Metering Plate for Paver Block Surface Pattern Control
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Solution Overview
Problem
Existing methods for producing concrete paving blocks with patterned surfaces lack control over the distribution of material mixtures, resulting in unpredictable patterns and particle sizes, making it difficult to replicate natural rock surfaces like granite or diorite within the same production cycle time as plain pavers.
Innovation Solution
An apparatus featuring a metering plate with strategically arranged holes and a rotatable metering member, driven by an electric motor with electronic control, allows for precise application of a mixture of granular material and binder onto the surface of concrete blocks, enabling controlled pattern formation by determining the screen aperture of holes to match the desired grain size and pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mixture of ornamenting material is applied to the surface of concrete blocks by high-speed dispensing apparatus, then the production cycle time is reduced, but the distribution of material particles cannot be controlled and patterns become unpredictable
Solution Approach 1:
A metering plate with specifically arranged holes is introduced as an intermediary element between the dispensing apparatus and the concrete block surface. This metering plate controls the distribution of ornamenting material particles, ensuring predetermined patterns while maintaining high-speed application. The plate acts as a mediator that translates the high-speed dispensing process into controlled, predictable material placement.
Solution Approach 2:
The metering plate is pre-configured with holes arranged in specific patterns before the dispensing process begins. This preliminary arrangement of holes determines the exact distribution pattern of ornamenting material particles on the concrete block surface, allowing predictable pattern formation without requiring real-time control adjustments during high-speed operation.
2Shape
If additive grains are dispersed throughout the total volume of base material to create grainy surface, then aesthetic effect is achieved, but production cost increases significantly
Solution Approach 1:
Instead of dispersing expensive additive grains throughout the entire volume of base material, the invention extracts and concentrates the ornamenting material application to only the surface layer. The metering plate delivers ornamenting particles specifically to the surface of concrete blocks, eliminating the need to mix additives throughout the bulk material, thereby significantly reducing material costs while maintaining aesthetic quality.
Solution Approach 2:
The invention applies ornamenting material locally to the surface of concrete blocks rather than uniformly throughout the entire volume. The metering plate creates localized grainy patterns only where needed on the surface, providing aesthetic quality where it matters most while minimizing the use of expensive additive materials in the base concrete mixture.
3Loss of substance
If baffle plates are used to prevent scattering loss of material particles, then material efficiency is improved, but the spray pattern is spoiled and particles accumulate in wrong places
Solution Approach 1:
The metering plate serves as a precise intermediary that replaces the need for baffle plates. Instead of using broad scattering-control structures that compromise pattern quality, the metering plate's precisely arranged holes provide both scattering control and pattern definition simultaneously, eliminating material waste without sacrificing distribution precision.
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
Enables the production of paving blocks with surface patterns resembling natural rocks, allowing for predetermined pattern and particle distribution, while maintaining the same production cycle time as plain pavers, ensuring consistent and aesthetically pleasing results.
Implementation Method 1
an actuator for moving the metering member, wherein the actuator is a shaft
Implementation Method 2
a metering plate provided with holes, and a metering member rotatable around its shaft and provided with blades fitting with the inner surface of the metering plate
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
This invention relates to a method and apparatus for producing paving blocks (K) having ornamented surface, and the apparatus consiss of a starting table (1), and a filling carriage (2) movable along a guide rail (3) towards and above a forming mould (4) comprising at least one mould cavity (4a) and connected to the starting table (1) is arranged; and in an interior space of the filling carriage (2) a first chamber for receiving base material (6a) and at least one second chamber (6b) for receiving ornamenting material are formed and separated by a septum (v), and a feeding device (7) for dispensing a mixture of ornamenting material is arranged in said second chamber (6b), characterized in that the feeding device (7) is formed by a metering plate (9,91,92,93) provided with holes (9a) and a metering member (10,101,102,103) fitted to and movable along the metering plate (9,91,92,93), and further provided by an actuator for moving the metering member (10,101,102,103).