Material delivery apparatus for controlled delivery of foam into a mixer for producing foam concrete

A material delivery apparatus for delivering foam into a mixer of a ready-mix truck comprising an elongated bar, a support arm, a guide tube and a delivery tube is disclosed. There is a foam tube having one end mounted to the delivery tube and another end mounted to a foam generator. The delivery tube slides within the guide tube. There is a cable mounted to the delivery tube and to a motor reel on an opposite end. Included is a control panel communicatively coupled to the motor reel and the foam generator. The mixer of a ready-mix truck is aligned underneath the delivery tube. The controller is operated to control volume and rate at which foam is to be delivered by the foam generator. The delivery tube is positioned to accurately delivery the foam in the mixer to mix the foam with concrete to produce foam concrete.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a device used for introducing foam into a mixer for producing foam concrete. More specifically, the present invention relates to a material delivery apparatus for controlled delivery of foam into a mixer for producing foam concrete.

2. Description of the Related Art

Foam concrete is a type of lightweight concrete that is manufactured or produced by mixing a lightweight mortar result from water, Portland cement, fine sand, including or alone fly ash, and preformed stable foam. The foam is typically produced with the help of a foam generator by using a foaming agent. It is known that the foam concrete is provided in the form of a foamed grout or a foamed mortar. The foam concrete in the form of bricks, blocks or poured in-situ is used for thermal insulation over flat roofs or for cold storage walls or as non-load bearing walls in RCC/Steel framed buildings or for load bearing walls for low-rise buildings. Further, the foam concrete is used for bulk filling, using relatively low strength material, for redundant sewerage pipes, wells, disused cellars and basements, storage tanks, tunnels, subways etc. Further, the foam concrete is used for grouting for tunnel work, backfill to retaining walls and bridge abutment, infill to the spandrel walls of arch bridges, and so on.

Generally, the foam concrete is manufactured using an inline method and a pre-foam method. In the inline method, the base mix of cement and sand is added to a unit. In the unit, the mix is blended with foam thoroughly. The process of mixing is carried out with proper control to help in mixing of larger quantities. In pre-foam method, a ready-mix truck brings the base material to the site. Through the other end of the truck, the pre-formed foam is injected into the truck, while the mixer is rotating. This results in production of the foam concrete in small quantities for small works, like for grouting or trench fill works.

There are different mechanisms disclosed in the past that were used to deliver foam into a mixer of the ready-mix truck for production of the foam concrete. One such example is disclosed in United States patent application 20050195681. In US20050195681A1, it is disclosed that an apparatus for on-site manufacturing of lightweight concrete used for insulation in roof decks and roof systems of building structures. The apparatus is supported on a transportable trailer frame and includes a mixer, one or more tanks for holding water and chemical products, such as foaming agents, and a concrete pump. The chemical agents and water are forced through a foam-generating carburetor with pressurized air to produce a foam product. Concrete and the foam product are combined in the mixer, in accordance with a predetermined mixture ratio, and released into the concrete pump for forced discharge from the apparatus and application to a roof structure. An internal combustion engine drives hydraulic pumps, which operate several components of the apparatus. Controls are provided for operating the several components, functions and operations of the apparatus.

Although the apparatus discussed above are capable of manufacturing lightweight concrete, they have a few problems. For instance, a foam delivery pipe used to deliver the foam into the mixer is not seen by an operator, which might result in foam being delivered only at one side of the mixer. This may lead to uneven mixing of the foam with the concrete in the mixer. Which leads to a less than optimal mixture that will not perform at its best.

Other documents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention. Specifically, none of the disclosures in the art disclose a material delivery apparatus capable of accurately delivering foam into a mixer of a ready-mix truck by controlling operation of a delivery pipe used for delivering the foam.

Therefore, there is a need in the art for a material delivery apparatus capable of controlling a delivery pipe used for delivering foam into a mixer of a ready-mix truck.

SUMMARY OF THE INVENTION

It is one of the objects of the present invention to provide a material delivery apparatus for delivering foam into a mixer and avoids the drawbacks of the prior art.

It is another object of the present invention to provide a material delivery apparatus facilitating controlled delivery of foam into a mixer for preparation of foam concrete.

It is still another object of the present invention to provide a material delivery apparatus comprising a delivery tube for delivering foam into a mixer. The material delivery apparatus comprises an image acquisition device placed near the delivery tube for monitoring position of the delivery tube, which can be used to adjust the position of the delivery tube with the help of a cable coupled to the delivery tube.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

The following detailed description is intended to provide example implementations to one of ordinary skill in the art, and is not intended to limit the invention to the explicit disclosure, as one or ordinary skill in the art will understand that variations can be substituted that are within the scope of the invention as described.

The present disclosure discloses a material delivery apparatus for delivering foam into a mixer of a ready-mix truck. The material delivery apparatus comprises an elongated bar, a support arm mounted to the elongated bar, and a delivery tube provided at the support arm. The material delivery apparatus comprises a foam tube wherein one end is mounted to the delivery tube and the other end is mounted to a foam generator. The material delivery apparatus comprises a cable. One end of the cable is mounted to the delivery tube and other end is mounted to a motor reel. The material delivery apparatus comprises a control panel communicatively coupled to the motor reel and the foam generator. The mixer of a ready-mix truck is aligned underneath the delivery tube. The mixer contains concrete. The controller is operated to control volume and a rate at which the foam is to be delivered by the foam generator. The control panel is operated to a control position of the delivery tube to accurately delivery the foam in the mixer to mix the foam with the concrete to produce foam concrete. Thereby resulting in an evenly mixed mixture.

Various features and embodiments of a material delivery apparatus for delivering foam into a mixer of a ready-mix truck are explained in conjunction with the description ofFIGS. 1-6.

Referring toFIG. 1, a perspective view of a material delivery apparatus10is shown, in accordance with one embodiment of the present disclosure. Material delivery apparatus10comprises a support structure20. Support structure20comprises an elongated bar22mounted to a base24. Elongated bar22might be made up of metal or any other suitable material. Base24might be made up of concrete structure or might be affixed to the ground using known mechanism. Further, support structure20comprises a support arm25mounted to elongated bar22using known mechanisms such as fasteners or welding. As can be seen, support arm25is mounted perpendicularly to elongated bar22at a top portion of elongated bar22.

Material delivery apparatus10further comprises a material delivery assembly30mounted to support arm25. Referring toFIGS. 2 and 3, material delivery assembly30is seen and explained hereafter. Material delivery assembly30comprises a frame32mounted to support arm25using known mechanisms such as fasteners or welding. Material delivery assembly30further comprises a bracket34mounted to frame32. Bracket34might be provided in a semi-circular or circular part made up of metal or any other suitable material. Bracket34is used for receiving a guide tube41. Guide tube41might be made of metal and might be provided as a hollow tube. Guide tube41might be configured to receive delivery tube40therein. Delivery tube40slides through guide tube41. Further, material delivery assembly30comprises a first pulley36and a second pulley38placed at either side of delivery tube40. First pulley36and second pulley38might be placed perpendicularly and might be used for receiving a cable45for controlling delivery tube40.

Delivery tube40might be made up of metal and might be provided as a hollow tube. As can be seen, delivery tube40is provided in guide tube41, in that delivery tube40is slidable through guide tube41. Delivery tube40comprises a first end42and a second end44. At first end42, delivery tube40is provided with a cable connector46. It should be understood that one end of cable45is mounted to cable connector46provided at delivery tube40and the other end might be mounted to a motor reel50. Motor reel50might be used to wind or release cable45so as to adjust the length of cable45, which in turn adjusts the position of delivery tube40via first pulley36and second pulley38. In one example, at least one third pulley52might be provided at support structure20and/or at support arm25. At least one third pulley52might be used to lower support arm25with respect to support structure20.

Further, material delivery apparatus10may comprise a foam tube60. Foam tube60may indicate a flexible hose made up of plastic or any other suitable material. Foam tube60is mounted to a connecting tube62and a foam generator65. In other words, one end of foam tube60is mounted to connecting tube62provided at second end44of delivery tube40and the other end is mounted to foam generator65. Further, connecting tube62is mounted to delivery tube40, as shown inFIG. 1.

Now referring toFIGS. 1 and 4, foam generator65is mounted to a foam concentrate supply67and an air compressor70. In addition, foam generator65is mounted to a power source72. Further, foam generator65is mounted to a water pump75. Water pump75may receive water from a water tank76that may receive water from a water source77. Furthermore, foam generator65is operatively mounted to a control panel80. Control panel80may include, but not limited to a computer/desktop, a laptop, a mobile phone, a server and so on. Control panel80may comprise a processor and memory, in which the processor is configured to execute program instructions stored in the memory. Additionally, control panel80may comprise one or more controllers82and a timer84. One or more controllers82may include switches/buttons or toggles to operate each of delivery tube40via cable45, the motor, foam generator65, air compressor70, and water pump75. It should be understood that control panel80might be placed close to material delivery apparatus10or might be placed remotely to material delivery apparatus10. Control panel80might use a wired or wireless communication means including but not limited to LAN, internet, Wi-Fi, cellular networks and so on to operate each of delivery tube40via cable45, the motor, foam generator65, air compressor70, and water pump75.

In order to generate foam and to supply through delivery tube40, a user of material delivery apparatus10may operate control panel80. At first, foam concentrate supply67might be filled with foam concentrate. In one example, 55 gallons of foam concentrate might be stored in foam concentrate supply67. In order to generate foam, the user may operate foam generator65by supplying water from water pump75, which comes from water tank76which is filled with water from water source77. It should be understood that the water might be pumped using a pump. Concurrently or consecutively, Control panel80might be operated to supply air pressure from air compressor70and water from water pump75. In one example, controllers82may be operated to supply air pressure at 24 CFM at the rate of 80 PSI. In one example, the water might be pumped at 20 gpm at the rate of 40 PSI. Subsequently, controllers82might be operated to generate foam in foam generator65.

In one embodiment, control panel80might be provided with timer84. Timer84might be used to operate controllers82for a predetermined time and also to operate foam generator65for generating the foam. After generating the foam, the user may operate control panel80to pump the foam generated to delivery tube40via foam tube60.

In one embodiment, material delivery apparatus10might be provided with an image acquisition device90mounted on top of delivery tube40as shown inFIGS. 1, 2 and 3. Image acquisition device90might be mounted to delivery tube40via a plate92. Plate92might be removably mounted to delivery tube40using known mechanisms such as fasteners. Image acquisition device90may indicate a camera or video capturing device capable of capturing still images or a video. Image acquisition device90is communicatively coupled to control panel80using a wired or wireless communication means. It should be understood that image acquisition device90is configured to capture still images or video of a field of view to control panel80for processing data at control panel80. In the current implementation, image acquisition device90is positioned in such a way that image acquisition device90is made to face first end42of the delivery tube40, as shown inFIG. 6. The images or video captured by image acquisition device90can be displayed on a display device of control panel80.

Now, referring toFIGS. 5 and 6, operation of material delivery apparatus10is explained. As explained above, elongated bar22is erected over base24at a height more than a ready-mix truck95. Specifically, elongated bar22is erected in such a way that delivery tube40is coupled to support arm25and is made to face down towards an opening of a mixer hopper97of ready-mix truck95, as shown inFIG. 5. Further, referring toFIG. 6, a top perspective view of delivery tube40placed towards the opening of mixer hopper97is shown.

As known, concrete is placed in mixer hopper97of ready-mix truck95. In order to produce foam concrete, foam generated at foam generator65is pumped into mixer hopper97. Specifically, the foam is pumped from foam generator65with foam tube60. It should be understood that a user or operator might operate control panel80to determine the amount of foam to be pumped from foam generator65. Further, the user might operate control panel80to determine a rate at which the foam needs to be pumped. When the foam is pumped from foam generator65, the foam is made to flow through foam tube60into delivery tube40via connecting tube62. Further, the foam is dispensed or delivered into mixer hopper97from first end42of delivery tube40.

Concurrently, the user may operate or configure control panel80in order to control position of delivery tube40with the help of cable45coupled to delivery tube40. In order to control the position of delivery tube40, the user may consider the image or video being provided by image acquisition device90. It should be understood that the image or video is displayed at the display device of image acquisition device90. Based on the position obtained using image acquisition device90, the user may control motor reel50to push/pull cable45such that delivery tube40is pushed or pulled with the help of cable connector46in order to move delivery tube40linearly. It should be noted that delivery tube40is pulled upwards by pulling cable45. In order to move delivery tube40downwards, cable45might be loosened so that delivery tube40comes down and cable45might be held to secure the position of delivery tube40. Delivery tube40is actuated by motor reel50to move delivery tube40either up, down or sideways with the use of first pulley36, second pulley38, third pulley52and cable45. Motor reel50moving forward lowers delivery tube40, while reversing of motor reel50raises delivery tube40. Further, cable45is operated to adjust first end42of delivery tube40slightly upwards or downwards or move sideways. The position of delivery tube40is adjusted to ensure delivery of the foam at desired position in mixer hopper97.

It should be understood that delivery tube40is pulled with the help of cable45such that delivery tube40is made to slide upwards when mixer hopper97of ready-mix truck95needs to be aligned underneath delivery tube40. Upon aligning mixer hopper97in line of axis of delivery tube40, cable95is operated to lower delivery tube40such that delivery tube40is made to enter the opening of mixer hopper97. Subsequently, foam generator65might be operated to deliver the foam into mixer hopper97with the help of foam tube60, connecting tube62and delivery tube40. As explained above, the user may view the position of delivery tube40with the help of image acquisition device90and the user may control motor reel50to push/pull cable45such that delivery tube40is pushed or pulled with the help of cable connector46in order to adjust first end42of delivery tube40slightly upwards or downwards or sideways. The position of delivery tube40is adjusted to ensure delivery of the foam at desired position in mixer hopper97. After delivering the foam in mixer hopper97, delivery tube40might be pulled away from mixer hopper97.

It should be understood that elongated bar22might be provided in such a way that the height of elongated bar22can be adjusted manually or electronically. Further, the length of support arm25may also be extended or contracted manually or electronically such that material delivery apparatus10can be used in various configurations. As such, the foam can be delivered into mixer hopper97of ready-mix truck95in various configurations.

In one example, cable45might be used to lower support arm25to align delivery tube40in a desired position to deliver foam into mixer hopper97.

It should be understood that the pulley system that controls the delivery tube could also be mounted on a support apparatus that exists at a concrete plant. Further, it should be understood that one cable is used to control movement of the delivery arm and other cable might be used to lower the arm.

Based on the above, it is evident that the material delivery apparatus provides controlled delivery of the foam into a mixer for preparation of the foam concrete. The present disclosure provides a unique way of controlling the rate and volume of the foam delivery and also the controlling the delivery tube with the help of the images or video captured by the image acquisition device placed near the delivery tube. This way, the user may delivery the foam into the mixer without much difficulty. In other words, the user can operate the controller to deliver the foam into the mixer without having to have complex mechanism to manually adjust position of the delivery tube or to climb up the mixer to adjust the position of the delivery tube. Importantly, with the present invention, an operator of the present invention may be able to inject foam in a precise and repeatable manner from a remote location into the mixer of a truck. The operator may be able to visually monitor the process and can control the present invention to make adjustments and modifications as needed while injecting the foam.

It should be understood that the figures are provided for illustrative purpose only and the shapes and sizes illustrated in the figures should not be construed in limited sense. A person skilled in the art will appreciate that shape and sizes of the parts shown in the figures can be altered and/or other mechanism similar to the constructional features described above may also be used to implement the features described above. Such implementations should fall within the scope of the present disclosure.

The parts described herein can be permanently coupled using known mechanism at a construction site or may be removably coupled using known mechanisms such as fasteners or other mechanisms so as to allow the user to assemble or disassemble based on the need.