Portable Sponge-Band Grouting Machine for Vertical Clad Walls
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Solution Overview
Problem
Existing grouting and cleaning machines are not suitable for vertical walls due to their dimensions and weight, making manual operation slow, laborious, and uncomfortable, and are not adaptable for vertical surfaces.
Innovation Solution
A portable grouting-cleaning machine with a lightweight aluminum frame, a motorized sponge band system, and safety features that allow easy handling and operation on vertical walls, incorporating a container for wash water and detergent, and adjustable feet for use on both vertical and horizontal surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a motorized grouting machine with wheels is used, then the grouting operation is mechanized and productivity increases, but the machine becomes too heavy and large to be supported by an operator at required height on vertical walls
Solution Approach 1:
The machine is divided into two separable structures (first structure with motor and sponge band, second structure with water container) that can be connected or used independently. This segmentation allows the operator to use only the lightweight first structure for vertical wall work while maintaining mechanized grouting capability, thus resolving the contradiction between productivity and portability.
Solution Approach 2:
The invention transitions from floor-based horizontal operation to wall-based vertical operation by providing a mounting structure that attaches to vertical surfaces. This dimensional change allows the lightweight first structure to be positioned at required heights on walls, enabling mechanized grouting on vertical surfaces without requiring the operator to support heavy equipment.
2Device complexity
If manual grouting with sponge is used, then the machine weight and complexity are minimized, but the operation becomes slow and laborious requiring frequent immersion in water
Solution Approach 1:
The sponge band is pre-loaded with grout and water in the first structure before operation begins. This preliminary preparation eliminates the need for frequent interruptions to replenish materials during grouting, significantly increasing productivity while maintaining relatively simple device structure. The pre-loaded system allows continuous operation without manual intervention.
Solution Approach 2:
The endless sponge band provides continuous grouting action as it moves along the deviation roller and applies grout to tile gaps. This continuous operation eliminates the stop-start nature of manual sponge grouting, maintaining simple device structure while dramatically improving productivity through uninterrupted grouting and cleaning cycles.
3Productivity
If a sponge band system with water container is used, then cleaning efficiency improves, but the machine becomes too heavy for portable use on vertical walls
Solution Approach 1:
The water container is placed in a separate second structure that can be connected to or separated from the first structure. For vertical wall applications, only the lightweight first structure is used, providing portability. The second structure with water container can be attached when working on horizontal surfaces where weight is less critical, thus resolving the contradiction between cleaning efficiency and portability.
Solution Approach 2:
The first structure is designed to function independently for vertical wall applications and can also connect to the second structure for horizontal surface work. This multi-functionality allows the same core mechanism to serve different applications with different weight requirements, enabling efficient cleaning on vertical walls with minimal weight while maintaining the option for enhanced cleaning capacity on horizontal surfaces.
4Stability of the object's composition
If the machine is designed for horizontal surfaces only, then the structure can be optimized for stability, but it cannot be used on vertical walls
Solution Approach 1:
The machine provides dynamic adaptability through the ability to switch between two operational modes: mounted on vertical walls using the first structure alone, or positioned on horizontal surfaces using both structures connected. This dynamic configuration change allows the machine to optimize its stability for each surface type while maintaining versatility across different applications.
Solution Approach 2:
The machine is designed with universal applicability to both vertical and horizontal surfaces. The first structure with mounting capability enables vertical wall operation, while the option to connect the second structure provides stability for horizontal surface work. This multi-functionality resolves the contradiction between stability optimization for a specific surface type and adaptability to multiple surface types.
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 rapid, efficient, and safe mechanization of grouting and cleaning operations on vertical and horizontal surfaces, reducing operator fatigue and improving operational consistency.
Implementation Method 1
a band (6) of spongy material which, during its movement, is passed through a container (8) containing wash water
Data Source
AI summary
A portable grouting-cleaning machine for clad vertical walls includes a frame, an upperly open water container of essentially vertical extension supported by the frame, an endless sponge band stretched between deviation rollers positioned such to form a straight vertical sponge portion to rest against the wall to be treated, the deviation rollers having at least one motorized roller and at least one roller housed in the container, to form a loop of the band therein, two handgrips positioned side by side on the portable frame, and grippable by the operator during the machine operation, and at least one pushbutton, fixed on the frame of machine, connected into the power circuit of an electric motor which drives the motorized roller and is driven by the operator who grips the handles.