Mortar Extrusion System with Recirculation Valve
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Solution Overview
Problem
Existing mortar application methods are inefficient and labor-intensive, leading to uneven mortar distribution and increased labor costs, as they often rely on manual application and gravitational feed systems that result in inconsistent mortar thickness and can cause mortar to harden in tools, requiring frequent cleaning.
Innovation Solution
A mortar extrusion and deposition system with a remotely supplied mortar gun that uses a flexible hose to extrude continuous ribbons or beads of mortar, featuring a rotating port valve to control mortar flow and recirculate it back to the hopper when not in use, preventing drying and allowing continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual mortar application is used, then labor flexibility is maintained, but application speed and consistency deteriorate
Solution Approach 1:
The patent replaces manual mechanical application with an automated extrusion system that uses a pump-driven hose to deliver mortar precisely to the application point. The mechanical system substitutes human hand movements with controlled extrusion through a hose, achieving both speed and consistency while requiring minimal operator intervention beyond triggering the extrusion mechanism.
Solution Approach 2:
The mortar application system is segmented into separate functional components: a remote mortar source, a delivery hose, an extrusion mechanism, and an application tool. This segmentation allows the heavy mortar supply to be positioned away from the application area while maintaining precise control at the point of use, improving both productivity and operational ease.
2Device complexity
If gravitational feed systems are used, then equipment complexity is reduced, but mortar flow consistency deteriorates
Solution Approach 1:
The patent replaces gravitational feed with a pump-driven mechanical feed system. The pump provides controlled positive displacement of mortar through the hose, ensuring consistent flow rate and pressure regardless of hose length or elevation changes. This mechanical substitution eliminates the thickness variation problem inherent in gravitational systems while adding manageable complexity through the pump mechanism.
3Manufacturing precision
If mortar is pumped to application tools, then application precision is improved, but tool clogging increases
Solution Approach 1:
The patent implements continuous circulation of mortar through the hose and application tool, even when not actively applying. The pump maintains mortar flow to prevent stagnation and curing inside the system, eliminating the root cause of clogging and jamming. This continuous action ensures the tool remains clear and ready for immediate use without manual clearing operations.
Solution Approach 2:
The system recirculates mortar that would otherwise be wasted or cause clogging. By continuously moving mortar through the system and back to the source, the patent recovers material that might otherwise harden in the hose or tool, maintaining both precision and reliability over extended operation periods.
4Ease of manufacture
If heavy mortar supply is positioned at application point, then material delivery is simplified, but substrate distortion increases
Solution Approach 1:
The system segments the mortar supply from the application point using a flexible hose as the connecting medium. The heavy mortar source can be positioned anywhere within reach, separated from the lightweight application tool that contacts the substrate. This segmentation eliminates the distortion problem while maintaining simple material delivery through the flexible connection.
Solution Approach 2:
The flexible hose acts as an intermediary between the heavy mortar supply and the lightweight application tool. It transmits mortar under pressure while allowing the tool to remain light and non-intrusive to the substrate, preventing distortion while ensuring reliable material delivery to the application point.
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 faster and more precise mortar application with consistent thickness, reducing labor costs and improving masonry efficiency by allowing less experienced workers to achieve high-quality results while minimizing tool maintenance and mortar wastage.
Implementation Method 1
a pump operable to deliver pressurized fluid material from the remote supply through the hose to the chamber
Implementation Method 2
a rotatable port valve positioned at the inlet end of the hose and operable to redirect the pressurized fluid material back to the supply
Data Source
AI summary
A method for continuously extruding and depositing an unbroken layer of a slurry or mortar onto a selected work surface uses a mortar gun assembly with a chamber for receiving mortar from a remote supply hopper and an extruder configured to selectively apply a bead or ribbon of mortar of selected thickness onto the work surface. The user selectively applies mortar by controlling a rotating port valve between the hopper and the mortar gun chamber, and the rotating port valve provides a “rest state” in which the mortar is not sent to the mortar gun, but is instead re-circulated by the pump back to the hopper so un-dispensed mortar is kept moving and cannot dry or set.