Concrete Slatted Grating Surface Texturing via Embossing
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Solution Overview
Problem
Existing methods for producing longitudinal slatted grating elements for animal stalls, such as cutting or milling grooves into concrete, can damage the concrete structure, reduce mechanical strength, and create sharp edges, while rubber coverings require careful monitoring and may not provide sufficient traction to prevent slipping.
Innovation Solution
A method and device that use a vibrating table and embossing elements to create surface structures on fresh concrete, such as triangular grooves, which improve grip without damaging the concrete and reduce the risk of injury from sharp edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If grooves are cut or milled into the concrete surface after demolding, then surface texture is created to improve grip, but the concrete structure is damaged and mechanical strength is reduced
Solution Approach 1:
The surface texture is created during the casting process before the concrete hardens, by pressing embossing elements into the fresh concrete. This preliminary action avoids the need for subsequent cutting or milling operations that would damage the hardened concrete structure and reduce mechanical strength.
Solution Approach 2:
The invention replaces the mechanical cutting/milling system with an embossing system that uses vibration and pressure to create surface textures in fresh concrete. This substitution eliminates the harmful effects of cutting while achieving the same grip improvement function.
2Ease of operation
If grooves are cut or milled into the concrete surface, then surface texture is created, but sharp edges are formed that can injure animals
Solution Approach 1:
The embossing elements create rounded surface textures by pressing into fresh concrete before hardening. This preliminary shaping action produces smooth, rounded edges rather than sharp cuts, eliminating the injury hazard while maintaining the grip-enhancing surface texture.
3Ease of operation
If rubber coating is pressed into fresh concrete, then surface structure is created, but concrete displacement must be carefully monitored to ensure proper flow out of the mold
Solution Approach 1:
The embossing elements are removed from the concrete surface after creating the texture pattern. This extraction simplifies the process by eliminating the need to monitor concrete flow around embedded rubber elements, while still achieving the desired surface structure for improved grip.
4Productivity
If the entire surface is structured using a stamp or die, then surface texture is applied, but the process requires subsequent blasting with liquids or solids
Solution Approach 1:
The embossing elements create the complete surface texture pattern directly during the casting process. This preliminary action eliminates the need for subsequent blasting operations, reducing both device complexity and processing time while maintaining productive surface structuring.
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 method enhances the surface properties and mechanical strength of the grating elements, providing improved traction and safety by creating localized depressions that enhance grip without compromising the structural integrity of the concrete.
Implementation Method 1
vibrating the mold during the filling process to achieve a uniform concrete distribution in the casting cavities
Implementation Method 2
the surface texture being produced by applying a vibrational motion to the at least one embossing element
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A device and a method for manufacturing a longitudinal gap grate element made of concrete are provided, wherein the longitudinal gap grate element comprises at least two spaced-apart longitudinal beams arranged in one plane and at least two spaced-apart transverse beams arranged in the plane of the longitudinal beams and crossing the at least two longitudinal beams, wherein a longitudinal gap is defined by two adjacent longitudinal beams and two adjacent transverse beams.The manufacturing process comprises the following steps: placing a mold on a vibrating table, the mold having upward-opening casting cavities that define the shape of the longitudinal and transverse beams; filling the open casting cavities with concrete to form the longitudinal and transverse beams; vibrating the mold during the filling process to achieve a uniform distribution of concrete in the casting cavities; creating a surface texture at least along the longitudinal beams by locally pressing at least one surface-texturing embossing element into the concrete of the longitudinal beams on the exposed surface of the longitudinal beams; removing the at least one embossing element pressed into the concrete; and releasing the longitudinal gap grate element thus formed from the mold.