Unit for Manufacturing and Preparation on the Worksite of a Mortar for Spraying

Abstract

A unit for manufacturing a mineral matrix 1 produced from a powder and water comprising a mixing module 20, connected to a primary water circuit and to a powder collector 30, comprising a mixer 22 and

Description

TITLE: UNIT FOR MANUFACTURING AND PREPARATION ON THE WORKSITE OF A MORTAR FOR SPRAYING

[0001] The invention relates to the field of devices for coating walls. PRIOR ART

[0002] To coat a construction element with a mortar, i.e. a matrix composed of a powder mixture comprising at least one hydraulic binder and aggregates as well as possibly one or more additives, mixed with water, it is known to use devices making it possible to operate the blending or mixing between the powder and the water in order to provide a matrix ready to be coated. This matrix can be conveyed with a spray system to spray said matrix onto the element to be coated.

[0003] Plasters are mortars specifically formulated to be sprayed on a wall or facade element.

[0004] There are two types of mixing devices, those enabling continuous mixing and those enabling batch mixing.

[0005] The element of the device in which the preparation of the matrix takes place by mixing between the powder and the water is called the mixer or blender. The element enabling the spraying of the matrix thus formed by the mixture is called the pump.

[0006] In batch mixing, the matrix is produced in a batch or lot. A quantity of powder and a quantity of water are poured into the mixer and then mixed for a predefined period, generally several minutes, in order to form a defined quantity of matrix. Once this quantity of matrix is formed, it is poured into the pump to be sprayed. Once this quantity of matrix has been used, it is necessary to recharge the device with water and powder to form a new lot / batch of matrix.

[0007] In continuous mixing, the powder and the water are mixed gradually, in quantities predefined by the setting, to obtain a continuous quantity of matrix to be coated. The residence time between the powder and the water in the mixer to form the matrix is then relatively short, generally a few seconds, before the matrix thus formed is available by the pump to be sprayed.

[0008] In addition, colored matrices, i.e. matrices incorporating a colorant, are increasingly used for aesthetic purposes when the sprayed mortar is a finishing layer of the construction element. This is particularly the case for finishing plasters and monolayer plasters for the facade.

[0009] In colored mortars, the colorant is composed of one or more pigments of mineral or organic origin. These pigments, in powder form, are incorporated in the factory as an additive to the powder mixture. The choice of pigments and their dosage enables the desired coloration to be obtained.

[0010] Due to the very low dosage of pigments in the powder mixture, generally below 1 % by mass in finishing plasters and monolayer facade plasters, and the need to disperse them homogeneously among the rest of the powder constituents, pigmentation is a critical step in the manufacturing of plasters and, to date, only a factory process provides the necessary reliability for the operations of weighing and dispersing the powder pigments in the powder mixture. [0011 ] However, shortcomings appear for these continuous or batch mixing devices.

[0012] The packaging of mortars leaving the factory is generally in the form of powder bags of 20 to 30 kilograms. The feeding of the spraying device is done by breaking bags of powder in the mixer and requires the intervention of an operator to regularly fill the device.

[0013] This shortcoming is valid for both types of devices, even if it can be circumvented in continuous mixing devices by using mortar in silos rather than in bags. The use of silos is generally not compatible with batch mixing. The silo is also unsuitable for low consumption (less than a pallet of bags), which may be the case for certain worksites or certain colorings on a worksite, and finally when the continuous device is mounted on a silo it becomes impossible to move on the worksite, which offers less flexibility for the applicator.

[0014] More specifically, the application of mortar of the monolayer plaster type generally requires the intervention of a team of 3 people: an operator for breaking of the bags, an operator for spraying the plaster at the end of the launch and an operator for smoothing the plaster on the wall in parallel to its spraying. Bag breaking therefore represents a significant labor cost, while this operation is considered by professionals to have low added value and is physically arduous, especially in the configuration of a team reduced to two people where the operator who fills the device is the same who operates the spraying of the plaster on the wall. Teams of two are therefore generally less expensive in terms of hourly labor but more demanding for the applicators and less efficient in terms of square meters of plaster applied per unit of time.

[0015] In addition, the use of mortar with different colors on the same worksite is common. This is particularly true for finishing plasters and monolayer facades, which are generally applied in two or even three or four colors on the same worksite. It requires the ordering and supply of bags of plaster of different colors in sufficient quantities and often generates a surplus of mortar that is not consumed. In addition, the purchase of bags of white plaster whose powder would be colored before mixing seems too complicated, as proficiency in coloring is an operation requiring great precision.

[0016] The management of different colors also makes it impossible to supply facade plasters in silos because it is not profitable for the mortarist to have different silos for each of the colors in the range. In addition, there is generally no space on worksites to store multiple silos.

[0017] Finally, cleaning the spraying machines is a time-consuming step, generally carried out at the end of the working day or during a change in the color of the plaster. In addition, this cleaning phase is carried out with a lot of water which, subsequently, is generally spread contaminated by the mortar on the worksite.

[0018] Continuous mixing also has the shortcoming that it does not allow the addition of admixtures of the setting accelerator or retarder type directly on the worksite, yet this practice is often used to adapt the setting of the plaster to the weather conditions. This practice is possible in the case of the batch device by adding the retarder or the accelerator in liquid form directly into the tank of the mixer during the preparation of the matrix. SUMMARY OF THE INVENTION

[0019] The present invention seeks to solve the problems of the prior art by providing an automated manufacturing unit for a mortar matrix, offering greater ease of use and improved productivity, notably with the possibility of producing a colored matrix whose quality of color is stable during manufacturing.

[0020] To this end, the present invention relates to a unit for manufacturing a mineral matrix made from a powder and water comprising a mixing module, connected to a primary water circuit and to a powder collector, comprising a mixer and a pump in which the powder and the water are mixed to form said matrix,characterized in that said manufacturing unit further comprises a control unit for controlling the manufacturing of said mineral matrix, said control unit being arranged to control the quantity of water coming from the primary water circuit and the quantity of powder taken from the powder collector to obtain the matrix.

[0021] The manufacturing unit further comprises means for coloring said matrix, said coloring means being connected to the primary water circuit and being arranged to supply colored water having a defined color and controlled by said control unit.

[0022] The coloring means comprise: - an array of storage tanks for primary colorants, - automated means for producing colored water from a colorant colored from at least one of said primary colorants and a defined quantity of water.

[0023] The automated means for producing colored water comprise a first container in which a defined quantity of water is mixed with a quantity of tinted colorant to obtain water having the defined color and a second so-called intermediate container in which said defined quantity of water is transferred and whose capacity is greater than the defined quantity, this second container being connected to the mixing module.

[0024] According to one example, said storage array of primary colorants comprises a plurality of compartments arranged in a container or each in a container, each compartment being used to store a primary colorant and is associated with a selection module.

[0025] According to one example, the mixer comprises a housing in which mixing means are arranged, said mixer being connected to a collector in which the base is placed and a pump through which the matrix exits.

[0026] According to one example, the manufacturing unit further comprises a clear water circuit connected to the pump making it possible to modify the consistency of the matrix without modifying its coloration.

[0027] According to one example, the manufacturing unit further comprises a cleaning unit connected to the clear water circuit making it possible to clean said manufacturing unit.

[0028] According to one example, said cleaning unit comprises a plurality of nozzles arranged in the first container, the second container and the housing of the mixing device.

[0029] According to one example, the mixer comprises an evacuation outlet connected to a collector enabling the water used for cleaning to be filtered and discharged.

[0030] According to one example, the first container and the second container are mounted on a scale.

[0031] According to one example, the first container and / or the second container comprise agitation means.

[0032] According to one example, the powder from the collector is brought to the mixer via an endless screw

[0033] The invention further relates to a method for operating the manufacturing unit according to one of the preceding claims, said method comprising the following steps: - Selecting and providing at least one of the primary colorants to form a defined amount of a tinted colorant; - Mixing said at least one of the primary colorants with a defined quantity of water in the first container to form a defined quantity of colored water; - Transferring this defined quantity of colored water to a second container; - Once the second container contains colored water, the control unit enables the transfer of colored water from the second container to the mixer to be mixed with a base.

[0034] According to one example, the control unit is capable of controlling the mixing of at least one of the primary colorants with a defined quantity of water in the first container based on the transfer of colored water from the second container to the mixer. BRIEF DESCRIPTION OF FIGURES

[0035] Other features and advantages will be clearly apparent from the description given below, for informational purposes only and in noway limiting, with reference to the accompanying drawings, in which: - Figure 1 schematically shows a manufacturing unit controlled by a control unit; - Figures 2 and 6 schematically represent a manufacturing unit according to the invention; - Figure 3 shows an array of storage tanks of the manufacturing unit according to the invention; - Figures 4 and 5 show a cleaning circuit of the manufacturing unit according to the invention; DETAILED DESCRIPTION

[0036] In Figure 1, a manufacturing unit 1 of a mineral matrix according to the invention is shown. This unit for manufacturing a mineral matrix is movably mounted directly on a trailer or in a vehicle or is fixed and is transported from work to worksite.

[0037] This manufacturing unit 1 makes it possible to manufacture a mineral matrix in an automated manner designed from a powder mixture (which can also be called powder or base), comprising at least one hydraulic binder and aggregates as well as optionally one or more additives, mixed with water.

[0038] The manufacturing unit 1 further comprises a mixing module or device 20 comprising a mixer 22 in which the powder and water are mixed to form said matrix.

[0039] The mixer 22 is in the form of a housing 220, for example tubular, forming a mixing chamber, comprising an upper part 222 and a lower part 224. The lower part 224 is connected to a pump 24 by which the matrix, formed by the mixture of water and powder, is expelled. For this, the pump 24 is connected to a hose 242 and sprayer 244 to spray said matrix.

[0040] The upper part 222 is arranged to be connected to a base / powder collector or silo 30 preloaded with the bulk powder. This collector or silo 30 is connected to said housing 220 via an endless screw controlled by the control unit UC and enabling the correct quantity of powder to be introduced into the housing 220. This valve or endless screw is integrated into the collector 30 or the mixer 22.

[0041] Optionally, an intermediate tank is placed between the collector 30 and the mixer 22. Such an intermediate tank is connected to the mixer by an endless screw F as shown in Figure 6. The connection between the collector 30 and the intermediate tank is made by an endless screw or a valve in the case where the powder is transferred from the collector to the intermediate tank by gravity.

[0042] The housing 220 is also connected to a primary water circuit CEP supplying the water necessary for mixing.

[0043] This housing 220 further comprises, within it, means 226 for mixing the mixture of powder and water in different forms such as an endless screw or blades.

[0044] The control unit UC is thus able to control the quantity of water in the primary water circuit and the quantity of powder from the collector 30 sent into the housing 220 so that the mixing takes place by obtaining a matrix having the desired viscosity and consistency.

[0045] According to the invention, the manufacturing unit 1 is such that it makes it possible to manufacture a colored mineral matrix.

[0046] For this, the manufacturing unit 1 comprises coloring means 10 of said matrix as shown in Figure 2. These coloring means 10 are used to provide coloring to the matrix and, more specifically, to provide selected and stable coloring. It is understood by this that the coloring of the matrix is identical throughout the manufacturing process of said matrix. It is understood by this that the delta E or color deviation, measured by spectrophotometry, of the colored plaster is less than 2. This value makes it possible to have a color of the plaster that can vary very slightly without this being visible to the naked eye.

[0047] This coloring of the matrix is carried out by coloring the water that will be mixed with said powder.

[0048] These coloring means 10 comprise a storage battery 12 of primary colorants in the form of a pigment powder. This array of storage tanks of primary colorants 12 comprises a plurality of compartments 120 each arranged in a container or in a single container, each compartment 120 being used to store a primary colorant in the form of pigment powder.

[0049] This array of storage tanks 12 is associated with automated means 14 for producing colored water from a defined quantity of tinted colorant. This defined amount of tinted colorant is made from at least some of said primary colorants. This amount of tinted colorant is associated with a defined amount of water to form the colored water.

[0050] These automated production means 14 comprise a first container 140 or colored water production container into which the defined quantity of water and the quantity of colorant are poured. These automated preparation means 14 are integrated into the primary water circuit CEP.

[0051] The quantity of colorant is defined by a control unit UC that controls a selection module 142 of the automated preparation means 14. This selection module 142, associated with the array of storage tanks 12, comprises selection valves 142a, each associated with a compartment 120, and a bucket 142b mounted on a scale (not shown) as shown in Figure 3. This selection module 142 is then controlled to open the selection valve 142a of the tank or container of a desired primary colorant in order to pour it into the bucket. The desired quantity is measured, by mass, by said bucket mounted on a scale. This enables precise mixing of the primary colorants.

[0052] The quantity or quantities of primary colorants are poured into the first container 140.

[0053] This first container 140, whose capacity is greater than the defined quantity of water, is provided with an inlet 140a through which the water is injected. The first container 140 is provided with a module for measuring the quantity of water making it possible to measure the quantity of water injected into said first container. This makes it possible to obtain a precise defined quantity of water. This water quantity measurement module is in the form of a scale B1 measuring the mass of the container or a flowmeter arranged at the inlet through which the water enters.

[0054] The first container 140 is further provided with agitation means 144 comprising an arm or a blade enabling the water to be mixed with the colorant(s) to obtain colored water whose pigment concentration is precise and conforms to the desired concentration.

[0055] This first container 140 further comprises an outlet 140b connecting the first container 140 with a second container 160 or intermediate container via a pipe provided with a valve V. This valve V is controlled by the control unit UC.

[0056] This second container 160 or intermediate container is part of the automated production means 14 and is a container whose capacity is greater than that of the first container 140. This capacity is preferably at least 50% greater, even more preferably at least double, or even triple. Thus, for a first container 140 having a container of 10 L, the second container will have a container of at least 15 L, preferably at least 20 L and even more preferably at least 30 L.

[0057] This second container 160 is optionally equipped with agitation means 162 comprising an arm or one or more blades enabling continuous mixing of the colored water to prevent the formation of deposits. The second container 160 includes an outlet 160b.

[0058] According to the invention, the mixing module 20 is connected to the second container 160 so that the water used to form the matrix is colored water coming from this second container 160. This connection is made by a pipevalve V pair controlled by said control unit UC to control the amount of water injected into the mixing module 20

[0059] This configuration is advantageous in that it uses the first container 140 of the production means 14 as the container in which a quantity of water colored with the correct coloring is produced, this quantity of water having the correct coloring is then sent to the second container 160 of the production means. This second container 160 is thus used as a container in which water having the right color is stored before use in the mixing module 20.

[0060] Thus, the use of this second tank 160 to supply the mixing module 20 makes it possible to use water whose pigment concentration is stable and therefore to obtain a matrix whose color is stable and conforms to that desired so that by adding the right amount of water to the right amount of powder, a color stable matrix is obtained.

[0061] Furthermore, the second container 160 is mounted on a scale B2 so that it is possible to continuously measure the quantity of colored water available. This measurement advantageously makes it possible to control the filling of said second container 160. Indeed, if the mass of the second container 160 reaches a mass called the low threshold, then this means that the quantity of colored water present in said second container is small. This ensures that there is continuous colored water available for mixing.

[0062] Thus, the control unit UC, connected to the various sensors such as the scales B1, B2, can control the automated production means 14 so that they produce colored water in the first container 140.

[0063] The operation of this manufacturing unit 1 therefore consists, firstly, in manufacturing a defined quantity of a tinted colorant using at least one primary colorant, each primary colorant used being selected by the selection module 142 then weighed by the bucket. Secondly, this defined amount of tinted colorant is then poured, placed in the first container 140 in which a defined amount of water is placed. This quantity of water is preferably placed in the first container 140 before the introduction of the tinted colorant but can optionally be placed after or simultaneously.

[0064] When the first container 140 comprises mixing means 144, these make it possible to obtain a homogeneous agitation of the water and the color.

[0065] This quantity of water is measured by the scale B1 on which the first container 140 is mounted.

[0066] Thirdly, the defined quantity of colored water from the first container 140 is transferred into the second container 160 by action of the control unit UC on the valve V arranged between the first container 140 and the second container 160.

[0067] This quantity of colored water is detected in the second container 160 by the scale B2 on which said second container 160 is mounted.

[0068] Once this colored water has been detected, the control unit UC can control the mixing module 20. Indeed, the second container 160 makes it possible to have available a quantity of colored water whose color is stable.

[0069] Fourthly, the control unit UC can thus activate the mixing module 20 and the valve V located between the second container 160 and the mixing module 20 so that the colored water from the second container can be injected into said mixing module 20.

[0070] Thus, the control unit UC is such that it activates the mixing module / device 20 in the event of the presence of water in the second container 160 and that it is capable of controlling the production of colored water in parallel. This production of colored water is made according to the level of colored water in the second container 160, this level being known by measuring the mass of said second container 160.

[0071] The control unit UC is thus capable of enabling the manufacturing unit 1 to always have a quantity of colored water available.

[0072] In an alternative embodiment, the control unit UC can comprise a user interface enabling an operator to enter data. These data relate to the quantity of matrix to be produced, the desired viscosity and the desired color. The quantity of matrix to be produced can be entered manually or can be calculated from a surface to be coated and a desired plaster thickness.

[0073] In this alternative embodiment, the control unit UC is programmed to be capable, depending on these data of quantity of matrix to be produced and of desired viscosity, of determining the quantity of powder and the quantity of water that must be produced.

[0074] From there, the control unit UC is able to manage the manufacturing of the matrix by manufacturing the necessary quantity of colored water and to operate the correct water-powder mixture to obtain the desired quantity of matrix.

[0075] In an alternative embodiment, the manufacturing unit 1 according to the invention further comprises a secondary water circuit 50. This secondary water circuit 50 includes at least one connection with the mixing module 20. Indeed, this mixing module 20 comprises at least one inlet through which the secondary water circuit 50 is connected. This connection is used to add clear water to the mixture of colored water and base in order to adjust the viscosity.

[0076] Indeed, it is possible that the matrix resulting from the mixture between the colored water and the base does not have sufficient viscosity. However, adding colored water would risk modifying the color of said matrix. Thus, this additional clear water circuit makes it possible to add water, which is uncolored, to adjust the viscosity of the matrix.

[0077] In another alternative embodiment, said secondary water circuit 50 is used to supply a cleaning unit 60 as shown in Figures 4 and 5. This cleaning unit 60 comprises a plurality of nozzles 62 connected to the secondary water circuit 50. These nozzles 62 are placed and used to spray clear water at different locations of the manufacturing unit 1 in order to clean it. Indeed, the manufacturing of a colored matrix leads to the appearance of colored traces or residues of colored matrix. The spraying of clear water thus makes it possible to remove these colored traces or residues, thus avoiding the pollution of a matrix subsequently manufactured by these traces or residues. In the housing 220, these nozzles 62 can be arranged on the inner wall or integrated into the mixing means 222.

[0078] Nozzles 62 are advantageously placed at the first container 140, of the second container 160, of the housing 220 and of the pump 24 as visible in Figures 4 and 5.

[0079] In this alternative embodiment, the mixing module 20 further comprises a discharge outlet 207 enabling the waste water to be discharged. Indeed, the cleaning operation consists of spraying water into the manufacturing unit: the various containers and the pump and operating the latter. The matrix outlet opening is closed by a selector 208 while the discharge outlet is opened, by said selector 208, so that the wastewater can be collected in a collector.

Claims

1. The unit for manufacturing a mineral matrix (1) produced from a powder and water comprisinga mixing module (20), connected to a primary water circuit (CEP) and to a powder collector (30), comprising a mixer (22) and a pump (24) wherein the powder and the water are mixed to form said matrix, characterized in that said manufacturing unit further comprises a control unit (UC) for controlling the manufacturing of said mineral matrix, said control unit (UC) being arranged to control the quantity of water coming from the primary water circuit and the amount of powder taken from the powder collector (30) to obtain the matrix,wherein said manufacturing unit further comprises coloring means (10) of said matrix, said coloring means (10) being connected to the primary water circuit (CEP) and being arranged to supply colored water having a defined color and controlled by said control unit wherein the coloring means (10) comprise:- an array of storage tanks for primary colorants (12),- automated means for producing colored water (14) from a tinted colorant from at least one of said primary colorants and a defined quantity of water andwherein the automated means for producing colored water (14) comprise a first container (140) wherein a defined quantity of water is mixed with a quantity of tinted colorant to obtain water having the defined color and a second so-called intermediate container (160) into which said defined quantity of water is transferred and whose capacity is greater than the defined quantity, this second container (160) being connected to the mixing module (20).

2. The manufacturing unit according to claim 1, wherein said storage array of primary colorants (12) comprises a plurality of compartments (120) arrangedin a container or each in a container, each compartment being used to store a primary colorant and is associated with a selection module.

3. The manufacturing unit according to one of the preceding claims, wherein the mixer (22) comprises a housing (220) wherein mixing means (226) are arranged, said mixer being connected to the powder collector (30) and to a pump (24) through which the matrix exits.

4. The manufacturing unit according to one of the preceding claims, wherein it also comprises a secondary water circuit (50) connected to the mixing module (20) making it possible to modify the viscosity of the matrix.

5. The manufacturing unit according to the preceding claim, wherein it also comprises a cleaning unit (60) connected to the secondary water circuit making it possible to clean said manufacturing unit.

6. The manufacturing unit according to the preceding claim, wherein said cleaning unit comprises a plurality of nozzles (62) arranged in the first container, the second container and the housing of the pump.

7. The manufacturing unit according to one of claims 5 or 6, wherein the mixer comprises a discharge outlet connected to a collector enabling the water used for cleaning to be discharged.

8. The manufacturing unit according to one of the preceding claims, wherein the first container, the second container are mounted on a scale (B1, B2).

9. The manufacturing unit according to one of claims 1 to 8, wherein the first container and / or the second container comprise agitation means.

10. The manufacturing unit according to one of the preceding claims, wherein the powder from the collector (30) is brought to the mixer (22) via a valve or an endless screw.

11. The method of operating the manufacturing unit according to one of thepreceding claims, said method comprising the following steps:- Selecting and providing at least one of the primary colorants to form a defined amount of a tinted colorant;- Mixing said at least one of the primary colorants with a defined quantity of water in the first container to form a defined quantity of colored water;- Transferring this defined quantity of colored water to a second container;- Once the second container contains colored water, the control unit enables the transfer of colored water from the second container to the mixer to be mixed with a base.

12. The method according to the preceding claim, wherein the control unit is capable of controlling the mixing of at least one of the primary colorants with a defined quantity of water in the first container based on the transfer of colored water from the second container to the mixer.

Images