Rack-and-Pinion Mortar Applicator for Consistent Joint Application
Solution Overview
Problem
Existing mortar application methods are labor-intensive and result in inconsistent joint quality due to manual application, and existing automated solutions are often complex, bulky, or expensive.
Innovation Solution
A mortar applicator with a duct, piston, pump, nozzle, motor, and rack and pinion assembly, which operates in both discharge and refill modes, allowing for automated and efficient mortar application with a clutch and controller for mode control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual mortar application is used, then flexibility and simplicity are maintained, but labor intensity increases and joint quality consistency deteriorates
Solution Approach 1:
The mortar applicator is designed to be manually operated by the worker themselves, combining automated consistent application with manual control. The device includes a mortar reservoir, application mechanism, and control system that the worker operates directly, eliminating the need for external automation while achieving consistent joint quality through the standardized application process built into the device
2Manufacturing precision
If automated mortar application systems are used, then productivity and joint quality consistency improve, but device complexity and cost increase
Solution Approach 1:
The automated mortar application system is divided into separate modular components: a mortar reservoir, a piston-driven application mechanism, and a control system. This segmentation allows each component to be optimized independently and simplifies the overall system architecture, reducing complexity while maintaining automated consistent application capability
Solution Approach 2:
A piston is introduced as an intermediary mechanism between the mortar reservoir and the application point. The piston provides controlled, consistent mortar discharge through standardized mechanical motion, achieving automated precision without requiring complex electronic control systems or sophisticated dispensing mechanisms
3Productivity
If automated mortar application systems are used, then productivity improves, but equipment bulk and manufacturing cost increase
Solution Approach 1:
The automated mortar application components are arranged in a nested configuration where the piston is housed within the mortar reservoir, and the application mechanism is integrated into the same structural envelope. This nesting reduces the overall equipment volume while maintaining all necessary automated functions for improved productivity
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 mortar applicator provides consistent and efficient mortar application, reducing labor costs and improving joint quality, while being adaptable to variable application requirements.
Implementation Method 1
the pump fills the first variable volume chamber with mortar thereby forcing the piston to retract away from the first end of the duct
Implementation Method 2
a rack and pinion assembly operatively connecting the motor to the piston, the rack and pinion assembly including a rack configured to drive the piston and a pinion connected to the motor
Implementation Method 3
the motor drives the rack and pinion assembly thereby moving the piston toward the first end of the duct to force mortar contained in the first variable volume chamber through the nozzle opening
Data Source
AI summary
A mortar applicator includes: a duct having a first end and a second end; a piston movably mounted within the duct, the piston dividing the duct into first and second variable volume chambers on opposite sides of the piston; a piston actuator operatively connected to the piston, the piston actuator being operable to move the piston within the duct; a nozzle assembly located at the first end of the duct, the nozzle assembly having a tip defining a nozzle opening in fluid communication with the first variable volume chamber to discharge mortar contained therein; and a cover member selectively movable between an open position and a closed position to respectively allow and prevent mortar to be discharged through the nozzle opening; a cover member actuator operatively connected to the cover member, the cover member actuator being operable to move the cover member between the open position and the closed position.