Automated Bulk Mortar Colorant Mixing System
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Solution Overview
Problem
Existing methods for preparing bulk dry colorant for mortar are labor-intensive, prone to human error, and result in uneven color distribution due to the handling challenges of dry colorant granules, which do not break down sufficiently during mortar mixing.
Innovation Solution
An automated system that precisely measures and mixes primary pigments (black, red, and yellow) to produce dry colorant powder, using a network of pigment dispensers, vibratory trays, and a control unit to ensure accurate and uniform colorant production, reducing the need for large inventory and minimizing manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If dry colorant is processed into granules to improve transfer and handling characteristics, then handling and transfer characteristics are improved, but the granules do not break down sufficiently during mortar mixing resulting in streaks and areas of highly-concentrated color
Solution Approach 1:
The patent changes the physical state parameter of the colorant from granulated form back to fine dry powder form. This parameter change ensures that the colorant can be properly dispersed during mortar mixing while maintaining good handling characteristics through controlled dispensing mechanisms.
Solution Approach 2:
The patent segments the colorant into very fine particles rather than large granules. This segmentation allows the colorant to break down and disperse uniformly during mixing, eliminating the streaking problem while the automated dispensing system maintains handling efficiency.
2Adaptability or versatility
If manual measuring and mixing of colorant batches is used, then flexibility in color preparation is maintained, but the process is labor-intensive and prone to human error
Solution Approach 1:
The system performs self-service by automatically measuring, mixing, and dispensing colorant batches without manual intervention. The automated control system maintains flexibility in color preparation while eliminating labor-intensive operations and human error through programmable precision.
Solution Approach 2:
The patent replaces manual mechanical mixing and measuring with an automated control system that uses sensors, motors, and computer control to precisely manage the colorant preparation process, improving both productivity and accuracy.
3Reliability
If large inventory of pre-batched colorants is maintained, then customer color requirements can be met immediately, but storage space and inventory management requirements increase
Solution Approach 1:
The system performs preliminary action by pre-programming color formulas and setting up the automated mixing system with all necessary pigments. When a color is needed, the system automatically prepares the batch on-demand, eliminating the need for large pre-stocked inventories while maintaining immediate availability.
Solution Approach 2:
The patent changes the inventory strategy from storing large quantities of pre-batched colorants to maintaining smaller quantities of base pigments and mixing them on-demand. This parameter change in inventory management reduces storage requirements while maintaining color availability through rapid automated preparation.
4Productivity
If dry colorant is handled in bulk, then production scale is increased, but the colorant clumps and sticks together forming cakes and lumps that are difficult to transfer
Solution Approach 1:
The patent applies mechanical vibration through vibratory trays to prevent dry colorant from clumping and sticking during bulk handling. The vibration keeps the fine particles flowing freely, enabling large-scale production while maintaining ease of transfer and preventing cake formation.
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 system provides on-demand production of colored mortar with precise color consistency, reducing streaks and inventory needs, while improving handling and transfer characteristics of the dry colorant powder.
Implementation Method 1
a vibratory tray having an exit opening
Data Source
AI summary
A system and apparatus for preparing bulk quantities of dry colorant or pigment for blending with mortar are described. The system mixes pigments of black, red, white and yellow to prepare a batch of the dry colorant having a particular color. The pigments or dry colorant are generally a powder of metal oxide crystals. The system includes pigment dispensers, wherein each pigment dispenser includes a tote that is in flowing communication with a valve. A receptacle receives pigments from the exit opening of the vibratory trays. A control unit serially operates the vibratory trays to dispense the pigment from each tote. A scale measures the weight of the pigments in the receptacle. The scale is in operational communication with the control unit.