Patent ID: 7766537
Filing Date: 2010-08-03
Classification: B01F,B28C,G05D,Y10S

Abstract:
1. An apparatus for manufacturing a lightweight concrete composition, comprising: at least one solution holding tank for holding a solution of foam concentrate and water; a flow meter for monitoring the rate of flow of the foam concentrate into the at least one solution holding tank; a water meter for measuring the rate of flow of water into the at least one solution holding tank; a programmable logic controller communicating with the flow meter and the water meter for determining and controlling the amount of foam concentrate and the amount of water entering into the at least one solution holding tank for achieving a desired ratio of mixture of the foam concentrate and water in the solution; at least one pump for pumping the solution from the at least one solution holding tank; an air compressor for generating a pressurized supply of air and including an air holding tank for containing a charge of the pressurized air supply; a foam control regulator for controlling air pressure and air flow rate of the pressurized supply of air released from the air holding tank, and said foam control regulator being further structured and disposed for controlling the flow rate of the pumped solution from said at least one pump, and thereby controlling the volume of air to be mixed with a controlled amount of the solution according to a desired ratio; a foam cylinder ejector for receiving the controlled air pressure and air flow and the controlled flow rate of the solution from said foam controlled regulator, and said foam cylinder ejector being structured and disposed for mixing the pressurized supply of air flow and the flow of solution, under pressure, to produce an air/solution mixture according to the desired ratio; a foam carburetor for receiving the pressurized flow of air/solution mixture, and said foam carburetor including a cylindrical housing at least partially filled with a plurality of beads and said foam carburetor being structured and disposed for generating a foam product by the mechanical impaction of the pressurized flow of air/solution mixture with the beads, and said foam carburetor being further structured and disposed for dispensing the generated foam product from the housing; a pneumatic valve between said foam cylinder ejector and said foam carburetor for controlling the pressurized flow of the air/solution mixture to said foam carburetor, and said pneumatic valve communicating with said programmable logic controller, said programmable logic controller controlling operation of said pneumatic valve for delivering a predetermined amount of the pressurized flow of the air/solution mixture to said foam carburetor according to a predetermined amount of foam product to be generated; a hopper for holding a charge of cement; a hydraulic auger operated by a motor for transferring the charge of cement from said hopper; a dual drum mixer having an open top for receiving the transferred charge of cement from the hydraulic auger, and said dual drum mixer being further structured and disposed for receiving the predetermined amount of foam product produced generated by said foam carburetor, and said dual drum mixer being structured and disposed for mixing the foam product and the cement to produce the lightweight concrete composition; and said programmable logic controller being further adapted for determining the weight of the cement being transferred and for controlling operation of said hydraulic auger to thereby control an amount of the cement transferred into said dual drum mixer for mixing with the foam product.