FIELD OF THE INVENTION
[0001] The present invention concerns an apparatus for the production of cement agglomerates
and in particular, for the production of cement agglomerates which have been made
lighter for example by additive particles such as particles of polystyrene, reinforcement
fibers, aramid fibers, carbon fibers, expanded clays, perlite, cork, vermiculite and
hemp.
[0002] The present invention also concerns the corresponding method for the production of
said cement agglomerate.
BACKGROUND OF THE INVENTION
[0003] Apparatuses for the production of cement agglomerates are known, such as concrete
mixers or spiral mixers, in which raw materials are introduced in order to form said
material.
[0004] In known apparatuses the raw materials are suitably mixed together to define a homogeneous
compound and with a desired consistency to allow it to be used in the designated zone.
[0005] These apparatuses comprise a loading hopper through which the raw material is introduced,
which is homogenized by a first mixer located on the bottom thereof. Then, the material
can be introduced into a second mixer, disposed downstream of the first, which provides
to mix it with additives, such as water and foam for example, to obtain a homogeneous
paste with the necessary technical requirements in relation to the application.
[0006] In particular, the foam is introduced to regulate the consistency and density of
the cement agglomerate so as to determine desired properties of heat and acoustic
insulation of the cement agglomerate when installed.
[0007] Known apparatuses also comprise a pumping device, for example a screw pump, located
downstream of the mixer, which provides to pump the paste obtained through pipes toward
the destination site.
[0008] It is also known, for specific applications, to add to the agglomerate solid additives
or solid particles to confer on the concrete determinate properties of resistance,
heat insulation, and acoustic insulation.
[0009] It can be provided for example to add polystyrene particles, expanded clay, perlite,
cork, vermiculite, hemp or other materials.
[0010] Said particles are introduced manually into the loading hopper together with the
other raw materials.
[0011] This makes it particularly difficult to control the quantity of particles inserted
into the hopper on each occasion, since such control is mainly determined by the experience
of the operator.
[0012] Furthermore, with a manual or discontinuous loading of the particles, cement blocks
are obtained that have compositions that vary from the start to the end of the cycle.
[0013] Moreover, a manual loading of the particles does not allow a continuous production
cycle of the mixer because, before the liquid and foam are added, the solid particles
added must be well homogenized with the other raw materials.
[0014] Furthermore, this solution requires great efforts from the operators to load the
particles into the hopper, with a consequent increase in production times.
[0015] One purpose of the present invention is to obtain an apparatus for the production
of a cement agglomerate that allows to precisely dose the addition of the particles
for the production of a cement agglomerate with the desired properties.
[0016] Another purpose of the present invention is to obtain an apparatus for the production
of a cement agglomerate that simplifies the production of a cement agglomerate and
makes it quicker.
[0017] Another purpose of the present invention is to obtain an apparatus for the production
of a cement agglomerate that does not require interruptions to the production cycle.
[0018] The Applicant has devised, tested and embodied the present invention to overcome
the shortcomings of the state of the art and to obtain these and other purposes and
advantages.
SUMMARY OF THE INVENTION
[0019] The present invention is set forth and characterized in the independent claims, while
the dependent claims describe other characteristics of the invention or variants to
the main inventive idea.
[0020] In accordance with the above purposes, an apparatus for the production of a cement
agglomerate comprises a mixing machine configured to mix raw materials making up at
least part of the cement agglomerate with at least a liquid substance such as water.
[0021] In accordance with one aspect of the present invention, the apparatus comprises a
machine for dosing additive particles in which the latter are located, and equipped
with at least a pipe that connects the dosing machine to the mixing machine and with
a pneumatic feed mean configured to feed the additive particles pneumatically into
the mixing machine through the pipe.
[0022] In this way, thanks to the pneumatic feed mean driven by compressed air, it is possible
to suitably dose the quantity of particles that must be added on each occasion to
the other raw materials to obtain a cement agglomerate of preestablished density.
[0023] The pneumatic feed mean allows to deliver the particles substantially continuously,
thus immediately obtaining in the mixing machine a cement agglomerate with properties,
that is, a density of homogeneous particles.
[0024] Moreover, the direct connection between the particle dosing machine and the mixing
machine allows to simplify the production operations of the cement agglomerate, without
requiring continuous intervention by the operators.
[0025] In possible forms of embodiment, the apparatus can comprise a management and control
device connected to the mixing machine and to the dosing machine at least to manage
and control the dosing of the additive particles in the mixing machine.
[0026] The management and control device allows to regulate the delivery of compressed air
on the basis of the properties that the cement agglomerate is intended to have, simplifying
and accelerating production. The management and control device also allows to deliver
the compressed air continuously, consequently rendering the feed of the additive particles
to the mixing machine continuous.
[0027] The present invention also concerns a method for the production of a cement agglomerate
which comprises mixing the raw materials that make up at least part of the cement
agglomerate with at least a liquid substance such as water.
[0028] In accordance with one aspect of the present invention, the method comprises a substantially
continuous pneumatic feed step, to feed additive particles to the raw materials and
to the at least one liquid substance during the mixing.
[0029] As well as the substantially continuous introduction of the additive particles, the
compressed air, used as a vector fluid, increases the foaminess of the aggregate thanks
to the formation of air bubbles inside it, which reduce its density and thus improve
the heat and acoustic insulation and also reduce the weight of the cast of agglomerate
once installed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] These and other characteristics of the present invention will become apparent from
the following description of some forms of embodiment, given as a non-restrictive
example with reference to the attached drawings wherein:
- fig. 1 is a schematic representation of an apparatus for the production of a cement
agglomerate according to the present invention;
- fig. 2 is a schematic view of the detail P in fig. 1.
[0031] To facilitate comprehension, the same reference numbers have been used, where possible,
to identify identical common elements in the drawings. It is understood that elements
and characteristics of one form of embodiment can conveniently be incorporated into
other forms of embodiment without further clarifications.
DETAILED DESCRIPTION OF SOME FORMS OF EMBODIMENT
[0032] We shall now refer in detail to the various forms of embodiment of the present invention,
of which one or more examples are shown in the attached drawing. Each example is supplied
by way of illustration of the invention and shall not be understood as a limitation
thereof. For example, the characteristics shown or described insomuch as they are
part of one form of embodiment can be adopted on, or in association with, other forms
of embodiment to produce another form of embodiment. It is understood that the present
invention shall include all such modifications and variants.
[0033] Figs. 1-2 are used to describe forms of embodiment of an apparatus 10 for the production
of a cement agglomerate that comprises a mixing machine 90, configured to mix raw
materials that make up at least part of the cement agglomerate with at least a liquid
substance such as water, and a machine for dosing additive particles 70, configured
to dose additive particles to be added to the raw materials and the at least a liquid
substance, during their mixing.
[0034] The additive particles can be chosen from a group comprising for example polystyrene
particles, reinforced fibers, aramid fibers, carbon fibers, expanded clay, perlite,
cork, vermiculite and hemp.
[0035] The dosing machine 70 and the mixing machine 90 can be reciprocally connected by
means of a pipe 60 with the function of transferring the additive particles from the
dosing machine 70 to the mixing machine 90.
[0036] The mixing machine 90 comprises a bearing structure 11 on which first containing
means are mounted, in this case a first hopper 12 to contain the raw materials making
up the cement agglomerate.
[0037] The mixing machine 90 comprises a mixing chamber 33 in which the raw materials are
mixed at least with a liquid substance.
[0038] Said pipe 60 can be connected directly to the mixing chamber 33 for the introduction
of the additive particles.
[0039] The mixing machine 90 can also comprise a first mixer 13 configured to remove the
raw materials from the first hopper 12 and to mix them in the mixing chamber 33. The
first mixer 13 can be disposed in the first hopper 12 and in the mixing chamber 33
as described hereafter.
[0040] The mixing machine 90 can also comprise a second mixer 15 disposed downstream of
the first, and a pumping device 16 that can be predisposed to pump the cement agglomerate
toward the site destination thereof.
[0041] The whole bearing structure 11 can be provided to support at least said components
inside it making a compact structure that can be easily transported even by road thanks
to the fact that it can be mounted on wheels provided for its movement.
[0042] The first hopper 12, see for example fig. 1, comprises a loading chamber 17 defined
by lateral walls 18 and by a bottom wall 19 and in which at least some of the raw
materials making up the cement agglomerate can be loaded.
[0043] Merely by way of example, the raw materials can be chosen from a group comprising
cement, recycled plastic, gravel, sand, clay. In particular, in the case where recycled
plastic is used, the latter can have an average size of about 10 mm and an apparent
or bulk density comprised between 200kg/m
3 and 300kg/m
3.
[0044] The first mixer 13 can extend beyond the bulk of the first hopper 12 and can be disposed
in particular in proximity to the bottom wall 19 of the loading compartment 17.
[0045] The first mixer 13 comprises a plurality of mixing sections and in this case a first
section 21, a second section 23 and an intermediate section 22, interposed between
the first hopper 12 and the mixing chamber 33. The first section 21 can be disposed
in the first hopper 12 and can extend substantially for the length of the bottom wall
19. The first section 21 can provide to mix the raw materials introduced through the
first hopper 12, thus obtaining a homogeneous composition thereof.
[0046] The intermediate section 22 can be configured to prevent a reflux both of the liquid
substance and also of the air introduced by the dosing machine 70 with the additive
particles to the first hopper 12.
[0047] The intermediate section 22 can be suitable to transfer the raw materials from the
first hopper 12 toward the second section 23, dosing the quantity thereof that is
taken from the first hopper 12.
[0048] In the second section 23 the raw materials introduced into the first hopper 12 can
be mixed with water, foam and possibly other additives.
[0049] The first mixer 13 can be provided with a rotation shaft 25 which can extend for
the entire length of the first and second sections 21 and 23 and the intermediate
section 22.
[0050] According to the present description, the rotation shaft 25 can comprise a first
segment 25a that can extend for the length of the first section 21 and intermediate
section 22, and a second segment 25b that can extend for the length of the second
section 23.
[0051] The first segment 25a and the second segment 25b can be reciprocally connected by
connection means, for example threaded or flanged connections or joints, or similar
or comparable connection means suitable for the purpose.
[0052] In the form of embodiment shown in fig. 1, the rotation shaft 25 can be made to rotate
by a single drive member 30 which can be keyed in proximity to the end of the first
segment 25a of the rotation shaft 25.
[0053] In other forms of embodiment it can be provided that the first segment 25a and respectively
the second segment 25b of the rotation shaft 25 are made to rotate independently of
each other, for example by respective drive members.
[0054] The rotation shaft 25 can be provided with a plurality of bladings having a different
configuration in the first section 21, second section 23 and intermediate section
22, which can be mounted or connected to the rotation shaft 25 by connection means
or by welding.
[0055] In particular, in correspondence with the first section 21, intermediate section
22 and second section 23, first bladings 26, second bladings 27 and third bladings
28 can be respectively provided.
[0056] The first bladings 26 can be blade shaped, they can extend radially with respect
to the rotation shaft 25 and can be disposed so that the width of their section is
disposed transverse to the axial direction of the rotation shaft 25.
[0057] In particular, the first bladings 26 can be inclined with respect to the axis of
rotation of the rotation shaft 25 by an angle of inclination α of about 30° with respect
to the direction of feed of the raw materials.
[0058] Merely by way of example, non-restrictive of the present invention, the first bladings
26 can have a rectangular section and a length in a radial direction comprised between
40 mm and 60 mm.
[0059] The first bladings 26 can perform both the function of feeding the raw materials
loaded in the first hopper 12, given precisely by the particular inclination of the
first bladings 26, and also a function of breaking up possible agglomerates that may
be present.
[0060] On one of the lateral walls 18 of the first hopper 12, and in correspondence with
the bottom wall 19 an aperture 31 can be made.
[0061] In correspondence with the aperture 31 an intermediate chamber 32 can be connected,
in which the intermediate section 22 of the first mixer 13 can be housed.
[0062] The second bladings 27 of the intermediate section 22 can be screw shaped and can
have the function of feeding the raw materials toward the second section 23 of the
first mixer 13.
[0063] The particular conformation of the second bladings 27 can allow to separate the first
section 21 from the second section 23 and prevent any reflux of material from the
latter to the first section 21.
[0064] By way of example, the second bladings 27 can have a diameter of about 90 mm and
a screw pitch that varies from 70 mm to 90 mm, to define an angle of deflection of
the bladings 27, or screw angle, comprised between 60° and 80°.
[0065] The helix of the second bladings 27 can be defined by a shaped blade that can be
attached to the first part 25a of the rotation shaft 25 and which can extend continuously
for the whole radial development thereof.
[0066] The second section 23 of the first mixer 13 can be housed inside the mixing chamber
33, which can be associated substantially in continuity with the intermediate chamber
32, and can have a bigger section size than the latter.
[0067] According to one form of embodiment not shown in figs. 1-2, the third bladings 28
of the second section 23 of the first mixer 13 can also be conformed as a blade, and
can be solidly associated with the respective rotation shaft 25, for example by welding,
disposing them with their longitudinal development substantially radial with respect
to the shaft 25 and with their width disposed transverse with respect to the axial
direction of the shaft 25.
[0068] According to another form of embodiment, shown in fig. 1, the third bladings 28 can
have a helical type conformation and are the type independent from the rotation shaft
25. In particular, the third bladings 28 comprise a shaped blade that affects part
of the diameter of the mixing chamber 33. The shaped blade can have a helical profile
and can be attached to the second part 25b of the rotation shaft 25 by connection
elements.
[0069] In the mixing chamber 33 and in proximity to the center line of its longitudinal
extension, at least one through hole can be made, for feeding water and/or foam.
[0070] In this case, with reference to fig. 1, two through holes can be made, to which a
first pipe 35 and a second pipe 36 can be respectively connected.
[0071] Furthermore, at least another through hole can be made in the mixing chamber 33 for
connection of the pipe 60.
[0072] The pipe 60 can be disposed in a position nearer the intermediate chamber 32 than
the position of the first 35 and second pipe 36, to allow to insert the additive particles
into the mixing chamber 33 before the water and/or foam.
[0073] In particular, the first pipe 35 can be provided to bring water inside the second
section 23, and to regulate the consistency of the mixture of cement to be obtained.
[0074] To this purpose, a pumping device, not shown in figs. 1-2, can be associated with
the first pipe 35, to feed the water to the mixing chamber 33.
[0075] The second pipe 36 can be provided to deliver foam to the mix that is made. The foam
can confer the desired density on the cement agglomerate.
[0076] A foam generation device, not shown in figs. 1-2, can be associated with the second
pipe 36, and provides to feed the foam to the mixing chamber 33.
[0077] In the second section 23 of the first mixer 13, first water and then foam can be
added to the raw materials in the desired quantities.
[0078] The pipe 60 can be, for example a flexible pipe, a rigid pipe, a connection union.
[0079] The mixing chamber 33 can be provided with a discharge aperture 43, in this case
facing downward, through which the cement agglomerate can be discharged already pre-mixed
with the additive particles, to feed it to the second mixer 15.
[0080] In particular, the cement agglomerate can be discharged from the first mixer 13 into
second containing means, in this case a second hopper 45 comprising lateral walls
46 and a bottom wall 47.
[0081] The second mixer 15 can be disposed in proximity to and for the whole extension of
the bottom wall 47 of the second hopper 45, to keep the cement agglomerate, already
mixed, stirred and prevent the formation of aggregates that could block the pipes
located downstream.
[0082] The lateral walls 46 can be convergent to each other so that the cement agglomerate,
when discharged from the first mixer 13, converges toward the bottom wall 47 and hence
toward the second mixer 15.
[0083] The second mixer 15 comprises a shaft 48 to which helix blades 49 can be solidly
associated. The helix blades 49 can be defined by a shaped blade continuous from its
attachment portion to the shaft 48 to its tip.
[0084] Longitudinal blades 50 can be associated to the helix blades 49, and can extend parallel
to the axis of the shaft 48 and can be disposed between one helix and the following
one. The blades 50 can have the function of increasing the stirring effect to which
the cement agglomerate is subjected.
[0085] The shaft 48 can be made to rotate by a drive member, not shown in figs. 1-2, possibly
by reduction devices.
[0086] One of the lateral walls 46 can be provided with an aperture that provides to convey
the cement agglomerate toward the pumping device 16.
[0087] The pumping device 16 in this case comprises a screw pump that in this case can be
made to rotate by the same shaft 48 that makes the second mixer 15 rotate.
[0088] More specifically, the screw pump can be associated with the shaft 48 of the second
mixer 15 by means of a joint element 58.
[0089] At exit from the screw pump an attachment portion 55 can be provided, to which can
be connected the pipes through which the cement agglomerate is pumped to convey it
toward the installation zone.
[0090] One or more devices - not shown in the drawings - to measure the level of the material
contained therein can be associated with the second hopper 45.
[0091] When a maximum level of material is reached in the second hopper 45, the measuring
device commands the first mixer 13 to stop, to prevent leakage of material.
[0092] The dosing machine 70 comprises a containing body 72 configured to contain the additive
particles inside it.
[0093] The containing body 72 can be defined by lateral walls 73 converging toward each
other and can be delimited below by a bottom 74.
[0094] The containing body 72 can comprise a loading member 77, for example a hopper, configured
to convey the additive particles into the containing body 72.
[0095] The dosing machine 70 can also comprise a pneumatic feed mean 78 configured to feed
the additive particles pneumatically into the mixing machine 90 through the pipe 60.
[0096] The pneumatic feed mean 78 can be incorporated inside the containing body 72 and,
in particular, in correspondence with the bottom 74 to contain the bulk.
[0097] The pneumatic feed mean 78 comprises a device 63 to generate compressed air, such
as a blower or compressor, and a device 83 with a Venturi effect connected to the
compressed air generation device 63 and the containing body 72 of the additive particles.
[0098] The pneumatic feed mean 78, see for example fig. 2, can be configured to move the
additive particles contained in the containing body 72, using a stream of compressed
air generated by the compressed air generation device 63.
[0099] The Venturi effect device 83 comprises a first tubular segment 79 connected to the
containing body 72, a second tubular segment 80 to which the compressed air generation
device 63 is connected, and a tubular segment delivery 81, connected to the pipe 60,
in which both the first tubular segment 79 and the second tubular segment 80 converge.
[0100] The compressed air passes from the second tubular segment 80 to the delivery tubular
segment 81, generating a depression in the first tubular segment 79.
[0101] The depression is caused by an increase in the speed of the air due to the geometry
of the delivery tubular segment 81 that accelerates the air according to a Venturi
effect.
[0102] The depression in the first delivery tubular segment 79 determines the suction of
the additive particles present in the containing body 72 and allows them to be subsequently
sent to the mixing machine 90.
[0103] The first tubular segment 79, the second tubular segment 80 and the delivery tubular
segment 81 can be made in a single body, or separately and assembled later.
[0104] In particular, the first tubular segment 79 and the delivery tubular segment 81 (see
for example fig. 2) can be coaxial with each other and disposed sequentially one after
the other in the order of transit of the compressed air.
[0105] The first tubular segment 79 can be disposed with its longitudinal extension parallel
to the bottom 74 of the containing body 72.
[0106] In particular, the first tubular segment 79 can be separated from the containing
body 72 by means of a valve 84, shown schematized in fig. 2, which can be installed
to choke the suction of additive particles.
[0107] The first tubular segment 79 can be disposed so that one end is free and located
in the containing body 72.
[0108] The delivery tubular segment 81 can have a decreasing cross section, such as for
example a truncated cone external shape, or truncated pyramid, suitable to determine
an acceleration of the compressed air in transit.
[0109] Between the delivery tubular segment 81 and the first tubular segment 79 the second
tubular segment 80 can converge.
[0110] The second tubular segment 80 can have a cylindrical shape and can be connected to
the compressed air generation device 63.
[0111] The compressed air generation device 63 can be driven by a motor 85.
[0112] The Venturi effect device 83 can be provided with a conveyor element 82, such as
for example an appendix mounted between the first tubular segment 79 and the second
tubular segment 80, and configured to direct the compressed air arriving from the
second tubular segment 80 toward the delivery tubular segment 81, preventing it from
flowing back toward the first tubular segment 79.
[0113] The conveyor element 82 can be disposed transverse with respect to the longitudinal
development of the second tubular segment 80.
[0114] In particular, the conveyor element 82 can define a passage gap L between the first
tubular segment 79 and the second tubular segment 80 to allow the passage of the compressed
air arriving from the second tubular segment 80 toward the delivery tubular segment
81.
[0115] The conveyor element 82 can also be configured to divert the path of the stream of
air arriving from the second tubular segment 80 toward the delivery tubular segment
81.
[0116] In some forms of embodiment, the apparatus 10 according to the present invention
comprises a management and control device 69 connected to the mixing machine 90 and
to the dosing machine 70, at least to manage and control the transfer of the additive
particles from the dosing machine to the mixing machine 90.
[0117] In some forms of embodiment, the dosing machine 70 can comprise a frame 71 on which
the containing body 72, the compressed air generation device 63 and the pneumatic
feed mean 78 are mounted.
[0118] The frame 71 can also be easily transported on the road, thanks also to the fact
that it can be mounted on wheels provided to move it.
[0119] In some forms of embodiment, the dosing machine 70 can comprise a support rod 61
attached to the frame 71 to keep sacks of additive particles, schematized in fig.
2, in suspension. The support rod 61 is configured to suspend each sack above the
loading member 77.
[0120] We shall now describe the functioning of the dosing machine 70, combined with that
of the mixing machine 90 for the production of a cement agglomerate.
[0121] The additive particles are loaded into the containing body 72.
[0122] Subsequently, the compressed air generation device 63 is driven to compress the air
to a suitable pressure, for example 4 bar, and to introduce it by means of the second
tubular segment 80 into the delivery tubular segment 81 of the Venturi effect device
83.
[0123] The compressed air is introduced into the delivery tubular segment 81 by means of
diverting it by the conveyor element 82. The compressed air, transiting in the delivery
tubular segment 81, is accelerated due to the Venturi effect.
[0124] The acceleration of the stream of compressed air generates a depression in the first
tubular segment 79 which attracts the additive particles located in the containing
body 72.
[0125] The action of attraction forms a mixture of compressed air and additive particles
that are sent, through the pipe 60, to the mixing chamber 33 of the mixing machine
90. The flow rate of compressed air can be modified by acting on the management and
control device 69. The flow rate of compressed air influences the characteristics
of the resulting cement agglomerate, modifying its density and consequently the properties
of heat and acoustic insulation, and the weight of the cast.
[0126] At the same time, the raw materials are loaded into the first hopper 12 of the mixing
machine 90. The first bladings 26 provide to break up any possible agglomerates that
can be present and to feed the raw materials toward the mixing chamber 33 in which
the water and foam are added in the desired quantities to determine the density and
consistency of the cement agglomerate to be obtained.
[0127] Furthermore, the pipe 60 transporting the mixture comprising compressed air and additive
particles and generated in the dosing machine 70 converges into the mixing chamber
33.
[0128] The addition of this mixture inside the mixing chamber 33 leads to an additional
mixing deriving from the blowing in of compressed air.
[0129] Subsequently, the cement agglomerate obtained is discharged through the discharge
aperture 43 into the second hopper 45.
[0130] The second mixer 15 provides to homogenize further the cement agglomerate generated
in the first mixer 13, preventing problems of aggregation of the concrete which could
compromise both the functioning of the screw pump and also obstruct the pipes that
are associated with the attachment portion 55.
[0131] By activating the second mixer 15, the pumping device 16 is also activated, and hence
the screw pump to pump the cement agglomerate toward the destination where it will
be installed.
[0132] It is clear that modifications and/or additions of parts may be made to the apparatus
10 for the production of a cement agglomerate and corresponding method as described
heretofore, without departing from the field and scope of the present invention.
[0133] In some forms of embodiment, the dosing machine 70 and the mixing machine 90 can
be integrated in a single support structure, with the advantage of great compactness
and versatility of use of the apparatus 10.
[0134] In these forms of embodiment, the pipe 60 can be a connector between the dosing machine
70 and the mixing machine 90.
[0135] It is also clear that, although the present invention has been described with reference
to some specific examples, a person of skill in the art shall certainly be able to
achieve many other equivalent forms of the apparatus 10 for the production of a cement
agglomerate, having the characteristics as set forth in the claims and hence all coming
within the field of protection defined thereby.