Vibratory Concrete Float Additive Broadcaster for Uniform Color Application
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Solution Overview
Problem
Existing methods for adding pigments and colorants to concrete result in waste due to monolithic mixing, non-uniform color application, and health risks from manual dispersion, as they require mixing before shaping and often lead to uneven distribution and inhalation hazards.
Innovation Solution
A concrete float with a vibratory broadcaster assembly is used to selectively apply dry color hardener or additives to specific areas of a concrete surface, allowing controlled dispersion and integration into the concrete as it is finished, reducing waste and health risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pigments are added to the entire batch of concrete before mixing, then the concrete achieves uniform color throughout, but this results in waste of pigment since much of the concrete will be hidden and not visible after finishing
Solution Approach 1:
The patent applies local quality by transitioning from global (batch-wide) pigmentation to localized (surface-level) pigmentation. The color hardener is applied only to the specific surface areas that will be visible after finishing, rather than mixing pigment into the entire concrete batch. This allows different regions of the concrete to have different color characteristics based on their final visibility, eliminating waste while maintaining aesthetic quality where needed.
2Ease of manufacture
If manual hand application of color hardener is used, then the process is simple and requires no special equipment, but this results in non-uniform color distribution and health hazards from powder inhalation
Solution Approach 1:
The patent introduces an intermediary device (the vibratory broadcaster attachment) that mediates between the operator and the concrete surface. This attachment provides controlled distribution of color hardener through vibration, ensuring uniform application without requiring the operator to manually handle and throw powder. The intermediary device eliminates direct contact with harmful powder while maintaining application simplicity through easy attachment and operation.
3Manufacturing precision
If the entire concrete batch is re-introduced to the coloring system for deeper color, then the desired color intensity is achieved, but this increases pigment waste and extends processing time
Solution Approach 1:
The patent applies preliminary action by providing controlled, concentrated application of color hardener to the surface from the beginning. The vibratory broadcaster delivers sufficient pigment in a single pass to achieve the desired color intensity, eliminating the need for re-processing the entire batch. This preliminary, targeted application prevents both time loss and additional pigment waste that would result from multiple mixing cycles.
4Productivity
If color hardener is applied by hand during finishing, then the additive can be applied during the finishing process, but this creates health hazards and environmental contamination from dispersed powder
Solution Approach 1:
The vibratory broadcaster attachment serves as an intermediary that eliminates direct human exposure to color hardener powder. The device mechanically distributes the pigment through vibration, containing the powder within the attachment mechanism and preventing it from becoming airborne. This intermediary approach maintains productivity by enabling continuous application during finishing while protecting worker health and preventing environmental contamination.
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
This method enables efficient, controlled, and safe application of colorants or additives to concrete surfaces, reducing waste and ensuring uniform color distribution while minimizing health hazards, allowing for targeted application and conservation of materials.
Implementation Method 1
The broadcaster assembly is suspended above the plane of the finishing tool, such as a bull float or other finishing tool, with a vibratory source attached
Implementation Method 2
a worker will take a handful of powderized color hardener and disperse it over the slab, in effect flinging a handful of dry color hardener powder into the air which disperses and falls by gravity on to the wet or plastic concrete surface
Data Source
AI summary
The apparatus and method comprise a concrete float with a vibratory additive broadcaster assembly attached therewith. The broadcaster assembly is suspended above the plane of the finishing tool with a vibratory source attached. The broadcaster assembly is filled with an additive and the apparatus is placed on a wet, concrete surface which is to be treated and finished, by a user. Actuation of a power switch by the user activates the vibratory source resulting in the substantial broadcast of additive on to the concrete surface at the desired location(s) on the slab as determined by the user. The additive is then integrated into the concrete by passage of the float over the treated concrete surface.