Brushless DC Motor Joint Pump for Polished Concrete Floors
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Solution Overview
Problem
Existing joint and crack-filling equipment for polished concrete floors is complex, inefficient, and difficult for a single operator to use, often requiring heavy frames with four wheels, chain drives, and inefficient electrical systems that increase maintenance and reduce maneuverability.
Innovation Solution
A lightweight, battery-operated walk-behind cart with a brushless DC motor directly coupled to two pumps, eliminating the need for belts, chains, and electrical power conversion, allowing a single user to easily dispense a two-part hardening material using a wand with flexible tubing, and optionally using biodegradable bag-in-box containers for reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If existing joint and crack-filling equipment is used, then crack filling function is provided, but device complexity increases and ease of operation deteriorates
Solution Approach 1:
The patent combines two separate pumps (one for each component of the two-part hardening material) into a single integrated pumping system. The motor drives both pumps through a common transmission mechanism, merging multiple functions into one unified device that mixes and dispenses both components simultaneously, thereby reducing overall system complexity while maintaining full functionality.
Solution Approach 2:
The pumping system is designed to handle two different materials (components A and B of the hardening mixture) through a single integrated mechanism. The system universally processes both materials using the same motor, transmission, and pumping architecture, eliminating the need for separate specialized equipment for each material while maintaining precise control over both dispensing operations.
2Ease of operation
If heavy frames with four wheels are used, then structural stability is improved, but weight increases and maneuverability deteriorates
Solution Approach 1:
The patent extracts and eliminates unnecessary structural elements from the equipment design. By removing the heavy four-wheel frame configuration and retaining only the essential two-wheel support structure, the design achieves adequate stability while dramatically reducing weight and improving maneuverability. The extracted elements were found to be redundant for the actual operational requirements.
Solution Approach 2:
The patent counteracts the inherent weight of the motor and pumping mechanisms by optimizing the overall weight distribution and using lightweight materials where possible. The balanced configuration of components minimizes the total weight while maintaining sufficient structural integrity for stable operation during crack filling tasks.
3Reliability
If chain drives and belts are used, then mechanical power transmission is achieved, but maintenance requirements increase and reliability deteriorates
Solution Approach 1:
The patent replaces traditional mechanical power transmission systems (chain drives and belts) with a direct-drive configuration. The motor is directly coupled to the pumping mechanisms through a simplified transmission system, eliminating wearing components that require maintenance. This substitution dramatically improves reliability by removing parts that can stretch, break, or require lubrication while simplifying the overall mechanical architecture.
4Productivity
If inefficient electrical power conversion systems are used, then motor operation is achieved, but energy loss increases and operational efficiency deteriorates
Solution Approach 1:
The patent replaces inefficient electrical power conversion systems with a direct brushless DC motor configuration that operates natively on battery power. This eliminates multiple stages of electrical conversion (rectification, inversion, regulation) that each introduce energy losses. The direct-drive motor system converts electrical energy to mechanical energy in a single efficient step, maximizing operational efficiency while minimizing energy waste.
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 solution provides enhanced maneuverability, reduced maintenance, and improved efficiency by allowing a single operator to effectively fill cracks and irregularities in concrete floors with a lighter, simpler machine that maintains performance even with reduced battery voltage, while minimizing environmental impact through biodegradable packaging.
Implementation Method 1
The motor is brushless and battery operated and is directly coupled to pumps
Implementation Method 2
The motor is coupled to a transmission mechanism operative to simultaneously drive opposing axles, each having a pump coupled thereto
Data Source
AI summary
Lightweight, battery-operated, walk-behind joint- and crack-filling equipment has no belts or chains to wear out, and no inverters or other electrical power-conversion apparatus. A single brushless battery-operated DC motor, directly coupled to two pumps, simultaneously delivers the resin and hardener to a wand, such that a single user can push the cart and apply the mixture. The portable cart includes a frame with a handle and single set of right and left wheels accommodates two containers holding the hardening components. The containers may be pails or buckets or bag-in-box containers that may be compressed and collapsed after use to reduce waste requirements. The boxes and/or bags may also be biodegradable for a more environmentally friendly solution.