Progressive bubble generating system used in making cementitious foam

Abstract

A process for producing insulating foam, wherein certain especially small inorganic minerals such as silica fume are directly integrated into bubble fluid to better mechanically strengthen bubbles formed and thus allow the formation of smaller bubbles to be reformed. The manner of reforming the bubbles is progressive and actualized by a glass bead chamber, a second stage consisting of two screened discs, separated from each other and located at the end of the glass bead chamber, and a third stage chamber presenting itself with a considerably enlarged screen area and having considerably finer meshes than the second stage.

Claims

1. A system for manufacturing and distributing a cementitious foam, comprising: a. a source of bubble fluid; b. a source of compressed air; c. a source of cement; and d. a foam generation and distribution gun, comprising: i. an upstream end and a downstream end; ii. a first elongated chamber of a first diameter and in which a plurality of bubble forming media are contained and that extends between a first end portion positioned adjacent to said upstream end, and an opposite second end portion; iii. first and second conduits for carrying said bubble fluid from said source of bubble fluid and said compressed air, respectively, to said first end portion, wherein a mixture of bubble fluid and compressed air is generated and forcibly passed through said first elongated chamber at a first pressure, whereby upon exiting said first chamber a foam fluid is formed from said compressed air and bubble fluid; iv. a second chamber extending from said first elongated chamber and in which a first foam fluid reforming structure is contained, whereby said foam fluid is reformed as it exits said second chamber; v. a third chamber extending outwardly from said second elongated chamber and in which a second foam fluid reforming structure is contained and through which said foam fluid passes, wherein said foam fluid is at a second pressure lower than said first pressure upon entering said third chamber and at a third pressure equal to said second pressure upon exiting said third chamber; vi. a foam distribution conduit positioned downstream from said third chamber; and vii. a third conduit for carrying said cement to said foam distribution conduit, wherein said cement is combined with said foam fluid prior to passing through said foam distribution conduit, wherein said cement and foam fluid combination are mixed together at a fourth pressure lower than said second and third pressures.

2. The system according to claim 1, wherein said bubble forming media comprises beads.

3. The system according to claim 2, wherein said beads are composed of glass.

4. The system according to claim 2 wherein each of said beads are of uniform size.

5. The system according to claim 1, further comprising first and second mesh screens positioned in spaced parallel relation to one another and within said first end portion.

6. The system according to claim 5, wherein said first mesh screen is of a first predetermined size and said second mesh screen is positioned downstream from said first mesh screen and is of a second predetermined size.

7. The system according to claim 6, wherein said first mesh screen is 30 mesh in size and said second mesh screen is positioned downstream from a third mesh screen and is 20 mesh in size.

8. The system according to claim 7, wherein said third mesh screen is of a third predetermined size and a fourth mesh screen is positioned downstream from said third mesh screen and is of a fourth predetermined size.

9. The system according to claim 8, wherein said third mesh screen is 20 mesh in size and said fourth mesh screen is positioned downstream from said third mesh screen and is 30 mesh in size.

10. The system according to claim 1, wherein said first foam fluid reforming structure comprises first and second mesh screens positioned in spaced parallel relation to one another.

11. The system according to claim 1, wherein said second foam reforming structure comprises a screened cartridge.

12. The system according to claim 11, wherein said screened cartridge is between 100 and 400 meshes per linear inch.

13. The system according to claim 1, wherein said first pressure is between 40 and 60 psi and said second and third pressures are between 20 and 40 psi.

14. A foam generation and distribution gun for use with a source of compressed air and a source of cement, comprising: a. an upstream end and a downstream end; b. a first elongated chamber of a first diameter and in which a plurality of bubble forming media are contained and that extends between a first end portion positioned adjacent to said upstream end, and an opposite second end portion; c. first and second conduits for carrying said bubble forming media and the compressed air, respectively, to said first end portion, wherein a mixture of bubble fluid and compressed air is generated and forcibly passed through said first elongated chamber at a first pressure, whereby upon exiting said first chamber a foam fluid is formed from said compressed air and bubble fluid; d. a second chamber extending from said first elongated chamber and in which a first foam fluid reforming structure is contained, whereby said foam fluid is reformed as it exits said second chamber; e. a third chamber extending outwardly from said second elongated chamber and in which a second foam fluid reforming structure is contained and through which said foam fluid passes, wherein said foam fluid is at a second pressure lower than said first pressure upon entering said third chamber and at a third pressure equal to said second pressure upon exiting said third chamber; f. a foam distribution conduit positioned downstream from said third chamber; and g. a third conduit for carrying the cement to said foam distribution conduit, wherein the cement is combined with said foam fluid prior to passing through said foam distribution conduit, wherein the cement and foam fluid combination are mixed together at a fourth pressure lower than said second and third pressures.

15. The foam generation and distribution gun according to claim 14, wherein said bubble forming media comprises beads.

16. The foam generation and distribution gun according to claim 15, wherein said beads are composed of glass.

17. The foam generation and distribution gun according to claim 15 wherein each of said beads are of uniform size.

18. The foam generation and distribution gun according to claim 14, further comprising first and second mesh screens positioned in spaced parallel relation to one another and within said first end portion.

19. The foam generation and distribution gun according to claim 18, wherein said first mesh screen is of a first predetermined size and said second mesh screen is positioned downstream from said first mesh screen and is of a second predetermined size.

20. The foam generation and distribution gun according to claim 19, wherein said first mesh screen is 30 mesh in size and said second mesh screen is positioned downstream from a third mesh screen and is 20 mesh in size.

21. The foam generation and distribution gun according to claim 20, wherein said third mesh screen is of a third predetermined size, and a fourth mesh screen is positioned downstream from said third mesh screen and is of a fourth predetermined size.

22. The foam generation and distribution gun according to claim 21, wherein said third mesh screen is 20 mesh in size and said fourth mesh screen is positioned downstream from said third mesh screen and is 30 mesh in size.

23. The foam generation and distribution gun according to claim 14, wherein said first foam fluid reforming structure comprises first and second mesh screens positioned in spaced parallel relation to one another.

24. The foam generation and distribution gun according to claim 14, wherein said second foam reforming structure comprises a screened cartridge.

25. The foam generation and distribution gun according to claim 24, wherein said screened cartridge is between 100 and 400 meshes per linear inch.

26. The foam generation and distribution gun according to claim 14, wherein said first pressure is between 40 and 60 psi and said second and third pressures are between 20 and 40 psi.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

(1) The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:

(2) FIG. 1 is a schematic view of the mechanical devices assembled in a typical arrangement for the production of cementitious foam and also views the three components of the process and their directional paths throughout the process.

(3) FIG. 2 is a sectional view of end cap 6 displaying the mechanical parts and geometry contained within. Included is a partial sectional view contained within an external view, of parts attached to the end cap.

(4) FIG. 3 is a sectional view of the invented three stage bubble generating system contained in end cap 6, bead chamber 3, end cap 7, Y Bubble Reforming Generator 10, and Mixing Wye 11. This view also displays the three components and their conveyance into, through, and out of the system.

(5) FIGS. 4a, 4b, and 4c are top, side, and bottom views of identical diffusion spinners 51 and 71, respectively.

(6) FIG. 5 is a sectional view of Mixing Wye 11, including cement orifice 78, spinner 71, and deflection ring 82 as represented in hose barb 15.

DETAILED DESCRIPTION

(7) The present invention relates to cementitious foam which is useful for insulation. This insulation can be used in cavities, such as found between walls, within or between foundation materials, or in open spaces such as attics. This foam is useful for both new and existing constructions.

(8) The cementitious foam is produced through the combination of three components. The first component is an aqueous solution of calcium-chloride and or magnesium-chloride, expanding agent of a proprietary nature, with the addition of but not limited to, silica fume and other similarly sized minerals such as kaolin, metakaolin, zeolite, artificial zeolite, pumice, gypsum and calcium derivatives. The second component is compressed air. When forced through and embolized within the first aqueous solution the resultant necessary bubbles are produced by means of an invented progressive bubble generating system. The third component consisting of an aqueous solution of magnesium-oxide and talc or not, with the additions of but not limited to, minerals such as wollastonite, artificial wollastonite, silica fume, metakaolin, kaolin, zeolite, artificial zeolite, pumice, perlite, gypsum, gypsum cement, fly ash, Portland cement, hydraulic cement, calcium-hydroxide, calcium-carbonate, aluminum cement, potassium-silicate, sodium-silicate and a proprietary cement retarder. The third component referred to as the cement and dispensed from a cement line, is forcefully sprayed on and through the bubble pack by means of a spinner and orifice, coating and filling in between the individual bubbles.

(9) With reference to the drawings, and in particular, to FIG. 1, there is shown a foaming gun system 40 for the manufacturing and dispensing a three component foam. The first component is the bubble fluid, containing calcium-chloride, expanding agent, small inorganic mineral solids and water, represented by dispensing line 1 and pumped from a 55 gallon barrel 2, utilizing diaphragm pump 4. This bubble fluid is routed into a bead chamber 3. The chamber is contained by ends, 6 and 7. A second line 1B, on the discharge side of pump 4, has a wye strainer 8 with a large surface area and fine straining capacity. On the suction side of the pump is a smaller wye strainer 9, with coarser straining abilities for large particulates. This strainer may be left out of the suction side, because of wye strainer 8's efficiency.

(10) The second component is compressed air sourced from 22, and conveyed in line 20 to glass bead chamber end cap 6 for primary mixing with the first component. From this mixing within the end cap 6, these two components are forced under both air pressure and liquid pumped pressure through the first stage bubble forming glass bead chamber 3 into end cap 7, having passed through the second stage reforming screens depicted later in FIG. 3. This now formed bubble pack is carried under continued pressure of a lesser differential, into the Third Stage Bubble Reforming Generator 10, whereupon entering and exiting, has a slight change of pressure. The bubble pack has now been reformed for a third and final time. This bubble pack is then forced forward under continued pressure into the Mixing Wye 11.

(11) The third component is the cement, dispensed to the gun in line 30, under pressure from diaphragm pump 5, and drawn from a 55 gallon barrel 12. On the discharge side is a basket strainer 13, and on the suction side, a wye strainer 14, that if used will have a coarse mesh screen. There is also a recirculating prime line 30B, on the discharge side of pump 5. The third cement component is forcibly dispersed in a semi hollow cone spiral spray pattern into the bubble pack to coat the bubbles and fill in between them, as mechanically depicted in FIGS. 3 & 5.

(12) The three combined components are further transported under pressure, although of a further diminished degree, into the hose barb 15, and then into the final conveyance, the application hose 16, to exist at its end as cementitious foam.

(13) Bubble fluid regulator 31 and air regulator 32 on the gun, with a cement regulator 33 regulating by use of air over fluid on the pump, are the means to control the three components in there disposition to each other. Bubble fluid pressure gage 34, and air pressure gage 35 on the gun, with the cement pressure gage 36, at the pump reading air over fluid pressure, is the means of evaluating the three component proportions.

(14) FIGS. 2-5 describe the application gun's assembly of parts and their individual involvement in greater detail. As bubble fluid is pumped under pressure, typically 130 p.s.i. within a line, it enters a regulator and is normally metered between 75 to 100 p.s.i. Viewed in FIG. 2, upon exiting, this fluid is directed toward the expanding agent orifice body 50, through reducer bushing 49. Upon entering the orifice body, it finds itself meeting the seated diffusion spinner 51 on the bottom of a threaded cylindrical cavity 42. The seated diffusion spinner, its nose flush to the bottom of the cavity has effectively sealed itself off against this bottom. However, four compound slots have been machined 90 degrees apart and off center to the central axis of the part as depicted. This forces the bubble fluid under pressure to confine itself and be directed through these slots. The diffusion spinners may be formed in either clock wise or counterclockwise configurations, and in this case, clockwise, as viewed from the back of the gun looking forward. As the bubble fluid jets through these compound slots, the four separate streams meet in a small internal dispensing chamber and combine once again for a high velocity spiraled exist through the orifice 43, having a small diameter. Detailing of the diffusion spinner and the droplet pattern generated will be included in the description of identical diffusion spinner 71. The expanding agent orifice body 50, in its external configuration has been designed to integrate within end cap 6 in such a manner as to allow regulated compressed air, typically between 75 to 100 p.s.i., to enter through the side of the cap into a region of void or recess 44, on the body of the orifice. In front of this recess is a collar 45 with multiple slots 46-46 machined at an inclined angle to the central axis as shown. The collar's outer periphery is against the end of the threaded bore 47 within the end cap 6, for sealing off this end portion, but allowing air and backed up bubble fluid through the inner circle of open slot areas in a spiraled and violent manner through a smaller bore 48, and to combine with the continuously sprayed bubble fluid from the centralized orifice 43. This amalgam is forced forward into a confined chamber 41 within end cap 6. As viewed in FIG. 3, the chamber is confined by a previously inserted end screen 52, typically of 30 mesh, separated by a square O ring 53 and a second screen 54 of typically 20 mesh. This second screen 54 retains the glass beads 55 at this end of the glass bead chamber 3. Glass bead chamber 3, previously invented, is a useful first stage bubble forming unit of the present invention. Within the chamber are 2 mm glass beads 55, of consistent size, surface, and roundness. These beads are packed in a deliberate manner to have a uniform matrix. As pressurized bubble fluid enters the chamber through screen 54, and likewise, so does compressed air, now interspersed with this bubble fluid. Typical pressure as read by a test gage 91 one inch into the bead pack of the combined air and bubble fluid is between 60 and 80 p.s.i. depending upon the regulated entry pressures of the now combined two components. If we treat air as a fluid, its viscosity is much less than that of the bubble fluid. It has been observed by looking through the translucent bead chamber 3, that air forms move at a faster rate through the bead matrix than does the bubble fluid. This is of particular advantage in that this embolized air, ever expanding as pressure declines, moves forward, and moving through the slower bubble fluid, it stretches and forms bubbles upon exiting through a 20 mesh screen 56, by a mechanical process somewhat similar to blowing bubbles through a hoop. A test pressure gage 92, one inch from the end of the bead chamber typically registers approximately 20 p.s.i. less than test gage 91. The further significance of the bead pack is its ability to disperse the two components because of its length and width as confined within the bead chamber. The glass bead chamber 3, typically has a cylindrical interior of 1 inches in diameter by 6 inches in length, derived from many experiments studying pressure differentials along the bead pack, in combination with pressure gage readings of back pressure further downstream within the system. This proportioning can however be scaled up for a greater quantity of product.

(15) The glass beads 55 are retained in the glass bead chamber 3 by end screen 56, separated by a square O ring 57, and a 30 mesh second screen 58, as seated in end cap 7. This last screen 58, represents the second stage in the progressive bubble generating system. Because of the newly discovered processes for the proper dispersement, unaglomeration, and straining out of unwanted solids within the bubble fluid, this second stage bubble reformer may now consist of a finer screen of 40 to 80 meshes, not previously useable before. Bubbles formed from the bead chamber and through retaining screen 56, may now be reformed into smaller bubbles in an unobstructed manner through screen 58. The typical glass bead chamber pressure readings one inch from its terminus from test gage 92, is 40 to 60 p.s.i., and the range of gaged pressures from test gage 93, entering the invented third stage Y Bubble Reforming Generator 10, is usually between 20 and 40 p.s.i.

(16) Y Bubble Reforming Generator 10 consists of a straight run to an entry into a Y that is cored to the interior of a screened cartridge 61, and that is sealed on its ends by means of O rings 62, 63 to tapered recesses 64, 65, contained within the body of the Y and within the end cap 67. The reformed bubbles from screen 58 are at a consistent p.s.i. and are now closely packed together in what would recognizably be termed foam. As the foam is pushed into the internal area of the screened cartridge 61, there is found to be a generous surface area of between 8 to 100 times greater than the second stage screen 58. The screen is of fine meshes between 100 and 400 per linear inch. The screen material may be either stainless steel or polyester. As a result of strengthening the surface tension of bubble fluid from the inclusion of specifically shaped, and generally, smaller than five micron sized solids, such as silica fume, the foam pack is successfully reformed for a third and final time. The individual bubbles of the foam pack are reformed in a manner friendly to their survival and as they emerge are of a smaller median size. This is due to the small differential pressure acrossed the screen meshes, usually between 1 to 4 p.s.i. and in combination with mesh fineness. The reformed foam or bubble pack is pushed back in a reverse direction between the outer area of cartridge screen and the internal wall of the Y, toward and exiting through a portal 68, located in line with coupled Mixing Wye 11. The pressure as indicated from a test gage 94 in the exiting portion of the Y Bubble Reforming Generator is generally between 20 and 40 p.s.i.

(17) Upon entering the Mixing Wye 11, the bubble pack, under a constant similar pressure as recorded by a pressure test gage 95, and as previously read at the exiting portion of the Y Bubble Reforming Generator by test gage 94, is thoroughly mixed with an aqueous solution of cement that coats and fills between the bubbles in such an integrated manner as to cause the Mixing Wye pressure to decrease by several p.s.i. This is explained by understanding that pressure recorded in the Mixing Wye 11 is the remaining pressure being resisted as back pressure in the downstream application hose 16, FIG. 1, typically inch in diameter by 10 to 12 feet in length. This resistance is lessened because of the lubricity or wetter quality of the added cement, having as its vehicle, a considerable amount of water.

(18) There is a cement dispensing line 80, continuance of 30, FIG. 1, mounted to an application gun control valve and ending in a cement reducer bushing. As viewed in FIG. 5, the cement upon entering through the reducer bushing 69, is now within the interior of the cement orifice body 70, where it is confronted with diffusion spinner 71, seated in the bottom of this cylindrical cavity 72, and threaded to it. The diffusion spinner 71, as mentioned, is identical to 51. In FIGS. 4a-4c, four slots 77-77, have been formed 90 degrees apart in a radial fashion offset to the central axis and entering the interior wall of a small internal dispensing chamber 74. There is in unison with these slots an enlargement of them in their upper portions by parallel radii slots 73-73, on the outside perimeter, ending also as concluding radii, exiting into this dispensing chamber in line to the central axis of the orifice opening. A stainless plug 76 has been press fitted into the back of the chamber to withstand the boring back pressure of the contained aqueous cement. The diameter of the chamber has been enlarged slightly represented by wall 75. These modifications to the original spinner have allowed a spiraled hollow cone pattern to be broader in its cross section by forcing some aqueous cement to a more centralized location within chamber 74 via 73-73, and another portion, to a larger outer perimeter within chamber 74, represented by wall 75, and thus discharge more broadly through the orifice. Viewed in FIG. 5, the orifice 78 is laser cut from an artificial sapphire, typically having a 120 diameter opening. This diameter may be increased for up scaled configurations necessary for more volume of product. The cement orifice 78 contained in body 70, are internally presented by means of a threaded bore 81 in the Mixing Wye 11, at 45 degrees to a central bore, 79. The resulting spray pattern of cement dispensed from orifice 78, is a spiraled semi hollow cone pattern to the bubble pack flow. Regarding its spiraled nature, the cone form is clockwise in rotation, looking toward the hose barb 15. There is a deflection ring 82, which is defined by the end of the threaded section of hose barb 15, threaded into the Mixing Wye 11. The function of the deflection ring is to fold the acute angled spiral, typically from 15 to 25 degrees, into a compact and revolving helix that rolls over and through the bubble pack. The joined stream of mixed cement and bubble foam, is now recognizable as cementitious foam, and is routed through hose barb 15 into the application hose 16, FIG. 1, and dispensed out its end.

(19) Among the cementitious foams that may be produced are EXAMPLES, using the following compositions listed below. Both mineral components and water are listed as pound weight measurements. An aqueous solution of calcium-chloride, and or magnesium-chloride, expanding agent of a proprietary nature, and with small minerals; will be represented as the First Component. This First Component is typically mixed in a quantity with 350 pounds of water; sufficient to be combined with approximately 6 barrel mixes of the Third Component each typically containing 150 to 175 pounds of water. Compressed air will represent the Second Component. The compressed air of the Second Component is essentially and quantitatively the same in the EXAMPLES given, and therefore not listed. An aqueous solution of magnesium-oxide and talc or without talc, with the additions of other minerals, will represent the Third Component, and also includes a proprietary cement retarder typically between 1 to 5 pounds in each of the EXAMPLES, but not individually listed in these EXAMPLES. Water temperatures are between 45-70 degrees Fahrenheit for the EXAMPLES. Microns given represent median sizes in the EXAMPLES. The expanding agent used in the EXAMPLES is of a proprietary nature. The Second Stage Bubble Reformer in the EXAMPLES is of 30 meshes, and if otherwise, will be listed individually in those EXAMPLES.

Example 1

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(20) First Component

(21) TABLE-US-00001 350 lb. water 100 lb. calcium-chloride (83-87%) 2.5 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(22) TABLE-US-00002 150 lb. water 4 lb. wallastonite (8 micron) .5 lb. silica fume (.4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 2

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(23) First Component

(24) TABLE-US-00003 350 lb. water 100 lb. calcium-chloride (83-87%) 2.5 lb. silica fume (.4 micron) 6 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(25) TABLE-US-00004 150 lb. water 4 lb. wallastonite (8 micron) 4 lb. kaolin (.2 micron) .5 lb. silica fume (.4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 3

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(26) First Component

(27) TABLE-US-00005 350 lb. water 75 lb. calcium-chloride (83-87%) 4 lb. silica fume (.4 micron) 6 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(28) TABLE-US-00006 150 lb. water 4 lb. wallastonite (2.8 micron) 4 lb. wallastonite (8 micron) 5 lb. metakaolin (2.1 micron) 1 lb. silica fume (.4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 4

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(29) First Component

(30) TABLE-US-00007 350 lb. water 75 lb. calcium-chloride (83-87%) 6 lb. silica fume (.4 micron) 2 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(31) TABLE-US-00008 150 lb. water 4 lb. wollastonite (8 micron) 5 lb. zeolite (4.5 micron) 5 lb. metakaolin (2.1 micron) 1 lb. calcium-hydroxide (4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 5

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(32) First Component

(33) TABLE-US-00009 350 lb. water 75 lb. calcium-chloride (83-87%) 6 lb. silica fume (.4 micron) 2 lb. kaolin (.2 micron) 4 lb. gypsum cement (5 micron) 90 lb. expanding agent
Third Component

(34) TABLE-US-00010 160 lb. water 4 lb. wollastonite (8 micron) 5 lb. zeolite (4.5 micron) 5 lb. metakaolin (2.1 micron) 1 lb. silica fume (.4 micron) 2 lb. calcium-hydroxide (4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 6

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(35) First Component

(36) TABLE-US-00011 350 lb. water 75 lb. calcium-chloride (83-87%) 4 lb. silica fume (.4 micron) 6 lb. kaolin (.2 micron) 10 lb. metakaolin (2.1 micron) 90 lb. expanding agent
Third Component

(37) TABLE-US-00012 150 lb. water 4 lb. wallastonite (2.8 micron) 6 lb. kaolin (.2 micron 1 lb. silica fume (.4 micron) 55 lb. magnesium-oxide (5 micron) 1 lb. calcium-hydroxide (4 micron) 50 lb. talc (5 micron)

Example 7

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(38) First Component

(39) TABLE-US-00013 350 lb. water 100 lb. calcium-chloride (83-87%) 2.5 lb. silica fume (.4 micron) 2 lb. hydrogen-peroxide (3%) 90 lb. expanding agent
Third Component

(40) TABLE-US-00014 150 lb. water 4 lb. wallastonite (2.8 micron) 5 lb. perlite (less than 10% retained on 325 mesh screen) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 8

200 meshes per inch, Third Stage Y Bubble Reforming Generator

(41) First Component

(42) TABLE-US-00015 350 lb. water 100 lb. calcium-chloride (83-87%) 2.5 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(43) TABLE-US-00016 150 lb. water 4 lb. wallastonite (8 micron) 55 lb. magnesium-oxide (5 micron) 25 lb. zeolite (4.5 micron) 25 lb. talc (9 micron)

Example 9

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(44) First Component

(45) TABLE-US-00017 350 lb. water 100 lb. calcium-chloride (83-87%) 2.5 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(46) TABLE-US-00018 150 lb. water 4 lb. calcium-carbonate (.7 micron) 2.5 lb. silica fume (.4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 10

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(47) First Component

(48) TABLE-US-00019 350 lb. water 100 lb. calcium-chloride (83-87%) 6 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(49) TABLE-US-00020 155 lb. water 4 lb. wollastonite (8 micron) 1 lb. perlite (20 micron) 1 lb. silica fume (.4 micron) .5 lb. perlite (less than 10% retained on 325 mesh screen) .5 lb. gypsum cement (5 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 11

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(50) TABLE-US-00021 350 lb. water 100 lb. calcium-chloride (83-87%) 4 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(51) TABLE-US-00022 150 lb. water 15 lb. perlite (20 micron) 1 lb. silica fume (.4 micron) 1 lb. perlite (less than 10% retained on 325 mesh screen) 1 lb. gypsum cement (5 micron) 55 lb. magnesium-oxide (5 micron) 35 lb. talc (9 micron)

Example 12

40 Meshes Per Inch, Second Stage Bubble Reformer

150 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(52) First Component

(53) TABLE-US-00023 350 lb. water 100 lb. calcium-chloride (77-80%) 4 lb. silica fume (.4 micron) 1 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(54) TABLE-US-00024 170 lb. water 4 lb. wallastonite (8 micron) 5 lb. zeolite (4.5 micron) 4 lb. metakaolin (2.1 micron) 3 lb. pumice (3 micron) 1 lb. calcium-hydroxide (4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (9 micron)

Example 13

40 Meshes Per Inch, Second Stage Bubble Reformer

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(55) First Component

(56) TABLE-US-00025 350 lb. water 100 lb. calcium-chloride (77-80%) 5 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(57) TABLE-US-00026 175 lb. water 6 lb. wollastonite (8 micron) 5 lb. zeolite (4.5 micron) 4 lb. metakaolin (2.1 micron) 10 lb. pumice (3 micron) 5 lb. kaolin (.2 micron) 2 lb. calcium-hydroxide (4 micron) 20 lb. gypsum (2 micron) 55 lb. magnesium-oxide (5 micron) 10 lb. talc (9 micron)

Example 14

40 Meshes Per Inch, Second Stage Bubble Reformer

150 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(58) First Component

(59) TABLE-US-00027 350 lb. water 100 lb. calcium-chloride (77-80%) 5 lb. silica fume (.4 micron) .5 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(60) TABLE-US-00028 175 lb. water 6 lb. wallastonite (8 micron) 5 lb. zeolite (4.5 micron) 4 lb. metakaolin (2.1 micron) 20 lb. pumice (3 micron) 20 lb. gypsum (2 micron) 1 lb. calcium-hydroxide (4 micron) 55 lb. magnesium-oxide (5 micron) 10 lb. talc (9 micron)

Example 15

60 Meshes Per Inch, Second Stage Bubble Reformer

200 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(61) First Component

(62) TABLE-US-00029 350 lb. water 75 lb. calcium-chloride (83-87%) 3 lb. silica fume (.4 micron) .5 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(63) TABLE-US-00030 175 lb. water 6 lb. wallastonite (8 micron) 5 lb. zeolite (4.5 micron) 4 lb. metakaolin (2.1 micron) 15 lb. pumice (3 micron) .5 lb. calcium-hydroxide (4 micron) 20 lb. gypsum (2 micron) 5 lb. gypsum stabilizing agent (hydrated lime, aluminum sulfate, gypsum) 55 lb. magnesium-oxide (5 micron) 10 lb. talc (9 micron)

Example 16

60 Meshes Per Inch, Second Stage Bubble Reformer

150 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(64) First Component

(65) TABLE-US-00031 350 lb. water 100 lb. magnesium-chloride (47%) 3 lb. silica fume (.4 micron) .5 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(66) TABLE-US-00032 175 lb. water 6 lb. wallastonite (8 micron) 3 lb. kaolin (.2 micron) 10 lb. pumice (3 micron) 20 lb. zeolite (4.5 micron) 4 lb. calcium-hydroxide (4 micron) 20 lb. gypsum (7 micron) 5 lb. gypsum stabilizing agent (hydrated lime, aluminum sulfate, gypsum) 55 lb. magnesium-oxide (5 micron)

Example 17

60 Meshes Per Inch, Second Stage Bubble Reformer

150 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(67) First Component

(68) TABLE-US-00033 350 lb. water 50 lb. magnesium- chloride (47%) 50 lb. calcium-chloride (83-87%) 4 lb. silica fume (.4 micron) 1 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(69) TABLE-US-00034 175 lb. water 3 lb. wollastonite (2.8 micron) 3 lb. wollastonite (8 micron) 5 lb. gypsum (2 micron) 10 lb. gypsum (7 micron) 5 lb. gypsum (12 micron) 10 lb. zeolite (4.5 micron) 1 lb. calcium-hydroxide (4 micron) 4 lb. kaolin (.2 micron) 55 lb. magnesium-oxide (5 micron) 25 lb. talc (9 micron)

Example 18

60 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(70) First Component

(71) TABLE-US-00035 350 lb. water 125 lb. magnesium-chloride (47%) 4 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(72) TABLE-US-00036 150 lb. water 20 lb. pumice (3 micron) 15 lb. zeolite (4.5 micron) 10 lb. gypsum (7 micron) 1.5 lb. calcium-hydroxide (4 micron) 2 lb. kaolin (.2 micron) 55 lb. magnesium-oxide (5 micron)

Example 19

40 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(73) First Component

(74) TABLE-US-00037 350 lb. water 100 lb. calcium-chloride (83-87%) 4 lb. silica fume (.4 micron) 90 lb. expanding agent
Third Component

(75) TABLE-US-00038 150 lb. water 4 lb. wallastonite (8 micron) 5 lb. gypsum (7 micron) 4 lb. pumice (3 micron) 10 lb. zeolite (4.5 micron) 2 lb. metakaolin (2.1 micron) 1 lb. silica fume (.4 micron) 3 lb. kaolin (.2 micron) .5 lb. calcium-hydoxide (4 micron) 55 lb. magnesium-oxide (5 micron) 15 lb. talc (9 micron)

Example 20

40 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(76) First Component

(77) TABLE-US-00039 350 lb. water 100 lb. calcium-chloride (83-87%) 3 lb. silica fume (.4 micron) 85 lb. expanding agent
Third Component

(78) TABLE-US-00040 150 lb. water 5 lb. potassium-silicate (99%, 2.17 weight ratio) 10 lb. wollastonite (8 micron) 15 lb. gypsum (7 micron) 5 lb. gypsum stabilizing agent (hydrated lime, Aluminum sulfate, gypsum) 10 lb. zeolite (4.5 micron) 5 lb. metakaolin (2.1 micron) 55 lb. magnesium-oxide (5 micron)

Example 21

40 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(79) First Component

(80) TABLE-US-00041 350 lb. water 100 lb. calcium-chloride (83-87%) 3 lb. silica fume (.4 micron) .5 lb. kaolin (.2 micron) 85 lb. expanding agent
Third Component

(81) TABLE-US-00042 150 lb. water 3 lb. potassium-silicate (99%, 2.17 weight ratio) 3 lb. sodium-silicate (82.5%, 2.4 weight ratio) 10 lb. wollastonite (8 micron) 5 lb. gypsum (2 micron) 10 lb. gypsum (4.3 micron) 1 lb. calcium-hydroxide 10 lb. zeolite (4.5 micron) 5 lb. metakaolin (2.1 micron) 55 lb. magnesium-oxide (5 micron)

Example 22

60 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(82) First Component

(83) TABLE-US-00043 350 lb. water 100 lb. calcium-chloride (83-87%) 3 lb. silica fume (.4 micron) 2 lb. sodium acid pyrophosphate (10% solution) 90 lb. expanding agent
Third Component

(84) TABLE-US-00044 150 lb. water 6 lb. potassium-silicate (99%, 2.17 weight ratio) 10 lb. wollastonite (8 micron) 4 lb. wollastonite (2.8 micron) 10 lb. zeolite (4.5 micron) 5 lb. metakaolin (2.1 micron) 5 lb. gypsum (4.3 micron) 3 lb. pumice (3 micron) 3 lb. calcium-hydroxide (4 micron) 55 lb. magnesium-oxide (5 micron) 5 lb. talc (5 micron)

Example 23

60 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(85) First Component

(86) TABLE-US-00045 350 lb. water 100 lb. calcium-chloride (83-87%) 2 lb. gypsum cement (5 micron) 90 lb. expanding agent
Third Component

(87) TABLE-US-00046 150 lb. water 2 lb. wollastonite (8 micron) 2 lb. metakaolin (2.1 micron) 2 lb. calcium-hydroxide (4 micron) 1 lb. silica fume (.4 micron) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (5 micron)

Example 24

40 Meshes Per Inch, Second Stage Bubble Reformer

120 Meshes Per Inch, Third Stage Y Bubble Reforming Generator

(88) First Component

(89) TABLE-US-00047 350 lb. water 100 lb. calcium-chloride (77-80%) 3 lb. silica fume (.4 micron) 4 lb. kaolin (.2 micron) 90 lb. expanding agent
Third Component

(90) TABLE-US-00048 150 lb. water 4 lb. wallastonite (8 micron) 3 lb. zeolite (4.5 micron) 5 lb. gypsum (4.3 micron) 1 lb. silica fume (.4 micron) 6 lb. calcium aluminate cement (AL2 O3 78%) 55 lb. magnesium-oxide (5 micron) 50 lb. talc (5 micron)

(91) Although the present invention has been described in connection with a preferred embodiment, it should be understood that modifications, alterations, and additions can be made to the invention without departing from the scope of the invention as defined by the claims.