Aqueous Abrasive Sprayer for Concrete Surface Texturing
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Solution Overview
Problem
Existing methods for texturing architectural precast concrete wall panels, such as acid washing and dry sand blasting, are either costly or generate environmental concerns due to dust and particulate matter.
Innovation Solution
A system using an aqueous-based particulate abrasive mixture is sprayed onto the panels to create a textured surface, employing a spray nozzle assembly that can be automatically positioned and controlled to apply varying pressures and patterns, reducing dust and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If acid wash is used to abrade the surface, then texture is produced, but chemical management becomes time-consuming and expensive
Solution Approach 1:
The patent replaces chemical abrasion (acid wash) with mechanical abrasion using dry or wet sand blasting equipment. The sand blasting process uses kinetic energy of abrasive particles to achieve surface texturing without the need for chemical management, thereby resolving the contradiction between achieving desired surface texture and avoiding complex chemical management.
Solution Approach 2:
The patent employs pneumatic systems to deliver abrasive material through hoses and nozzles to the concrete surface. The compressed air propels the abrasive particles at high velocity, enabling controlled mechanical abrasion that produces the desired texture while eliminating chemical management requirements.
2Manufacturing precision
If dry sand blasting is used to abrade the surface, then texture is produced, but dust and particulate matter fill the air creating environmental concerns
Solution Approach 1:
The patent introduces water as an intermediary medium in wet sand blasting. The water binds the abrasive particles together, reducing dust generation while maintaining the abrasive action needed for surface texturing. This resolves the contradiction between achieving surface texture and minimizing harmful dust and particulate matter release into the environment.
3Productivity
If automated spray nozzle assembly is used, then productivity increases, but device complexity increases
Solution Approach 1:
The spray nozzle assembly is designed to perform multiple functions: delivering abrasive material, controlling spray pattern, adjusting pressure, and enabling automated movement along the concrete surface. This multi-functionality allows a single complex device to achieve high productivity while consolidating what would otherwise require multiple separate systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively textures the panels with less dust generation and lower costs, providing a controlled and efficient method for creating desired surface finishes on architectural precast concrete wall panels.
Implementation Method 1
spraying a surface portion of an architectural precast concrete wall panel with an aqueous-based particulate abrasive mixture under conditions adequate to at least partially abrade the surface portion
Data Source
AI summary
Apparatuses, components, methods, and techniques for selectively texturing concrete surfaces are provided. An example method of providing a surface portion of an architectural precast concrete wall panel with an abraded texture is provided. The method includes a step of spraying a surface portion of an architectural precast concrete wall panel with an aqueous-based particulate abrasive mixture under conditions adequate to at least partially abrade the surface portion. An example sprayer system for abrading a concrete surface is also provided. The system includes an aqueous-based particulate abrasive mixture dispenser including a spray nozzle arrangement. The system also includes a material communication assembly in abrasive flow communication with the aqueous-based particulate abrasive mixture dispenser. The system also includes a dispenser positioning arrangement.