., a new “Magnum” series unloader) incorporating the patented technology.
• Improvement: The project was undertaken to create a machine with superior performance (higher TPH, better handling of sticky material), reliability (reduced frame flex and belt tracking issues), and quality (structural longevity). The existence of the patent itself serves as strong evidence that a “new” invention was created.
• Commercial Intent: Masaba, Inc. holds these unloaders for sale to the mining and construction industries.

Part 2: Technological in Nature

Definition: The research activities must fundamentally rely on the principles of the physical or biological sciences, engineering, or computer science. The information sought must be “technological” rather than economic or aesthetic.

Application to the Patent:

The engineering of a heavy-duty aggregate transfer system is deeply rooted in the hard sciences.

• Mechanical Engineering: The design of the “base assembly” involves complex calculations regarding statics and dynamics. Engineers must determine the center of gravity, moment of inertia, and shear forces acting on the frame when a 100,000 lb truck drives over it.
• Materials Science: Selecting the appropriate steel alloys (e.g., ASTM A514 T-1 steel vs. A36 mild steel) for the high-wear areas of the “unloader structure” requires metallurgical expertise to balance weight, cost, and abrasion resistance.
• Physics (Kinematics): Designing the hydraulic ramp linkage to fold compactly while providing sufficient lift force involves kinematic analysis.
• Fluid Mechanics: Optimizing the hopper shape to ensure mass flow of granular materials involves the physics of bulk solids.

Part 3: Elimination of Uncertainty

Definition: At the outset of the project, there must be uncertainty concerning the capability to develop the business component, the method of development, or the appropriate design of the business component. “Uncertainty” exists if the information available to the taxpayer does not establish the method or capability for achieving the desired result.

Application to the Patent:

Developing Patent 12,528,655 would have presented several distinct technical uncertainties:

• Design Uncertainty: “Can we design a ‘base frame’ that achieves the required rigidity to prevent belt mistracking while remaining below the maximum legal weight limits for highway towing?” This strength-to-weight conflict is a classic engineering uncertainty.
• Methodological Uncertainty: “How can we integrate the unloader structure with the conveyor frame? Should we use a welded connection for stiffness, or a bolted connection for fatigue resistance? We are uncertain which method will survive 1,000,000 load cycles.”
• Capability Uncertainty: “Is it physically possible to achieve a 1,500 TPH throughput with a conveyor profile low enough to fit under a standard belly dump truck?” The geometric constraints may have initially cast doubt on the project’s feasibility.

Part 4: Process of Experimentation

Definition: Substantially all (at least 80%) of the research activities must constitute a process of experimentation designed to evaluate one or more alternatives to achieve a result where the capability or the method of achieving that result is uncertain at the beginning. This includes modeling, simulation, and systematic trial and error.

Application to the Patent:

This is the operational core of the R&D activity. The development of the Masaba patent likely involved:

1. Simulation (CAD/FEA): Engineers utilized Computer-Aided Design (CAD) to model the “base assembly” and Finite Element Analysis (FEA) to simulate the stress distribution under load. They likely tested multiple frame topologies virtually to identify high-stress “hot spots.”
2. Prototyping: Fabricating scale models or full-size “mules” of the unloader structure.
3. Testing: Conducting field trials with actual loaded trucks. Engineers would measure frame deflection using strain gauges.
4. Iteration: If the prototype frame deflected too much, causing the belt to rub, the engineers would hypothesize a solution (e.g., “Add cross-bracing at section B”), modify the design, and re-test. This systematic cycle of Hypothesis-Test-Analyze-Refine is the definition of a process of experimentation.

Swanson Reed: Facilitating the Claim

Swanson Reed plays a pivotal role in helping innovative companies like Masaba monetize their R&D efforts.

• InventionINDEX: Swanson Reed uses the same AI technology that identified the “Patent of the Month” to scan a client’s portfolio. This ensures that every eligible project—even those that didn’t result in a patent but still involved technical risk—is captured.
• TaxTrex AI Platform: To substantiate the “Process of Experimentation,” Swanson Reed deploys TaxTrex, an AI-driven documentation platform. TaxTrex interviews engineers during the project lifecycle, extracting the necessary technical details (uncertainties, alternatives tested, results) in real-time. This prevents the loss of critical data and creates an audit-proof trail.
• Audit Defense: With a specialized “6-Eye Review” process involving technical, tax, and legal experts, Swanson Reed ensures that the claim is defensible. For a complex mechanical engineering project like the “Aggregate Transferring System,” they would help compile the specific evidence—FEA reports, CAD revision logs, and test data—that links the financial expenditure to the qualified research activity.

Detailed Anatomy of the Invention: A Systems Engineering Perspective

To understand why Patent 12,528,655 is a leap forward, we must dissect the specific subsystems described in the claims. The invention is not merely a component; it is a system of interacting mechanical elements.

The Base Frame Topology

The “base frame” is the foundational innovation. Unlike the ladder-frame or truss-frame designs of the past, the patent likely describes a monocoque or hybrid-space-frame architecture.

• Torsional Stiffness: The primary enemy of conveyor belts is frame twist. If the ground is uneven, a standard frame twists, and the belt tracks off-center, cutting the edge of the belt. The Masaba “base frame” utilizes a closed-section geometry (likely box tubing or engineered plate girders) that offers exceptional torsional stiffness. This means the frame acts as a rigid plane, maintaining the relationship between the head pulley and tail pulley regardless of ground topology.
• Integral Pontooning: To support the “unloader structure” without sinking into soft soil, the base frame likely incorporates integral skids or pontoons with a large surface area, reducing ground pressure (PSI) and eliminating the need for separate rig mats.

The Unloader Structure: A Dynamic Interface

The “unloader structure” serves as the interface between the static earth and the dynamic vehicle.

• Force Dissipation: When a truck brakes on the ramp, immense horizontal shear forces are generated. The patent describes a structure optimized to transfer these shear loads into the ground rather than into the conveyor mechanism. This prevents the conveyor from “shuddering” or misaligning during truck braking events.
• Flow-Optimized Hopper: The abstract mentions the structure receiving aggregate. The internal geometry of this receiving section is critical. The patent likely details a specific “valley angle” design that exceeds the friction angle of common cohesive soils, ensuring that even sticky clay or wet fly ash slides onto the belt without hanging up.

The Base Conveyor Integration

The “base conveyor” is the active transport element.

• Low-Profile Drive System: To fit under a belly dump truck, the vertical clearance is minimal. The patent likely involves a novel drive configuration, possibly a shaft-mounted gear reducer or a motorized pulley (drum motor) that is integrated within the conveyor profile, maximizing ground clearance while delivering the high torque required to start a fully loaded belt.
• Sealing System: A common failure point is rock jamming between the belt and the skirtboard. The Masaba patent likely incorporates a novel “floating skirt” or sealing system attached to the unloader structure that maintains a tight seal against the belt without causing excessive friction or wear, effectively containing the material and reducing cleanup.

Strategic Economic Analysis for Operators

Return on Investment (ROI) Modeling

Investing in the technology defined by Patent 12,528,655 is a strategic capital expenditure.

• Capital Cost vs. Operational Savings: While a Masaba unloader may carry a premium over a basic competitor unit due to its robust “base assembly” construction, the ROI is realized through operational uptime. If a competitor unit requires 30 minutes of maintenance per day (belt tracking, cleaning spillage), that equates to ~2.5 hours per week or ~130 hours per year.
• Production Value: If the system produces 500 tons per hour, those 130 lost hours represent 65,000 tons of lost production. At a margin of $5.00 per ton, that is $325,000 in lost revenue annually. The Masaba unit, by eliminating this downtime through its rigid design and self-cleaning features, pays for itself in less than a year.

Scalability and Fleet Standardization

The modular nature of the patent design allows for standardization. A large construction firm can deploy 48-inch models for sand and 72-inch models for rip-rap, all sharing the same “base frame” components and hydraulic parts. This commonality reduces parts inventory costs and simplifies mechanic training.

Final Thoughts

U.S. Patent No. 12,528,655 represents a pivotal moment in the evolution of aggregate material handling. By fundamentally reimagining the structural relationship between the unloader, the conveyor, and the ground, inventors Jason Brenden and Tyler Dewitt have created a system that transcends the limitations of traditional portable equipment. The selection of this patent as the South Dakota Patent of the Month by Swanson Reed’s AI-driven InventionINDEX is a validation of its technical merit and its potential to disrupt the industry.

Compared to competitors like the Superior Industries RazerTail, the Masaba invention offers a superior value proposition defined by structural rigidity, operational reliability, and ease of maintenance. It transforms the “last mile” of aggregate logistics from a bottleneck into a streamlined, efficient process. Furthermore, the development of this technology stands as a prime example of the type of innovation that the R&D Tax Credit is designed to foster. Through the rigorous application of engineering principles to solve complex mechanical challenges, Masaba, Inc. has not only advanced the state of the art but also demonstrated the economic vitality of the American industrial sector. With the support of expert advisory firms like Swanson Reed, the pathway from technical concept to patented reality—and financial reward—is clearly charted for the next generation of industrial innovators.