Grouting Pan Curved Sidewall Filling Composite Floor Voids
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Solution Overview
Problem
Existing methods for grouting composite surfaces, such as epoxy and terrazzo floors, are inefficient in completely filling surface imperfections like pin holes and subsurface voids, as they often leave behind imperfections due to the manual nature of the process and the inability to consistently push mortar into voids.
Innovation Solution
A grouting pan with a curved sidewall and planar bottom surface, designed for use on finishing machines, that rotates to push mortar into surface imperfections and mix fillers with the mortar, effectively filling voids and smoothing the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand trowelling is used to apply mortar to the composite surface, then the process is simple and requires minimal equipment, but the mortar cannot consistently fill subsurface voids and surface imperfections
Solution Approach 1:
A grouting pan with specific geometric features (curved sidewall, angled portion, rounded edge portion, and obtuse included angle) is introduced as an intermediary tool between the mortar and the composite surface. This pan acts as a mediator that transforms the application method, allowing mortar to be forced into voids through rotational motion while maintaining a relatively simple overall system.
Solution Approach 2:
The grouting pan is designed to be rotated during the grouting process, transforming the static hand trowelling method into a dynamic application process. The rotation enables the pan to push mortar into voids from multiple angles and directions, significantly improving filling completeness while adding only minimal mechanical complexity.
2Shape
If the top layer is rough cut to even out surface imperfections, then the surface becomes more uniform, but pin holes remain and subsurface voids may be opened to the surface
Solution Approach 1:
The grouting process is performed after rough cutting as a preliminary filling operation before final finishing. The grouting pan forces mortar into voids and pin holes created or exposed during rough cutting, addressing these defects before the surface receives its final treatment, thereby preventing them from affecting the ultimate surface quality.
3Manufacturing precision
If mortar is applied and trowelled over the surface, then some voids are covered, but the trowel pulls mortar out of voids as it moves past, leaving imperfections
Solution Approach 1:
The grouting pan is rotated during application, creating a dynamic pressing action that continuously forces mortar into voids rather than allowing the trowel to simply pass over them. This rotational motion transforms the operator's action from a passive spreading motion to an active pressing and forcing motion, significantly improving void filling effectiveness.
Solution Approach 2:
The grouting pan features a curved sidewall with specific geometric characteristics including an angled portion, rounded edge portion, and obtuse included angle. This curved geometry concentrates pressure onto the mortar and voids, enabling more effective forcing of mortar into imperfections compared to a flat trowel surface.
Data Source
AI summary
Methods and apparatus are provided for finishing a composite floor. The apparatus includes a grouting pan configured to be affixed to the rotating head of a finishing machine. The grouting pan has a planar bottom surface and a curved sidewall. Grouting pans are rotated over a prepped surface such that the curved sidewalls trowel the mortar onto the rough composite surface and the bottom surface which is in contact with the prepped floor forces the mortar into the surface voids such that a grouted surface.