Description:FIELD OF THE INVENTION

[0001] The present invention relates to a multi-layered insulating concrete form slab manufacturing device that is capable of automatically manufacturing slabs, with reduced manual labor, increased productivity, and ensuring proper removal of air bubbles to enhance slab integrity and minimize risk of defects.

BACKGROUND OF THE INVENTION

[0002] The multi-layered Insulating Concrete Form (ICF) slab is essential for enhancing energy efficiency, structural integrity, and comfort in modern buildings. The ICF consists of layers of insulating foam that are filled with reinforced concrete, providing both insulation and strength. The multi-layered design offers superior thermal resistance, reducing heat transfer and improving energy efficiency. This is especially important in climates with extreme temperatures, as it helps maintain consistent indoor temperatures and lowers energy consumption. Additionally, ICF slabs provide excellent soundproofing and moisture resistance, contributing to a healthier living environment. The concrete core offers durability and protection against natural disasters like storms and earthquakes, making it a safe and resilient choice for buildings.

[0003] Traditional methods of manufacturing Insulating Concrete Forms (ICFs) often involve labor-intensive processes like manual assembly and the use of basic materials such as foam blocks or panels, which are then filled with concrete. The foam forms were typically made from expanded polystyrene (EPS) or styrofoam, which were cut or shaped manually, and the concrete was poured on-site, requiring significant time and effort. These methods can lead to inconsistent quality and increased potential for human error during construction. Moreover, traditional production techniques are resource-heavy, requiring substantial amounts of labor and materials, which increase costs. The lack of advanced technology can also lead to inefficiencies, such as gaps in insulation or weak structural bonding between layers.

[0004] US5332191A relates to adjustable forms for pouring precast concrete slabs and similar articles of manufacture. The forms may be used either on site to produce concrete slabs as needed, or at a central manufacturing location, for transport to the site where needed. Concrete slabs produced with the adjustable forms may be used in patios, sidewalks, storage room or pump house floors, driveways, mobile home landings, and the like. The slabs may be steel reinforced, with expandable interlocking design, of various sizes, patterns and colors. Similar construction materials or decorative articles, such as tile, wallboard, and the like may also be produced with the improved forms.

[0005] EP0021362A1 relates to a process for the continuous manufacture of cement articles containing a reinforcement of net-like polymeric structures, which comprises the steps of depositing a layer of water-cement mix on a horizontal porous conveyor belt, depositing an open-mesh, net-like polymeric structure on said layer, depositing a cement layer onto said structure, compacting the thus obtained assembly by vibrations in at least vertical sense, then compressing said assembly to reduce the water content to 25-35% by weight. A device is also disclosed for performing the process, comprising one or more operational units arranged in series, each one comprising, according to Fig. I, a feeder 1 for the net-like polymeric structure, a horizontal porous conveyor 7, a device 3 for guiding said structure on said conveyor, at least one feeding-dosing device 4 for the deposition of the cement mix on the conveyor or the net-like structure, a vibrator 8 which vibrates at least in the vertical sense, and a compressor 10.

[0006] Conventionally, many devices are available in the market that helps the user in manufacturing of slabs. However, these existing devices mentioned in the prior arts lack in removing air bubbles to enhance slab integrity. In addition, these existing devices also fail in generating foam for lightweight, insulating concrete, for energy-efficient and sustainable building materials.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to be capable of generating foam for lightweight, insulating concrete, thereby addressing the growing need for energy-efficient and sustainable building materials. In addition, the developed device also needs to be capable of monitoring concrete temperature and controlling mixing duration, thereby ensuring optimal slab quality.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that is capable of automatically manufacturing multi-layered insulating concrete form (ICF) slab, thereby reducing manual labor, increasing productivity, and ensuring consistency in the manufacturing process.

[0010] Another object of the present invention is to develop a device that is capable of removing air bubbles to enhance slab integrity, thus reducing risk of weak points or defects in the finished slab.

[0011] Another object of the present invention is to develop a device that is capable of generating foam for lightweight, insulating concrete, thereby addressing growing need for energy-efficient and sustainable building materials.

[0012] Yet another object of the present invention is to develop a device that is capable of monitoring concrete temperature and controlling mixing duration, thereby ensuring optimal slab quality, preventing premature hardening, and improves overall performance of the final product.

[0013] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0014] The present invention relates to a multi-layered insulating concrete form slab manufacturing device that is capable of generating foam for lightweight, insulating concrete, thereby meeting the demand for energy-efficient, sustainable building materials, while also monitoring concrete temperature and controlling mixing duration to ensure optimal slab quality, preventing premature hardening, and enhancing the final product's performance.

[0015] According to an embodiment of the present invention, a multi-layered insulating concrete form slab manufacturing device, comprises a housing installed with plurality of chambers stored with constructional aggregates and binders of varying types, a touch interactive display panel is provided on the housing to provide input commands regarding dimensions and type of concrete slab the user desires to construct, a motorized iris lid mounted on side walls of the chambers, each lid connected to a conduit for dispensing precise quantities of ingredients into at least two mixing containers provided inside the housing, a first mixing containers is configured to mix cement, sand, and water, and a second containers is configured to mix foam beads and glass beads, each container is equipped with motorized stirrers, a third container provided inside the housing for storing foaming agents to be mixed with water, a hydraulic pusher with a circular unit is provided inside the housing to compress the mixture for coarse texture as per user input, multiple set of dies installed within the housing, each set having a cavity corresponding to the slabs of different dimensions, a motorized slider configured inside the housing for translating and aligning a box attached with the slider via a pneumatic link underneath the containers, a motorized iris unit provided with each of the containers to dispense the mixed constructional aggregates, a robotic link provided inside the housing and integrated with a motorized roller as an end-effector to work in collaboration for smoothing the surfaces after each layer.

[0016] According to another embodiment of the present invention, the device further comprises of a plurality of heating units arranged around each of the set of dies to strengthen the concrete and remove air pockets, a vibrating unit is embedded in the dies to impart vibrational sensations over the mold, removing air bubbles to enhance slab integrity, a tactile sensor positioned on each of the dies for detecting hardness of the slab, a rotary feeder is integrated with the box and operably connected to the motorized iris units of the containers to facilitate controlled sequential dispensing of concrete mixtures layer by layer into the selected die, a speaker mounted on the housing for notifying the user to collect the manufactured slab from the hosing via an opening provided on the housing, water vessel is provided on the third container and integrated with an electronic valve to dispense an optimum amount of water over the foaming agents to generate foam for lightweight, a sliding unit coupled to a vertically mounted pneumatic rod with a conical end plate integrated via a motorized ball and socket joint dynamic ingredient transfer, a temperature sensor is integrated with the containers for monitoring concrete temperature and controlling mixing duration, a storage unit is installed inside the housing and stored with crushed ice that is added to the ingredient mix for moisture-controlled applications, an electronic nozzle attached with a cuboidal member stored with a mold-releasing solution and configured inside the housing for continuously dispensing the mold-releasing over the mold prior dispensing of mixtures and a battery is associated with the device for supplying power to electrical and electronically operated components associated with the device.

[0017] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a multi-layered insulating concrete form slab manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0020] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0021] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0022] The present invention relates to a multi-layered insulating concrete form slab manufacturing device that is capable of generating foam for lightweight, insulating concrete and removing air bubbles, thereby addressing the need for energy-efficient, sustainable building materials and enhancing slab integrity to reduce the risk of defects.

[0023] Referring to Figure 1, a multi-layered insulating concrete form slab manufacturing device is illustrated, comprises of a housing 101 installed with plurality of chambers 102, a touch interactive display panel 103 is provided on the housing 101, a motorized iris lid 104 mounted on side walls of the chambers 102, each lid connected to a conduit 105, a first container 106, second container 107 and third container 108 provided inside the housing 101, each container is equipped with motorized stirrers 109, a hydraulic pusher 110 with a circular unit 111 is provided inside the housing 101, multiple set of dies 112 installed within the housing 101, a motorized slider 113 configured inside the housing 101, a box 114 attached with the slider 113 via a pneumatic link 115.

[0024] Figure 1 further illustrates a robotic link 116 provided inside the housing 101 and integrated with a motorized roller 117, plurality of heating units 118 arranged around each of the set of dies 112, a speaker 119 mounted on the housing 101, an opening 120 provided on the housing 101, a water vessel 121 is provided on the third container 108 and integrated with an electronic valve 122, a sliding unit 123 coupled to a vertically mounted pneumatic rod 124 with a conical end plate 125 integrated via a motorized ball and socket joint 126, a storage unit 127 is installed inside the housing 101 and an electronic nozzle 128 attached with a cuboidal member 129 stored with a mold-releasing solution and configured inside the housing 101.

[0025] The device discloses herein includes a housing 101 installed with plurality of chambers 102 stored with constructional aggregates and binders of varying types. These chambers 102 are strategically arranged to ensure efficient access, mixing, and delivery of the materials used. The housing 101 structure is constructed from durable, high-quality materials to withstand the rigors of continuous operation, ensuring long-term performance and reliability. Each chamber is equipped with controlled compartments, allowing for the precise storage and management of different types of aggregates. The design of the chambers 102 includes arrangement for easy loading, unloading, and segregation of materials, minimizing cross-contamination and ensuring that each material is dispensed in the correct proportions.

[0026] The user via a touch interactive display panel 103 provided on the housing 101, provide input command regarding dimensions and type of concrete slab the user desires to construct. The database stores environmental and user-specific data including weather conditions, structural location, and slab texture preferences, used by the microcontroller to determine ingredient ratios and layering sequence.

[0027] The display panel 103 allows the user to select dimensions and type of concrete slab user desires to construct. The touch interactive display panel 103 as mentioned herein is typically an (Liquid Crystal Display) screen that presents output in a visible form.

[0028] The screen is equipped with touch-sensitive technology, allowing the user to interact directly with the display using their fingers. A touch controller IC (Integrated Circuit) is responsible for processing the analog signals generated when the user inputs details regarding dimensions and type of concrete slab user desires to construct. The touch controller is typically connected to an inbuilt microcontroller linked with the panel through various interfaces which may include but are not limited to SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit). The microcontroller processes user commands and actuates the required components for selecting dimensions and type of concrete slab the user desires to construct.

[0029] A motorized iris lid 104 mounted on side walls of the chambers 102, each lid connected to a conduit 105 for dispensing precise quantities of ingredients into at least two mixing containers provided inside the housing 101. The iris lid 104 operates by opening 120 and closing in a controlled manner, to regulate the flow of materials. The lid expands to allow a measured amount of the stored ingredient to pass through the conduit 105, ensuring accurate and consistent dispensing. The motorized lid is typically connected to a motor, when the motor activates, the segments of the lid move symmetrically outward, creating an adjustable opening 120 through which the construction aggregates or binders are dispensed. The size of this opening 120 can be finely tuned based on the desired quantity of material to be released, ensuring that only the required amount flows through the conduit 105.

[0030] Once the correct amount of material has been dispensed into the conduit 105, the motorized arrangement reverses the movement, causing the segments of the iris lid 104 to close, sealing the chamber and preventing any further material from escaping. The conduit 105 are designed to be robust and flexible, allowing for easy movement and connection between the chambers 102 and the containers while maintaining the integrity of the materials being transferred. The conduit 105 also feature precise flow control arrangement to ensure that only the intended amounts of each ingredient are dispensed into the containers.

[0031] The containers, constructed from durable, non-corrosive materials and are designed to handle large volumes of mixed materials, offering enough space to allow for thorough and uniform mixing. The first and second mixing containers, each equipped with motorized stirrers 109, are designed to efficiently blend their respective materials into a homogenous mixture. In the first container 106, the motorized stirrer is responsible for thoroughly mixing cement, sand, and water. The stirrer consists of rotating blades or paddles that move in a continuous motion, ensuring the ingredients are evenly distributed and combined. The motorized arrangement ensures that the stirrer operates at a consistent speed, which is adjusted based on the specific needs of the mixture. As the stirrer rotates, it generates a swirling motion that encourages the water to hydrate the cement particles and evenly distribute the sand, preventing clumping and ensuring the formation of a smooth, consistent concrete mixture.

[0032] Similarly, in the second container 107, the motorized stirrer is designed to mix foam beads and glass beads, which require careful agitation to ensure that the beads are evenly dispersed throughout the mixture. The stirrer's blades or paddles avoids crushing or breaking the delicate foam beads while effectively distributing the glass beads within the foam. The stirring action creates a gentle but thorough mixing process, allowing the foam to expand and form a lightweight, insulating mixture while maintaining the integrity of the individual beads.

[0033] The third container 108, provided inside the housing 101, stores foaming agents, which are to be mixed with water. The foaming agent is added to the water in precise quantities to produce the desired foam consistency. The stirrer in this container works similarly to the others, utilizing motorized agitation to ensure that the foaming agent is evenly dispersed throughout the water, creating a stable, consistent foam. This process is essential for producing lightweight insulating concrete that retains its desired properties and can be used effectively in construction.

[0034] To dispense an optimum amount of water over the foaming agents to generate foam for lightweight, insulating concrete, the microcontroller actuates an electronic valve 122 integrated with water vessel 121 provided on the third container 108. The water vessel 121 is made from durable materials that can withstand the pressure and conditions involved in the foam generation process. The valve 122 operation is driven by an electronic actuator, which is controlled by the microcontroller. The microcontroller receives inputs from various sensors that track parameters such as the current volume of water, foam consistency, or pressure, and uses this data to calculate the optimal amount of water to be dispensed.

[0035] When the microcontroller determines the required water flow, it sends an electrical signal to the electronic valve 122. This signal activates the valve 122 actuator, which is a solenoid, motor, or piezoelectric element, depending on the design of the valve 122. For instance, in a solenoid-based valve 122, an electromagnetic coil creates a magnetic field that pulls or pushes a plunger or diaphragm, opening 120 or closing the valve 122. In motorized valve 122, a small electric motor drives a shaft or screw arrangement to adjust the valve 122 opening 120, allowing water to flow through at the desired rate. The electronic valve 122 is designed to precisely control the flow of water, which is essential in ensuring the correct water-to-foaming agent ratio. By adjusting the opening 120 of the valve 122 in small increments, the valve 122 dispenses a controlled amount of water, which then interacts with the foaming agents to generate foam.

[0036] Additionally, a hydraulic pusher 110 with a circular unit 111 is provided inside the housing 101, adapted to compress the mixture for coarse texture as per user input. The hydraulic pusher 110 operates by utilizing pressurized fluid to generate force, which is transferred to the pusher 110 arrangement. The pusher 110 itself is mounted with a circular unit 111, typically a robust, cylindrical plate or disk, designed to apply even pressure across the mixture. Upon activation, the hydraulic arrangement drives the circular unit 111 towards the mixture, exerting a controlled compressive force.

[0037] The circular unit 111 moves across the surface of the mixture, applying uniform pressure to compact the materials. This compression process ensures that the mixture achieves the desired coarse texture, which is often important for creating insulating concrete forms with better structural integrity or a more uniform surface. The circular design of the pusher 110 allows for consistent pressure distribution, reducing the risk of uneven compaction or defects in the final product.

[0038] As the hydraulic pusher 110 works in conjunction with the circular unit 111, the compressive force helps to eliminate air pockets, ensuring a dense and cohesive mixture. The user-controlled pressure settings provide flexibility, allowing for different textures depending on the application requirements, whether for standard concrete or for lightweight, insulating forms. This efficient and precise compression process enhances the overall quality of the mixture, making it more suitable for various construction needs.

[0039] Within the housing 101, multiple sets of dies 112 are installed, each set having a cavity corresponding to the slabs of different dimensions. These dies 112 serve as molds that determine the final form of the slab being produced. When a user inputs the desired slab dimensions to be constructed, the microcontroller processes this input and selects the appropriate die set from the multiple options available.

[0040] When the user inputs the required dimensions, the microcontroller determines which die set is necessary and actuates a motorized slider 113 configured inside the housing 101 for translating and aligning a box 114 attached with the slider 113 via a pneumatic link 115 underneath the containers. The motorized slider 113 works by driving a motor, often a stepper motor or a servo motor, which moves the slider 113 with high precision. The motor is connected to a gear or a belt, that translates rotational motion into linear movement, causing the slider 113 to move horizontally. The slider 113 is connected to the box 114 that holds the selected die set. As the slider 113 moves, it brings the box 114, and thus the die, into the correct position. The movement is controlled with such accuracy that the die set aligns perfectly with the containers, ensuring the proper cavity is ready to receive the material for slab formation.

[0041] The pneumatic link 115 works by using compressed air to either assist or control the movement of the slider 113. It can be used to provide a cushioning effect to absorb shocks, which is particularly useful when the slider 113 reaches its desired position, reducing the risk of misalignment or mechanical damage. Additionally, the pneumatic arrangement also aids in fine-tuning the slider 113 position, allowing for micro-adjustments that are crucial for aligning the die perfectly under the containers.

[0042] Additionally, the pneumatic link 115 help in controlling the speed and force applied during the movement of the slider 113, ensuring a consistent and smooth operation. The motorized slider 113 moves the box 114 with the die set into place beneath the containers, while the pneumatic link 115 ensures smooth, controlled movement, allowing for precise adjustments and alignment. This ensures that the die set is correctly positioned according to the user's specifications for slab production.

[0043] A rotary feeder is integrated with the box 114 and operably connected to motorized iris units of the containers, which house the concrete mixture. The rotary feeder consists of a rotating drum or plate with evenly spaced compartments or pockets designed to hold a specific amount of concrete mix. As the feeder rotates, these compartments scoop and transport the concrete mixture from the container to the die in a controlled manner.

[0044] The feeder is actuated by the microcontroller, which precisely coordinates the timing and movement of the rotary arrangement based on the predefined layering pattern. When it's time to dispense a layer of the concrete mixture, the microcontroller sends a signal to the motor that drives the rotary feeder, causing it to rotate a specific amount. As the rotary feeder turns, the compartments holding the concrete mixture align with the opening 120 of the die, and the concrete is released layer by layer. The motorized iris units in the containers control the flow of concrete into the feeder, ensuring that the material is dispensed in the correct amount and at the right speed for each layer.

[0045] To dispense the mixed constructional aggregates, binding aggregates and foam mixture in a sequential manner, the microcontroller actuates a motorized iris unit provided with each of the containers. The motorized iris is controlled by the microcontroller, which receives input based on the slab design, including material ratios and layer thickness. The microcontroller then sends signals to the motorized iris to open to the required width for dispensing the material.

[0046] As the motorized iris unit opens to a specific size, it dispenses the appropriate amount of material for each layer, one after another. The microcontroller determines the timing and flow rate for each material, ensuring that the bottom, middle, and top layers are dispensed in the correct order. The microcontroller continuously adjusts the opening 120 size of the iris unit during dispensing to ensure that the correct quantity of material is being released, based on the predefined specifications for each layer. Once a layer is dispensed, the iris unit close slightly to stop the flow and prepare for the next material, keeping everything precise and controlled. After each layer is dispensed, the materials spread evenly or leveled out within the mold to ensure consistent thicknesses.

[0047] The microcontroller dispenses the mixtures in a defined layer. The bottom layer of traditional concrete, designed to provide the structural strength necessary for the slab’s foundation. This concrete mixture contains cement, sand, gravel, and water, which combine to form a durable, strong base capable of supporting weight and maintaining stability under stress. Once this bottom layer is in place, the microcontroller then controls the dispensing of the middle layer, which consists of insulating concrete made by mixing foam and glass beads with cement. This layer serves an essential function by providing thermal insulation, reducing heat transfer and enhancing the slab’s energy efficiency. Finally, the microcontroller activates the dispensing of the top layer of concrete, which is a durable surface layer designed to withstand wear, abrasion, and weathering. This layer is made from a more traditional concrete mix that offers protection to the underlying layers, ensuring the longevity and durability of the slab's exterior.

[0048] For smoothing the surfaces after each layer, the microcontroller regulates actuation of a robotic link 116 provided inside the housing 101 and integrated with a motorized roller 117 to work in collaboration. The robotic link 116 consists of a series of interconnected joints, actuators, and sensors that allow it to move with a high degree of flexibility and precision. The microcontroller controls the robotic link 116’s movements, determining the path and speed at which the motorized roller 117 is applied to the surface. The robotic link 116 enables the roller 117 to move across the surface of the freshly dispensed layer of material, ensuring that it covers the entire area uniformly.

[0049] The motorized roller 117 is powered by an electric motor and attached to the robotic arm at the end-effector. As the robotic link 116 moves, the roller 117 rotates over the surface of each layer, evenly distributing the material and eliminating any imperfections, air pockets, or unevenness. The motorized roller 117 provides a controlled, constant force that presses and flattens the material, achieving a smooth, even finish.

[0050] Upon filling of the mixture in the mold, the microcontroller activates plurality of heating units 118 arranged around each of the set of dies 112 to strengthen the concrete and remove air pockets. The heating units 118 work by applying controlled thermal energy to the mold and the concrete mixture within it, which serves two primary purposes: accelerating the curing process and eliminating air pockets. When concrete is poured into a mold, it contains moisture and trapped air. The heating units 118, strategically arranged around the dies 112, raise the temperature of the mold in a uniform manner. This elevated temperature speeds up the hydration reaction between cement and water, leading to faster setting and early strength gain. At the same time, the heat causes trapped air bubbles to expand and rise to the surface, escaping from the mixture. This results in a denser, more compact concrete structure with fewer internal voids, which enhances its mechanical strength and durability. The microcontroller regulates the temperature and duration of heating to ensure optimal curing conditions without overheating, preventing cracks or thermal damage.

[0051] To impart vibrational sensations over the mold, removing air bubbles to enhance slab integrity, the microcontroller actuates a vibrating unit embedded in the dies 112. The vibrating unit embedded in the dies 112 functions by generating mechanical oscillations that are transmitted throughout the mold and the freshly poured concrete mixture. The vibrating unit produces rapid and controlled vibrations, through the use of an eccentric rotating mass or an electromagnetic actuator. These vibrations cause the concrete particles to move and settle more efficiently, reducing internal friction and allowing trapped air bubbles to rise to the surface and escape. As the air voids are removed, the concrete becomes denser and more uniform, which significantly enhances the integrity and strength of the resulting slab. Additionally, vibration helps the concrete flow better into every corner and cavity of the mold, ensuring complete filling and preventing weak spots.

[0052] Additionally, for detecting hardness of the slab, a tactile sensor is positioned on each the dies 112. The tactile sensor works by measuring the force response when it comes into contact with the surface of the slab and contains pressure-sensitive elements that react to mechanical resistance from the slab when a known force is applied. As the sensor presses against the surface, it records the amount of deformation or displacement that occurs. Harder materials exhibit less deformation under pressure, while softer or uncured concrete shows more. The sensor translates this mechanical response into electrical signals, which are analyzed by the microcontroller to assess the slab’s hardness in real time.

[0053] When slab detected hardness matches a threshold value, the microcontroller activates a speaker 119 mounted on the housing 101 for notifying the user to collect the manufactured slab from the hosing via an opening 120 provided on the housing 101. The design of the opening 120 ensures that the removal process is both efficient and safe, providing sufficient space for the slab to be taken out without damaging its surface. The speaker 119 consists of: a driver (cone), voice coil, magnet, suspension, frame, and terminals. When an electrical signal is sent to the voice coil, it generates a magnetic field that interacts with the permanent magnet, causing the voice coil and the attached diaphragm (cone) to move. This movement creates sound waves by displacing air, which are emitted as auditory signals. The speaker 119 components work together to produce sound based on the frequency and amplitude of the electrical signal, enabling it to provide auditory feedback, such as alerts.

[0054] Furthermore, a sliding unit 123 coupled to a vertically mounted pneumatic rod 124 with a conical end plate 125 integrated via a motorized ball and socket joint 126, adapted for dynamic ingredient transfer. The sliding unit 123 consists of a motor-driven linear guide or track that allows controlled horizontal or vertical movement of the attached components. When activated, the motor causes the sliding unit 123 to move along its designated path, carrying the pneumatic rod 124 with it. This motion allows the rod to be accurately positioned above different containers or mixing zones, depending on where the ingredient transfer is required.

[0055] The pneumatic rod 124 itself is mounted vertically and operates using compressed air, which provides the force necessary for its up-and-down movement. When air pressure is applied, the rod extends downward; when the pressure is released or reversed, the rod retracts. This allows the rod to push or insert the conical end plate 125 into a material bed or outlet port for transferring or metering ingredients. The rod's precise vertical actuation ensures accurate control during ingredient delivery.

[0056] The conical end plate 125, which is specifically designed to facilitate efficient and guided transfer of materials. The conical shape helps funnel or direct loose or semi-fluid ingredients smoothly into a desired container or path, minimizing spillage and ensuring proper flow. The entire rod and plate 125 assembly is connected via the motorized ball and socket joint 126, which provides multi-axis flexibility and dynamic positioning. The ball and socket joint 126 consists of a spherical ball mounted at the base of the rod that fits into a concave socket connected to the sliding unit 123 or mounting frame. The motorized component enables controlled rotation and tilting of the joint 126, allowing the rod and conical plate 125 to pivot in various directions. This enables the rod to tilt, rotate, and align with specific angles or target points for ingredient transfer.

[0057] For monitoring concrete temperature and controlling mixing duration, a temperature sensor is integrated with the containers. The sensor comprises a thermocouple or resistance temperature detector (RTD), detects changes in temperature and sends real-time data to the microcontroller. The sensing element is the core component, and its electrical properties such as resistance or voltage—change in response to temperature variations. For instance, in a thermistor, resistance decreases as temperature increases (NTC type), and this change is measured and translated into a readable temperature value. Based on this temperature feedback, the microcontroller adjusts the mixing duration accordingly. If the concrete temperature rises too quickly indicating accelerated hydration the microcontroller shortens the mixing time to prevent premature setting. Conversely, if the mixture remains too cool, the microcontroller can extend the mixing duration to ensure proper blending and activation of the cementitious materials.

[0058] A storage unit 127 is installed inside the housing 101 and stored with crushed ice that is added to the ingredient mix for moisture-controlled applications, and the microcontroller via the temperature sensor ensures complete melting for even distribution. The storage unit 127 purpose is to temporarily store the ice before it is gradually introduced into the ingredient mix. This controlled release helps maintain optimal moisture levels, enhancing texture, consistency, and performance of the final product. The storage unit 127 is engineered with insulation to minimize premature melting, ensuring that the ice retains its solid form until needed.

[0059] For facilitating easy removal of slab from the mold, the microcontroller activates an electronic nozzle 128 attached with a cuboidal member 129 stored with a mold-releasing solution and configured inside the housing 101 for continuously dispensing the mold-releasing over the mold prior dispensing of mixtures. The microcontroller sends a signal to a solenoid or valve 122 within the nozzle 128, controlling its opening 120 and closing to allow the solution to flow. The nozzle 128 is equipped with a pump to ensure that the solution is delivered at a consistent rate.

[0060] The nozzle 128 is designed with specific channels or opening 120 that enable it to release the solution in a fine mist or spray pattern, ensuring even coverage across the mold surface. The cuboidal member 129 is a storage container designed to hold the mold-releasing solution. This member 129 serves as a reservoir, ensuring a continuous supply of the solution to the nozzle 128. It is built to be leak-proof and durable, allowing for consistent and controlled dispensing over time.

[0061] Lastly, a battery is installed within the device which is connected to the microcontroller that supplies current to all the electrically powered components that needs an amount of electric power to perform their functions and operation in an efficient manner. The battery utilized here, is preferably a dry battery which is made up of Lithium-ion material that gives the device a long-lasting as well as an efficient DC (Direct Current) current which helps every component to function properly in an efficient manner. As the device is battery operated and do not need any electrical voltage for functioning. Hence the presence of battery leads to the portability of the device i.e., user is able to place as well as moves the device from one place to another as per the requirements.

[0062] The present invention works best in the following manner, where the housing 101 with multiple chambers 102 as disclosed in the invention is dedicated towards storing construction aggregates and binders of varying types, each equipped with controlled compartments to ensure precise material management and minimize cross-contamination. The touch interactive display panel 103 allows users to input the dimensions and type of concrete slab, with the touch controller processing signals to actuate necessary components. The motorized iris lid 104 control the dispensing of materials into mixing containers, ensuring accurate ingredient flow. The containers, equipped with motorized stirrers 109, efficiently blend ingredients such as cement, sand, water, foam beads, and glass beads. The hydraulic pusher 110 with the circular unit 111 compresses the mixture for coarse texture. The device includes multiple sets of dies 112 for different slab dimensions, with the motorized slider 113 moving the selected die into place. The rotary feeder, connected to motorized iris units, dispenses concrete mix layer by layer into the mold, based on material ratios and layer thickness. The vibrating unit embedded in the dies 112 enhances slab integrity by removing air bubbles. The tactile sensors detect slab hardness, alerting users via the speaker 119 when the slab is ready for removal. The sliding unit 123 with the pneumatic rod 124 and conical end plate 125 efficiently transfers ingredients, while the temperature sensor monitors the concrete temperature, adjusting mixing duration as needed. Finally, the storage unit 127 with crushed ice regulates moisture levels, ensuring consistency in the final product.

[0063] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A multi-layered insulating concrete form slab manufacturing device, comprising:

i) a housing 101 installed with plurality of chambers 102 stored with constructional aggregates and binders of varying types, wherein a touch interactive display panel 103 is provided on the housing 101 that is accessed by a user to provide input commands regarding dimensions and type of concrete slab said user desires to construct;

ii) a motorized iris lid 104 mounted on side walls of the chambers 102, each lid connected to a conduit 105 for dispensing precise quantities of ingredients into at least two mixing containers provided inside the housing 101, wherein a first mixing containers is configured to mix cement, sand, and water, and a second container 107 is configured to mix foam beads and glass beads, each container is equipped with motorized stirrers 109;

iii) a third container 108 provided inside the housing 101 for storing foaming agents to be mixed with water, wherein a hydraulic pusher 110 with a circular unit 111 is provided inside the housing 101, adapted to compress the mixture for coarse texture as per user input;

iv) multiple set of dies 112 installed within said housing 101, each set having a cavity corresponding to said slabs of different dimensions, wherein based on said user-defined dimensions of said slab to be constructed, said microcontroller determines one of said set of dies 112 to be utilized, in accordance to which said microcontroller actuates a motorized slider 113 configured inside the housing 101 for translating and aligning a box 114 attached with the slider 113 via a pneumatic link 115 underneath the containers;

v) a motorized iris unit provided with each of the containers that is actuated by the microcontroller to dispense the mixed constructional aggregates, binding aggregates and foam mixture in a sequential manner, wherein said microcontroller dispenses the mixtures in a defined layers corresponding to:

a) a bottom layer of traditional concrete for structural strength;
b) a middle layer of insulating concrete comprising foam and glass beads; and
c) a top layer of concrete for surface durability.

vi) a robotic link 116 provided inside the housing 101 and integrated with a motorized roller 117 as an end-effector, wherein said microcontroller regulates actuation of the robotic link 116 and roller 117 to work in collaboration for smoothing the surfaces after each layer;

vii) plurality of heating units 118 arranged around each of said set of dies 112, upon filling of said mixture in said mold, said microcontroller activates said heating units 118 to strengthen the concrete and remove air pockets, wherein a vibrating unit is embedded in the dies 112 that is actuated by the microcontroller to impart vibrational sensations over the mold, removing air bubbles to enhance slab integrity; and

viii) a tactile sensor positioned on each of said dies 112 for detecting hardness of said slab, wherein as soon as said detected hardness matches a threshold value, said microcontroller activates a speaker 119 mounted on said housing 101 for notifying said user to collect said manufactured slab from said hosing via an opening 120 provided on the housing 101.

2) The device as claimed in claim 1, wherein a water vessel 121 is provided on said third container 108 and integrated with an electronic valve 122, said valve 122 is actuated by the microcontroller to dispense an optimum amount of water over said foaming agents to generate foam for lightweight, insulating concrete.

3) The device as claimed in claim 1, wherein a sliding unit 123 coupled to a vertically mounted pneumatic rod 124 with a conical end plate 125 integrated via a motorized ball and socket joint 126, adapted for dynamic ingredient transfer.

4) The device as claimed in claim 1, wherein the database stores environmental and user-specific data including weather conditions, structural location, and slab texture preferences, used by the microcontroller to determine ingredient ratios and layering sequence.

5) The device as claimed in claim 1, wherein a temperature sensor is integrated with the containers for monitoring concrete temperature and controlling mixing duration.

6) The device as claimed in claim 1, wherein a storage unit 127 is installed inside said housing 101 and stored with crushed ice that is added to the ingredient mix for moisture-controlled applications, and the microcontroller via the temperature sensor ensures complete melting for even distribution.

7) The device as claimed in claim 1, wherein an electronic nozzle 128 attached with a cuboidal member 129 stored with a mold-releasing solution and configured inside said housing 101, that is activated by said microcontroller for continuously dispensing said mold-releasing over the mold prior dispensing of mixtures, facilitating easy removal of slab from the mold.

8) The device as claimed in claim 1, wherein a rotary feeder is integrated with said box 114 and operably connected to said motorized iris units of the containers, said valve 122 being actuated by said microcontroller to facilitate controlled, sequential dispensing of concrete mixtures layer by layer into the selected die, in accordance with the predefined layering pattern.

9) The device as claimed in claim 1, wherein a battery is associated with said device for supplying power to electrical and electronically operated components associated with said device.