Concrete Block Surface Pattern via Centrifugal Applicator
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Solution Overview
Problem
Existing methods for creating varicolored concrete blocks or slabs fail to produce surfaces that resemble streaked and/or speckled natural stones effectively, as they only produce dot-like color patterns, which do not fully meet the visual requirements for mimicking natural stone appearances.
Innovation Solution
A method involving the application of pigmented or diversely colored finishing materials onto the surface layer or face concrete layer using an applicator before compaction, which can include materials like rock grains, semiprecious stones, or metal chips, and utilizing a centrifugal feeder disk or paddle wheel to achieve a flamed, veined, or speckled surface pattern, with optional use of a metering vessel and compressed air for uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pigmented layers are moved freely downward in the supply vessel to form a marbled face layer, then the manufacturing process is simplified, but the visual appearance only produces dot-like color patterns that do not resemble natural stones
Solution Approach 1:
The patent applies pigmented finishing materials to the concrete surface before compaction occurs. This preliminary application allows the color patterns to be established on the surface layer where they will be visible in the final product, rather than attempting to create patterns through layer movement during compaction. The finishing material is applied to the plastic concrete surface, ensuring proper adhesion and pattern formation before the concrete sets.
Solution Approach 2:
The patent introduces a finishing material as an intermediary substance that carries the pigmentation to the concrete surface. This finishing material can be a slurry, paste, or dry mix containing pigments, rock grains, or other coloring agents. It mediates between the compaction process and the desired visual appearance, allowing complex natural stone-like patterns to be created without complicating the fundamental manufacturing process.
2Manufacturing precision
If an applicator throws finishing material onto the surface layer before compaction, then natural stone-like surfaces are achieved, but the device complexity increases
Solution Approach 1:
The patent employs applicators that can be moved over or beside the mold, allowing the finishing material to be applied in a controlled manner. The applicator system is designed to be relocatable and adaptable to different mold configurations, reducing the need for complex fixed installation infrastructure. The system serves itself by being able to position and apply material where needed without requiring elaborate support structures.
Solution Approach 2:
The patent uses movable and adjustable applicators rather than fixed, static application systems. The applicator can be moved over or beside the mold, and its position, speed, and material application rate can be adjusted dynamically. This dynamic approach allows a relatively simple device to achieve complex pattern formation by varying its motion and application characteristics during the process.
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
This approach generates surfaces that closely resemble the natural structure of stones, offering enhanced durability and protection against staining through the use of binders and post-compaction treatments, resulting in aesthetically pleasing and durable concrete products.
Implementation Method 1
the applicator exhibits at least one centrifugal feeder disk or one paddle wheel or one throwing arm or one catapult
Implementation Method 2
if ejection is effected with compressed air
Implementation Method 3
Here vibrations or vibratory impacts, performed uniformly and/or nonuniformly and/or intermittently, are preferably exerted on the metering strip
Implementation Method 4
the concrete is compacted by vibration and/or tamping
Implementation Method 5
the concrete is compacted by vibration and/or tamping
Data Source
AI summary
The invention relates to a method for the production of concrete blocks or concrete slabs of varying formats and sizes, whereby concrete is filled into molds for several blocks or slabs, the surface layer of which or the facing concrete layer of which has a base color and the surfaces, which have regions of difference colors, is puddled by means of vibration and/or compacting and subsequently hardened, whereby, before puddling, at least one portion of a pigmented and/or variously-pigmented and/or a color- and/or various color-containing finishing material is projected or thrown by means of at least one application device.