Method for manufacturing a wall, building element for constructing a wall, building element set and building shell

Abstract

Method (1000) for manufacturing a wall (200, 300, 3000a), comprising: computer-aided design (1010) of the wall (200, 300, 300a), wherein the wall (200, 300, 300a) has an installation channel (1); computer-aided disassembly (1020) of the constructed wall (200, 300, 300a) into building elements (100, 110, 120, 130, 140, 150, 160), wherein a plurality of adjacent building elements (100, 110, 120, 130, 140, 150, 160) comprise at least one section of the installation channel (1); Computer-aided creation (1030) of a control data set for controlling an additive manufacturing device (500) configured to individually provide the plurality of components (100, 110, 120, 130, 140, 150, 160) from at least one building material; additive manufacturing (1040) of the plurality of components (100, 110, 120, 130, 140, 150, 160) for the wall (200, 300, 300a) using the additive manufacturing device (500) with the control data set;and typically erecting the wall (1100) by an orderly joining of the multitude of manufactured building elements (100, 110, 120, 130, 140, 150, 160) comprising forming a bond (200, 300, 300a) of the building elements 100, 110, 120, 130, 140, 150, 160).;

Description

[0001] The invention lies in the field of the construction industry and civil engineering, in particular the application of additive manufacturing processes for the construction of buildings in the residential, industrial, commercial, administrative, and agricultural sectors. The proposed method also falls under the category of building services engineering and building technology, which, as is well known, encompasses all measures necessary for making buildings usable. Prior art

[0002] When building a small or medium-sized house, such as a detached house, a shell is first constructed, which is then equipped with the necessary infrastructure, such as electrical wiring, water / sewage, air conditioning and / or heating. During this process, some of the material erected as the shell is removed to make room for the installation of cables, pipes, air ducts, etc. Disadvantages of the state of the art

[0003] The described procedure is labor-intensive and time-consuming, and the installation of cable ducts, wall penetrations, etc., leads to unnecessary dust, debris, and noise. Subsequent milling of cable ducts into already finished walls for concealed wiring or the covering of pipes with cover plates can hardly be considered resource-efficient. Recesses and channels in the wall, or ultimately in the wall components, serve, in the broadest sense, the building services engineering. Hereinafter, they will be collectively referred to as installation channels. Problem statement

[0004] Against this background, it is an object of the present invention to provide a method, here also referred to as a process chain, for the construction of a fully usable building, for example a residential building, or another building, for example a garden shed, a stable, a transformer station, a waiting shelter, a distribution station, a protective wall, etc., which avoids the aforementioned disadvantages.

[0005] A further object of the present invention is to enable the installation and commissioning of the described technical infrastructure or supply technology for the corresponding building, which is the subject of the so-called technical building equipment, with a significantly reduced workload and thus lower costs than for conventional methods. Inventive solution

[0006] A solution to this problem is provided by the additive manufacturing process proposed here for individual wall components, from which the wall can be constructed. The proposed process is described below with process steps suitable for manufacturing a wall as an elementary component of the structures mentioned above. The components can be considered multifunctional building blocks or a kit comprising such building blocks. A corresponding kit is thus suitable for constructing a building that includes at least one service duct, or at least for constructing a wall that includes a service duct.

[0007] The building components of the kit will be referred to simply as building blocks in the following text. The terms "building component" and "building block" are used synonymously in the following text and its associated requirements: A "building block" suitable for constructing a building or parts thereof, such as a wall, including a load-bearing wall, does not necessarily have to be made of stone, nor does it have to have the traditional cuboid shape of a brick. As can be demonstrated, for example, by the walls of Machu Picchu, a 2D puzzle, a geometry puzzle, the video game "Tetris," or even a 3D puzzle, a "building block" can certainly have different contours and shapes that deviate from the form of a rectangle or a cuboid, and yet still result in a completely closed structure.

[0008] Typically, the external form of the building elements described herein can be characterized as ultimately reducible to essentially cuboid-shaped basic elements. The multitude of proposed building elements are therefore not necessarily brick-shaped, but rather, in a planar projection of their side view, as in the computer game "Tetris" or in certain types of 3D puzzles when assembled, also as... or to be considered structural elements with a distinctive shape. The structural elements proposed according to the invention can therefore be compared in their external shape to etc. -shaped “building blocks”, whereby the examples given above only represent a projection of three-dimensional blocks onto a two-dimensional surface. However, it is also possible that the building elements described herein have curved (outer) surfaces (shell surfaces), e.g., shaped like a hollow cylinder segment or a curved beam. Apart from any cavities / pass-throughs for one or more installation channels or sections thereof, the shape of the building elements described herein typically corresponds to an extruded body (in the geometric sense, more generally a cylinder in the mathematical sense), whose flat base is surrounded or even defined by an (outer) contour such as a rectangle or another polygon. The (outer) contour may also have or consist of curved sections, in particular those that cannot be produced by extrusion.This also applies to one or more optional inner contours. For the sake of readability, the following description often refers to the commonly used, essentially cuboid-shaped components.

[0009] Typically, only the aforementioned "multiple components" are involved in forming a wall installation channel. Similarly, components that do not include a section of the installation channel are typically manufactured according to the proposed method. A wall constructed using this method, i.e., the wall built with the components manufactured according to this method, is typically at least 1 m wide and 1 m high, preferably at least 2.50–2.80 m high.

[0010] The individual building blocks, which are at least partially multifunctional (i.e., each comprising a section of installation channel), are configured for the construction of a functional overall structure, such as a freestanding wall or a building with multiple walls. The walls can serve as load-bearing walls or non-load-bearing walls, e.g., partition walls or protective walls. Thus, each of the additively manufactured individual building blocks is a component of the respective functional overall structure.

[0011] In particular, the described problem is solved by the disclosed manufacturing process for a wall comprising a multitude of structurally and functionally coordinated building blocks or components. The multitude of building blocks, i.e., the multitude of components, of the wall are configured with regard to their material composition, their shape, and ultimately their load-bearing capacity (final strength) for the construction of a structure, for example, a building. The proposed method includes the design and / or planning, typically computer-aided design, of the structure according to architectural, and optionally also interior design, considerations. In contrast to previously known methods, the proposed method includes essential aspects of the respective planned technical building services or the corresponding building equipment. The terms technical building equipment and service structure, respectively, are defined as follows:Building services engineering describes technical measures that serve the energy supply (heating, cooling, and lighting), material supply (water supply, ventilation), and / or waste disposal of buildings. As a result of the technical building equipment, the building is not only made usable or habitable for the users / residents, but optionally also ensures the fulfillment of safety requirements. Examples of safety requirements include devices or components of alarm and security systems, such as burglar and fire protection systems. The method proposed here, by providing a complete set of building components for the completion of the building, offers advantages for the fields and trades of electrical engineering, building automation, HVAC, plumbing, heating, and cooling technology.

[0012] According to various embodiments, at least a large number of the proposed building components have installation channels or sections of an installation channel for conveying liquids, such as drinking water, process water, and wastewater. According to this and other embodiments, or additionally, the conveyance of gases, particularly air, can be achieved within the building components arranged together in a structure—the wall. Possible applications include, for example, systems for ventilation, exhaust air, and / or air conditioning. The proposed process chain for manufacturing the wall further comprises the additive manufacturing of a large number of building components required for the construction of the planned wall and / or building, and optionally, their material- and / or form-fit joining or installation into a brickwork structure that can be part of a building, such as a structure.

[0013] (1) According to one embodiment, a method for producing a wall is proposed which comprises the following process steps: - computer-aided construction, encompassing or synonymous with building construction, design, planning or design of the wall, wherein the wall has an installation channel and optionally an additional opening, selected from a door opening and a window opening; - computer-aided disassembly of the constructed wall into virtual building elements, wherein a plurality of mutually adjacent virtual components comprise at least a section of the installation channel and / or optionally a section of one of the openings mentioned above; - computer-aided creation of a control data set for controlling an additive manufacturing device configured to individually provide at least the multitude of individual components as a result of a manufacturing cycle; and - additive manufacturing of the multitude of individual components for the wall using the additive manufacturing device and the control data set; and typically - Erecting the wall by orderly joining the multitude of manufactured building elements, including forming a bond between the building elements.

[0014] The aforementioned control data set typically comprises CAD / CAM data, for example, in the form of an STL file. The control data set is configured to control the functions of an additive manufacturing device, for example, to control a print head of a 3D printer, or to control the interaction of the print head with a laser of the device; and / or to control the targeted interaction of a laser and / or a print head with a squeegee of the device. As a result of the aforementioned control processes, at least the multitude of adjacent components of the planned wall can be individually additively manufactured. The control data set therefore comprises a corresponding multitude of control data, each specifically and precisely corresponding to one component from the multitude of virtual components and thus ultimately to the multitude of components to be physically manufactured.are required for their additive manufacturing and are used during the manufacturing process.

[0015] If the device in question includes a 3D printer, the printing material can be, for example, in the form of a filament. The filament is plasticized, partially melted, and / or partially melted by the print head and, for example, placed on a build platform and applied step by step or layer by layer until the component or a blank thereof is fully formed.

[0016] If the device in question includes a doctor blade, a laser, and / or a printhead, the processed material can be in the form of a dry powder or a suspended powder, such as a slurry or a paste. The dry powder, slurry, and paste are applied layer by layer using the doctor blade or a corresponding element, such as a roller or a brush (which may also be rotating). This is typically done by stacking layers on a work platform within a work chamber of the device. The laser can be used for the sequential, localized melting or fusion of powder components in one or more layers of the resulting powder or slurry bed.The printhead typically serves to apply a binder or a second building material to the uppermost layer of the layer stack before the next layer is applied and processed or structured according to the contours applicable to that layer. In this way, the component or a blank thereof is formed layer by layer.

[0017] The described method advantageously enables the material-, time-, and cost-saving production of a wall or even a building shell, or at least of a wall or a section of one or more walls. A particular advantage arises for the design of the building in question, as the wall can be designed as a freeform surface, meaning its outer contour can be complexly curved. In this context, a freeform surface is understood to be a closed wall surface that deviates from a flat surface, for example, one that has curves and / or bulges or is provided with door and / or window openings and / or niches.

[0018] The advantages of this manufacturing process are that the building components, and ultimately the walls constructed with them, offer the structural engineer, architect, or client maximum design freedom. For example, buildings can be erected that are inspired by living nature (biomimetic) and / or utilize principles of bionics.

[0019] The functional arrangement and routing of installation channels and / or recesses for supply and signal lines in the building components or the wall enables the intended arrangement of electrical cables (cable ducts) and / or the intended routing of fluids and / or the intended arrangement of corresponding hoses and / or pipes within the building, without the need to remove previously erected material. Advantageously, the disclosed method allows the arrangement and routing of required installation channels within the proposed system components, within a wall comprising a brick bond, or throughout the entire structure to be predetermined during the building design phase, without the time-consuming removal of the material erected during the construction phase, which would involve dust, debris, and noise.

[0020] (2) According to one embodiment, the proposed method involves the computer-aided decomposition of the constructed wall into virtual components layer by layer. The constructed structure, in the simplest case the constructed wall, is decomposed into individual virtual layers. These virtual layers are adjacent to each other and extend essentially horizontally. The computer-aided decomposition step is comparable to a process commonly referred to as slicing in additive manufacturing. During decomposition, the resulting virtual layers are themselves divided into a sequence of virtual components comprising the aforementioned plurality of adjacent components.

[0021] The resulting building elements – initially virtual – are essentially similar in their external form to conventional bricks. In other words, the corresponding control data sets describe at least two parallel surfaces of the virtual building element: a base or mounting surface on the underside and a top surface on the upper side, as well as the sections of the installation duct arranged within the space defined by these surfaces.

[0022] Advantageously, the physical components obtained as a result of the additive manufacturing process have an essentially cuboid shape when viewed from the outside. More generally, i.e., excluding any cavities, installation channel sections, or penetrations, the components have the geometric form of extruded bodies, or more generally, the mathematical form of cylinders. They can be arranged, or "laid down," similarly to bricks, so that ultimately the wall can be formed, or at least those sections of the wall that contain the installation channel. It goes without saying that the components manufactured using the proposed method can be adapted so that they can be installed together with conventionally manufactured components, such as hollow blocks, window lintels, or door lintels.For structural reasons, a lintel typically does not have an installation channel. However, according to embodiments, window and door lintels can also be manufactured using the described method and can advantageously even be equipped with corresponding additional, integrated stiffening elements or effectively stiffening internal structures.

[0023] (3) According to one embodiment, the division of the adjacent virtual layers into virtual components described above is carried out in such a way that substantially vertically arranged surfaces of the components of directly adjacent layers forming a wall surface are offset from each other.

[0024] A key advantage of the additive manufacturing process is the ability to create a brick bond pattern. Such a brick bond can, for example, include a stretcher course, where the elements of a course are arranged so that a wider side of the elements forms a wall surface. The achievable brick bond can also include a header course or be comparable to one if the elements are oriented so that their narrower ends form a wall surface. Similarly, the brick bond, initially achieved only virtually, can feature a rowlock course, a specific type of header course. Compared to the latter, the elements (comparable to bricks) are rotated by 90 degrees.Finally, the constructible wall surface can feature a so-called soldier course, in which "bricks," essentially cuboid building elements, are arranged side by side in a standing position, so that the broad sides of the building elements form the wall surface. The advantages of this type of bond, or rather the computer-aided division of a layer of the constructed wall into the aforementioned stretcher course, header course, rowlock course, and / or soldier course, arise from decorative aspects, but primarily from structurally stabilizing effects for the wall ultimately erected from the physically manufactured building elements. Naturally, the aforementioned variety of shapes of the building elements, which are typically based on cuboid elements, allows for numerous different arrangements of the building elements in a wall than are possible with bricks in a masonry structure.In particular, interlocking and interlocking arrangements of the building elements, rather than just layered “stacked”, can be provided in the wall ultimately achieved.

[0025] (4) According to one embodiment, the process steps “creating the control data set” and “additive manufacturing” are adapted such that the control data set controls the additive manufacturing device in such a way that the section of the installation channel is provided with at least two openings, wherein a plane of a first cross-sectional end surface of the installation channel section is oriented substantially parallel or substantially orthogonal to a plane of a second cross-sectional end surface of the installation channel section of the manufactured component.

[0026] Thus, the building element manufactured according to this embodiment differs from conventional building blocks, such as hollow blocks or hollow concrete blocks, which typically have one, two, or more straight, continuous "channels." These channels are typically vertically oriented when installed. Functionally, these channels serve, for example, to improve sound and heat insulation. They generally remain at least partially empty, filled with air, and are not permeated by fluids. As a rule, they are sealed by the mortar layers used when the hollow concrete blocks are installed. However, they can also be used to achieve greater stability in the resulting wall. For this purpose, reinforcing bars, such as rebar (ribbed steel), are inserted into channels of stacked hollow concrete blocks and encased in concrete.Building walls are also known where, for improved stability, for example in earthquake-prone areas, the bricks are additionally secured by long screws and nuts fastening the masonry in channels formed by several stacked bricks. The installation channels of the building elements described here typically serve a different function.

[0027] (5) According to one embodiment, the proposed wall manufacturing process includes the process step "wall formation." The wall is formed by the orderly and thus intended joining of the numerous building elements, which are initially only virtually adjacent to one another. The adjacent building elements are optionally fixed with an adhesive, for example, with a glue, mortar, or cement, in a bond or arrangement, e.g., in the form of an arrangement that forms the wall. In the case of using conventional masonry units to construct a wall, their bond is usually referred to as a brick bond. The term "building element bond" is used analogously here.

[0028] The building elements are advantageous not only in terms of their configuration for the installation channel inside the wall, but also because their respective external shapes are designed to create a largely or nearly form-fit connection. The width of one or more joints between adjacent building elements can be specified as desired and / or required via the process step "computer-aided creation of a control data set...", i.e., tailored to the respective adhesive and any applicable building standards and / or regulations.

[0029] (6) According to one embodiment, the installation channel is adapted with regard to its dimensions: its cross-section, length, width and depth, its position relative to a side surface of the component, its surface properties such as structure, porosity, wetting properties, the material of its channel walls, etc., for an installation, e.g., for receiving and / or guiding a cable, in particular a power cable, a signal line, an optical fiber or a light guide, a pipe, for example, a flexible hose, and / or for transporting a fluid. The fluid arranged and / or transported or transportable in the channel is selected from: drinking water, process water, wastewater, a fire extinguishing liquid, a fire extinguishing foam, a gas (e.g., a fire extinguishing gas such as argon for oxygen displacement in a server room), and a gas mixture (e.g., supply or exhaust air, air conditioning, etc.).including humidified or dehumidified air.

[0030] Advantages arise from the diversity of the respective installations and the applications that can be developed. It was mentioned at the beginning that the technical equipment of a building is what makes it usable in the first place, for example, habitable.

[0031] (7) According to one embodiment, the plurality of components comprises at least 3, preferably 3 to 1 million, more preferably 10 to 50,000 pieces.

[0032] It is assumed that the shell of a house can typically weigh 100 tons or more. Advantageously, the building components required for its construction have an average mass of approximately 5-10 kg. Components of this mass are individually easy and precise to handle. The term "handleability" here refers both to a structure literally built by human hands and to one assembled with adapted machinery, such as a robot, crane, forklift, or transport drone. The requirement for precise handling arises from the need for an exact and precise arrangement of the components forming the wall(s) and the functionally required integrity of the associated service ducts.Components weighing more than approximately 10 kg require significantly more robust and complex assembly systems due to their moment of inertia during movement, which in turn leads to higher costs. Lifting heavier loads, and even more so precisely positioning them, is physically demanding and becomes unreasonable or even impossible over extended periods.

[0033] (8) According to one embodiment, the component produced as a result of the method has a substantially cuboid shape and / or is reducible to cuboid basic shapes, typically having anchoring structures on opposite sides which, by their respective size, shape and position, in other words, by their location and fit, are such that at least sectionally an engagement can be formed between a first anchoring structure of a first component and a second anchoring structure of a second component which is arranged in the wall next to, below, behind, in front of or above the first component.

[0034] Advantageously, this external form of the building elements and their interaction ensures a high stability of the erected wall, and ultimately of the building containing the wall.

[0035] (9) According to one embodiment, the proposed method includes a process step of individually packaging the manufactured components with a packaging material.

[0036] Packaging can be done, for example, with shrink film. This is advantageous because each manufactured component is protected from dirt, water, and other climatic influences immediately after production, during storage, and during transport to the construction site. Additionally, the packaging material is designed to ensure reliable mechanical protection. Suitable materials include, for example, films such as foamed polymer, thick polymer films, and bubble wrap.

[0037] (10) According to one embodiment, the process step "computer-aided disassembly of the constructed wall into the components" is carried out in such a way that the material density of the building material used to manufacture the components is taken into account. Different building materials can thus result in different dimensions and / or shapes (contours) of the ultimately obtained components. A technical result of this process step is that, taking into account the material density of the respective building material used for additive manufacturing, the mass of the components is between 1 kg and 25 kg, preferably between 5 kg and 10 kg.

[0038] These components offer the advantage of being individually and precisely handled with comparatively little effort, and above all, precisely positioned. The shape of the components is essentially determined by their function. For example, components intended for use as door or window lintels project sufficiently far into the wall on both bearing surfaces above the respective door or window opening and possess the necessary load-bearing capacity to withstand assumed continuous loads and potential traffic loads. It should be noted, however, that the components are preferably not limited in terms of either their dimensions (size) or mass (weight), as they can also be installed using appropriately designed robots. Ideally, all components should be of similar size and weight. While this is not strictly necessary, it does facilitate the installation process for both humans and / or robots.A few of the building elements used in a wall may be longer for structural reasons, e.g. to bridge window and door openings (lintels), possibly reinforced by inserted reinforcements or otherwise, and may not be additively manufactured.

[0039] This advantageously allows for a high degree of flexibility in the construction of the building.

[0040] (11) According to one embodiment, the proposed method includes marking the components with an individual code identifying their respective position in the wall. The code can be a numerical combination, such as a sequential layer number and a sequential number indicating the component's position within that layer. Alternatively, a barcode or other machine-readable marking is also suitable. The codes are preferably generated directly during the additive manufacturing of the component. This can be achieved, for example, by locally incorporating or applying a pigment, a distinctly pigmented material, or by selectively creating external recesses or raised areas. Alternatively, the marking can be applied or affixed to the component or its packaging in the form of a label.It is also possible to initially mark only the work platform on which the specific component is manufactured. This mark, or a corresponding code or equivalent, can be transferred to the component at a later time. This can be done directly or indirectly, for example, by marking the packaging of the individual component.

[0041] This advantageously simplifies the assembly of the components and the actual construction on site. Errors, instabilities caused by incorrectly placed components and / or unintended interruptions of an installation channel are largely avoided or, with additional "coding," for example according to the principles of a 3D puzzle (i.e., the existence of unique fits between correctly placed, adjacent components), completely eliminated.

[0042] (12) According to one embodiment, in the process step “additive manufacturing of the component…”, a building material is used comprising: concrete, mortar, loam, clay, an aluminosilicate, a silica-containing compound, metakaolin, an organic polymer, a crosslinkable monomer, a pozzolan, and / or a mixture of materials suitable for geopolymer formation. The corresponding materials may optionally be fiber-reinforced. For example, loam or clay mixed with chopped straw or other plant fibers or residues may be used. Concrete mixed with shredded glass fiber reinforced plastic (GFRP) may also be used. A crosslinkable polymer is understood to be an organic compound that typically has at least two functional groups.an organic compound that is configured to enable a crosslinking reaction with similar, related, or other organic macromolecular compounds.

[0043] Advantageously, the materials and additives used ensure a projected strength and / or a desired indoor climate, reduce construction costs and are sometimes even available at negative costs as waste (e.g. shredded material from decommissioned wind turbine blades).

[0044] (13) According to one embodiment, in the process step “additive manufacturing…” a gradient of a relative concentration of a building material type, a building material density, a porosity, a pigmentation, a wettability, a thermal conductivity and / or a sound insulation effect is generated in the building components, wherein the gradient is oriented substantially orthogonally to a wall surface.

[0045] This advantageously ensures, or at least promotes, a desired indoor climate. The thermal conductivity λ is important for the location of the dew point or dew point plane within the building structure, so that, for example, preventing condensation can suppress mold growth in living spaces. Further advantages include, for example, reduced material or heating costs, or are obvious to a professional.

[0046] (14) According to one embodiment, the proposed method includes the following additional process steps: - automatic picking up and arranging of the numerous components on a means of transport; - Transporting the large number of building components arranged on the means of transport to a construction site; - Unloading the means of transport comprising the orderly placement and / or arrangement of the numerous building elements on a storage area, wherein the orderly placement is determined according to the position of the building elements in the wall specified by the respective code and / or corresponds to a sequence of the aforementioned continuous code, and / or - the intended arrangement of the numerous building elements directly on a suitable foundation, for example on a foundation or a building structure designed as a lower floor, wherein the intended arrangement is carried out using an individual marking or an individual code of the building elements and building elements arranged adjacent to each other are optionally fixed by an adhesive.

[0047] The means of transport can be selected from a rail vehicle, a truck, an aircraft, in particular a drone: the intended arrangement is carried out using a previously described individual marking of the components. Optionally, adjacent components are fixed in place during their intended arrangement using one or more of the previously described adhesives.

[0048] These process steps contribute to a clear and space-saving construction site, thus reducing construction costs. The actual construction process of the structure containing the wall is described here as "arranging the building elements on a foundation as intended." This process step eliminates the need for intermediate storage of the building elements, although it can also follow such storage. Instead of unloading onto a storage area, the wall or building is erected directly from the transport vehicle. This saves additional space, time, and therefore construction costs. The transport vehicle is equipped, for example, with an attached or separate, associated lifting device or lifting apparatus, such as a crane. An associated lifting device / lifting apparatus is defined as a device assigned to the transport vehicle and directly communicating with or controlling it or its assigned operator, e.g., a crane.This can refer to a crane or a robotic arm with a gripper. The transport vehicle can also include a drone, which is activated at the transport vehicle's stopping point and individually picks up the components from the transport vehicle or storage area and arranges them as intended on the foundation or on already installed components. The application of an adhesive layer can also be carried out by the appropriately configured drone. For this purpose, the drone can be equipped with an adhesive reservoir and a dosing device. Naturally, assembly can also be carried out manually or partially manually.

[0049] (15) According to one embodiment, a building element is proposed that is configured to form a wall. The building element has a bottom base, a top connection surface typically parallel to the bottom base, and at least one side surface. For example, the building element may have a nearly elliptical base or a one-sided convex and an opposite one-sided concave connection surface. Strictly speaking, such a building element has only one circumferential side surface, since no edges divide the side surface into multiple side surfaces. In other words, the at least one side surface connects an outer contour x 10 , y 10 the lower mounting surface with an outer contour of the upper connection surface x 11 , y 11in a substantially vertical direction z together (extruded body-shaped), wherein at least two or even three adjacent building elements in the wall, as a result of their intended arrangement, joining or mounting, form at least a section of an installation channel located inside the wall and / or a section of an opening selected under a window opening and a door opening, and wherein the building element optionally has a marking in which or by means of which the position of the building element in the wall is encoded.

[0050] These types of building elements are advantageous for the efficient construction of a wall that incorporates various technical supply lines or installation channels. As explained in more detail below, the described building elements make it possible to provide a shell structure for a complex building, such as a single-family home, which, upon completion, already largely incorporates all necessary utility installations or is immediately prepared for their installation.

[0051] (16) According to one embodiment, the section of the installation channel of the component has at least two openings and a plane of the first cross-sectional end face of the installation channel section is oriented substantially parallel or substantially orthogonal to a plane of the second cross-sectional end face of the section of the installation channel arranged in the component.

[0052] This implies that the installation channel section of a building component can also be T-shaped. The previously mentioned orthogonal angle of 90° can also be replaced by an angle of 120°. The resulting installation channel section then no longer follows a literal L-shape. In the case of three cross-sectional end faces, a Y-shape results. The advantages of L-, T-, and Y-shaped pipe connections are generally known and apply here as well. For example, the L-shaped installation channel section of the building component advantageously achieves a substantially right-angled course or a change of direction for the installation channel in question. Such installation channels or sections can contribute to creating a meandering course of the installation channel in the wall if they are appropriately combined with other building components whose installation channel sections are oriented horizontally or vertically.Naturally, the two or three corresponding openings of adjacent components are arranged within each component in such a way that, when installed in the wall, a closed installation channel free of steps or jumps is achieved. Meandering channels can offer advantages for a fluid flowing through the channel, for example, for the air conditioning / heating or cooling of a room with a fluid (gas or liquid).

[0053] (17) According to one embodiment, the proposed component is essentially cuboid. "Essentially cuboid" is understood to mean a substantially rectangular three-dimensional parallelepiped. This parallelepiped has six substantially rectangular faces that are at substantially right angles to one another. At least some of the twelve edges of the substantially rectangular faces may be chamfered or rounded, so that the resulting eight corners also have a rounded shape. "Essentially" here refers to deviations from the specified values, specifically from right angles, of up to ±5°. Furthermore, the component is adapted to form a wall that fills the entire surface.In this context, the term "surface-filling" refers to a design of a side surface of the building element that contributes to the formation of an outer wall surface and is adapted to create a continuously closed wall surface. This design, when combined with other building elements or installed, results in a closed visible wall surface. The building element of this embodiment has anchoring structures on opposite sides. These anchoring structures are individually configured, depending on their position on the building elements within the wall, by virtue of their respective size, shape, and position (i.e., location and fit), such that at least in certain sections, an engagement of the anchoring structures of adjacent building elements is possible.Thus, the anchoring structures of a building element achieve at least one engagement between a first anchoring structure of the first building element and a second anchoring structure of a second building element adjacent to the wall, and one engagement between a second anchoring structure of the first building element and an anchoring structure of a third building element adjacent to the first building element in the wall. The first building element is surrounded by at least two other building elements; ideally, in a building element assembly of a wall, it is surrounded by six other building elements. The side surface of the building element according to this embodiment is therefore configured to form or enter into a positive-locking connection (interlocking, engagement) with at least two adjacent building elements, at least in sections. The positive-locking connection is mediated by an adhesive intermediate layer.In addition, incorrect installation of the components can be prevented by means of a staggered offset of the respective anchoring elements or a varying shape and / or size of the components arranged in a layer and / or in adjacent layers and / or the studs and recesses arranged on them, in addition to their individual coding. Incorrect installation here refers to an assembly that deviates from the planned (i.e., designed) arrangement of the components in the wall and leads, for example, to an unintentional interruption or blockage of the installation channel.

[0054] (18) According to one embodiment, the orientation of the installation channel in one component of the plurality of components manufactured according to the method deviates at least section by section from an orientation orthogonal to the lower mounting surface.

[0055] Optionally, the deviation of a portion of the channel section, projected onto a plane in which a side face of the building element lies, or onto the wall plane, can be, for example, substantially 90°. Deviations of substantially 45° are also possible. This advantageously allows for the realization of a complex installation channel layout within the wall without deviating from the horizontal or vertical routing of supply lines prescribed by any applicable building regulations. Furthermore, with section-by-section orthogonal orientation to the wall surface, this allows for standard connection to an external supply line (see [reference]). Fig. 3), an inlet or an outlet.

[0056] (19) According to one embodiment, the component has a first opening of the installation channel on a side surface of the component. A second opening of the installation channel section of the component can be arranged on the lower mounting surface or on the upper connection surface. According to a modification of this embodiment, an installation channel opening is arranged directly in an anchoring structure. By forming an engagement of the corresponding anchoring structures of the components adjacent in the wall during their installation, a largely fluid-tight installation channel is achieved. The impregnation of installation channel sections with an impregnating agent, as already described above, can advantageously also be carried out only after all corresponding components of the wall or building have been completely installed.

[0057] Advantageously, for example, a pipeline can be "laid" virtually without the usually required installation effort, the wall penetrations that are usually subsequently introduced into the shell of the building, etc., since the pipeline is formed at the same time as the wall or the shell of the building.

[0058] (20) Advantageously, according to one embodiment, the installation channel follows an inner or outer side surface of the building component at a constant distance and thus runs along an isotherm when there is a temperature difference between the inner and outer surfaces of the building components relative to the external environment. Such temperature differences between an outer surface, e.g., the exterior of a house, and an inner wall surface, e.g., the interior of a house, typically occur under changing climatic conditions and / or when a house is heated. The importance of the location of the dew point plane and the risk of condensation on interior walls are well known to those skilled in the art, so the advantages of correctly arranging a suitable installation channel and / or the temperature of the fluid carried therein are also obvious.

[0059] The proposed installation channels do not necessarily have to carry infrastructure to be installed, i.e. cables, pipes to be laid separately, but can also fulfill functionalities such as ventilation together with cooling or heating or for moisture regulation of the building, e.g. a house, and be integrated into the relevant building elements of a wall, i.e. arranged in the wall.

[0060] (21) According to further embodiments, the cross-section or cross-sectional area of ​​an installation duct can have a preferred geometric shape: for example, circular, elliptical, square, rectangular, star-shaped, etc. The cross-sectional area can thus be described as: circle, ellipse, triangle, rectangle, square, trapezoid, trapezoid, star, and polygon. Typical average diameters range from 0.5 to 500 mm. Naturally, the dimensions of the installation ducts are adapted to the thickness of the wall or the depth of the relevant building elements.

[0061] For example, a star-shaped cross-section of the installation duct can be advantageous, ensuring a larger contact area between the fluid flowing in the duct and the building material or component, and thus the wall. This enables improved heat transfer and temperature control when the installation duct is used for air conditioning.

[0062] (22) According to one embodiment, the installation duct section in the building element is designed as a self-supporting structure. In other words, the installation duct section may appear to be embedded in a solid matrix of building material, or alternatively, it may be connected, only partially, to a portion of the building material appearing as the installation duct wall, to one or both of the substantially parallel outer surfaces of the building element for stabilization purposes. In other words, the wall of the installation duct is surrounded, at least partially, by one or more cavities. The latter arrangement is referred to here as a self-supporting arrangement of the installation duct.

[0063] Advantages of a self-supporting arrangement of the installation duct section in the building element or of the installation duct in the wall constructed from the building elements include, on the one hand, aspects of thermal insulation: The air present in the remaining cavities acts as effective thermal insulation, improves the room climate and results in energy savings when heating or cooling the room formed with the participation of the wall.

[0064] On the other hand, a suitable "suspension," i.e., the self-supporting arrangement of the installation channel section within the component or wall constructed from such components, allows for at least partial "depowdering"—the removal of unsolidified powder bed components—which is economically advantageous for powder-based manufacturing processes. A multitude of individual connections, such as rod-shaped ones, to the outer surfaces of the component or wall can be used to stabilize the installation channel section within the component or wall. Using these connections, or employing a gyroidal structure to connect the installation channel section to sections of the component's outer surfaces, advantageously enables complete depowdering, i.e., the complete removal of the powder originally used in the powder bed.The portions of the typically still free-flowing powder or granules removed during this separation step can be reintroduced into the additive manufacturing process, for example, for the additive manufacturing of the next component. This "recycling" of a powdered material improves or even enables the highest possible sustainability of the additive manufacturing process used here.

[0065] (23) According to one embodiment, the installation channel section of the component opens into an installation channel opening in a side face of the component and is flush with the wall surface. This opening can have a different inner diameter and cross-sectional shape than the installation channel sections of the individual or multiple components leading to it. In other words, several installation channel sections from different components can open into this installation channel opening. The opening can serve as an externally accessible distribution box for electrical connections. It can advantageously be covered by a lid, preferably made of plastic, and thus remains accessible. The distribution box functions, for example, as an interface for a plurality of channels through which electrical cables are routed.Therefore, at least one installation channel is accessible via the opening or the distribution box. The cross-section of the opening can preferably be round, square, or rectangular. It offers sufficient space so that cables can be connected with clamps. Preferably, round boxes can also serve as receptacles for sockets or switches in conjunction with corresponding cable ducts or supply lines.

[0066] This advantageously simplifies the installation of complete supply structures for a room or building.

[0067] (24) According to one embodiment, a kit for constructing a wall is proposed, wherein the wall has an installation channel and / or optionally an opening selected below a door opening and a window opening. The kit comprises a plurality of components according to the embodiments described above and below. These components of the kit are configured such that, in a sequential arrangement as designed or designed using the method described above, they form the wall, wherein a plurality of the components of the kit each form at least one section of the installation channel and / or optionally one section of the designated opening.

[0068] The achievable benefits are those already mentioned above.

[0069] (25) According to one embodiment, a building shell comprising at least one wall is proposed, wherein the wall is composed of a plurality of building elements. These building elements are manufactured according to at least one of the embodiments mentioned above. In other words, the building shell comprises at least one wall having building elements according to at least one of the corresponding embodiments of building elements described above. In other words, the building shell can comprise building elements according to the kit described above. It is deliberately left open here how the roof of the building shell is constructed. It can be equipped with a traditional roof with a truss. However, several walls can also be designed using computer-aided design such that the additively manufactured building elements, when arranged as intended, form a vault or a dome.Examples include a cross vault, a cloister vault, a pointed vault, a barrel vault, a mirror vault, a dome, a hanging dome, or any other self-supporting structure that closes off the building at the top. The building's structural frame, comprising the building elements, may include supporting elements, reinforcements, or bracing necessary for the building's stability, which in turn may consist of the additively manufactured building elements proposed here or may include such elements alongside other building stones.

[0070] This advantageously ensures maximum design freedom, variety of shapes and stability.

[0071] The embodiments described above can be combined with each other as desired.

[0072] In addition to those already mentioned, the advantages achievable with individual embodiments or combinations thereof include the potential elimination of formwork during building construction. Furthermore, the proposed process chain opens up the use of building materials whose use would otherwise be precluded by the waiting times required for curing ("maturation") or complete solidification to reach final strength.Because the individual components are also individually additively manufactured, particularly sustainable building materials, such as clay, clay-fiber mixtures, and / or pastes made from various inert waste materials and their mixtures, can be used to produce far more complex building blocks than simple prefabricated blocks for construction. This is because the manufacturing process for further components can be connected regardless of the waiting times required for each individual component. The additive manufacturing device used can therefore operate continuously without downtime, producing the individual components one after the other according to the respective control data set(s).

[0073] In contrast to fast-setting cement, for example the building materials known as Sorel cement, which are very expensive due to their necessarily high MgO content, according to the invention, cost-effective natural materials or even materials available at a negative price (waste materials from various industries) are used for construction or even made available for use in the first place. Character description

[0074] The accompanying drawings illustrate embodiments and, together with the description, serve to explain the principles of the invention. The elements of the drawings are relative to one another and not necessarily to scale. Identical reference numerals denote correspondingly similar parts. Fig. Figure 1 schematically shows a component according to one embodiment. Fig. Figure 2 schematically shows a component of another embodiment. Fig. Figure 3 schematically shows a detail of a wall. Fig. Figure 4 shows a perspective view of a component according to a further embodiment. Fig. Figure 5 shows two top views of the same component, one of the real component (5A) and one of the virtual component (5B), directly reproduced using the control data set. Fig. 6 shows that Fig. 5 comparable, the narrow side surface of the component of an embodiment. Fig. Figure 7 shows a view of the previously discussed embodiment of the component from below in the “virtual” form stored in the corresponding STL file. Fig. Figure 8 shows a structure, or part of a wall, comprising individual building elements. Fig. Figure 9 shows the same section of a wall, formed from individual building elements with interlocking structures. Fig. Figure 10 is a detailed view of a side surface of a component in its assembled state. Fig. Figure 11 shows a joint of a wall section constructed from nine building elements. Fig. Figure 12 illustrates the proposed process chain, or the proposed procedure for constructing a wall. Fig. Figure 13 schematically shows the proposed building construction process, encompassing the wall construction process and the erection of the shell. Detailed explanation of the characters

[0075] In particular, it shows Fig. 1. A component 100 according to one embodiment. The component 100 comprises a section of an installation channel 1 which is arranged obliquely in the matrix of the component. The basic cuboid shape here results, in addition to the base 10 or support surface 10 and the top surface 11, in the two side surfaces 12 and 13 with the smaller side surfaces 14 and 15, or first end surface 14 and second end surface 14. The studs 18.1 and 18.2 arranged on the top surface or cover surface 11 of the component engage, when properly installed, in corresponding recesses 18' of the components arranged in the wall above the component 100 shown. Accordingly, the recesses 18.1' and 18.2' arranged on the underside of the component 100 shown in its mounting surface 10, together with corresponding studs of the two other components arranged below the component 100 shown, each form an engagement that allows the assembly 200, 300, 300a to be formed in this way.The wall 200, 300, 300a is stabilized. This advantageously stabilizes the wall 200, 300, 300a. It is clearly evident that the installation channel section 1 of the other components adjacent to the shown component 100, both above and below, runs differently, i.e., laterally offset. To prevent incorrect assembly under the cover of the intended installation channel 1, the studs, or protrusions 18.1, 18.2, ... and their associated recesses 18.1', 18.2', ... in the components of the respective adjacent component layers can be arranged irregularly, but in a uniquely matching manner. The arrangement of the protrusions (studs, stubs, protrusions, etc.) and corresponding recesses of two adjacent components is similar to the uniquely matching fits of immediately adjacent puzzle pieces known from a 3D puzzle.

[0076] Fig. Figure 2 schematically shows a component 110 of a further embodiment with a vertically extending channel section 1. The anchoring elements 25.1 and 25.2 have a slightly different shape here than in the previously described embodiment 100. They are adapted to form an engagement comparable to a tongue-and-groove fit. Naturally, the first and second anchoring structures 25.1 and 25.2 of laterally adjacent components can also be designed as just described for the studs and recesses, so that these features additionally prevent incorrect assembly of the components 100, 110, as well as the other embodiments 120, 130, and 150 described below. As can be seen, the studs 18.1, 18.2, 18.3, 18.4, and 18.1 arranged on the cover surface 11 engage here.5 into corresponding recesses of the respective components arranged above, forming the assembly of components, while the recesses 18.1', 18.2', 18.3', 18.4' and 18.5' arranged in the mounting surface 10 accommodate corresponding elevations 18, 18.1, 18.2, 18.3, 18.4, 18.5... in the cover surfaces of the components arranged below the component 110, corresponding to them in terms of size, shape and location. Naturally, in the components adjacent above and below in the wall, the channel section 1 is arranged offset in the respective component compared to the channel section 1 shown in this figure, so that a continuous channel 1 is obtained in the formed wall 200, 300, 300a.

[0077] Fig. Figure 3 schematically shows a wall section 200, or a assemblage 200 comprising an installation duct 1. The detail of the wall 200 can, for example, be viewed as a perspective view of the outside of a wall 200. The section or assembly 200 shown comprises 20 components 130, 140, 150, 160 (others are not specifically marked), with a plurality of five components 130, 140, 150 forming the installation duct section 1 shown. The components, arranged adjacent to each other in a layer or position, are engaged in pairs via corresponding interlocking elements 25.1, 25.3. For the sake of clarity, studs and corresponding recesses are not shown here. The lowest component 150 of the components forming the duct section 1 has an opening formed in one side surface 12, 13 of its section of the installation duct 1.The installation channel section 1 of this component 150 includes, for example, a "knee" of the installation channel section 1, which causes the channel 1 to bend by 90°. The opening in the side surface 12, 13 is adapted, at least with its inner diameter and possibly with sealing elements that can be arranged therein, at least partially, for connecting the installation channel 1 of the wall 200 to an external supply line 50. Joints formed between the components 130, 140, 150, 160, .... can be filled with an adhesive that stabilizes the connection. According to the embodiment already described above, the installation channel section 1 opening in a side surface of the wall can also transition into an opening or recess of a larger diameter and cross-sectional area and thus serve, for example, as a distribution box.Covered with a lid and thus essentially flush with the wall 200, at least one installation channel or several installation channels 1 leading into this larger recess remain accessible from the outside.

[0078] The opening in the wall required for the supply line 50 can also be flush with the wall, thus forming, for example, an externally accessible distribution box for electrical connections. This box is then covered with a lid, preferably made of plastic, ensuring permanent access. The distribution box can serve as an interface for a multitude of installation channels carrying electrical cables. The cross-section of the opening can preferably be round, square, or rectangular. The opening is dimensioned to provide sufficient space for cables to be connected with clamps. Preferably, round boxes can also serve as housings for sockets or switches in conjunction with cable ducts or supply lines.

[0079] Fig. Figure 4 shows a perspective view of a component 120 of a further embodiment. The gyroidal structure 30 of the anchoring of the installation channel section 1 inside the component 120 is clearly visible. A circular cross-sectional area 1b of the installation channel 1 closes off the channel section in a structure 25.2 of the component 120, which serves for anchoring and has a curved side surface 12. The anchoring structure 25.2 is designed here in the form of a "groove". On the opposite narrow side surface 14, or end surface 14, of the component 120, the corresponding anchoring structure 25.1, comparable to a "spring", is formed. The tongue and groove of components directly adjacent to each other in a wall are in engagement with one another. On the top surface, the cover surface 11 of the component 120, raised areas or knobs 18.1 and 18.2 are formed. These knobs or stumps 18.1, 18.The two elements are adapted with respect to their location – either on the top surface 11 or directly on the upper surface of the adjoining lateral anchoring structures 25.1, 25.2 – with respect to their size and shape, and are also designed to form engagements with one or more corresponding recesses 18' on a bottom surface 10 of one or more of the wall assembly elements arranged above them. These loosely engaged structures 25.1, 25.2 can also be advantageously additionally fixed by an adhesive. Due to the cantilevered arrangement of the channel section 1 by means of a gyroidal structure 30 inside the building element 120, the top surface 11 of this building element 120 does not appear as a closed surface but as a fractured surface 11. The large side surfaces 12 and 13 (not shown) are each concavely and convexly curved, respectively.

[0080] In addition to the tongue-and-groove joint shown here, comprising a "slot" 25.2 and a "tenon" 25.1, other anchoring structures 25 are also possible. One example is a dovetail joint. Alternatively, other forms of long-timber joints, such as those known from joinery, can be used, for example, a lap joint, a wedge joint, or a finger joint. Typically, the formation of a gap / joint for the respective adhesive is provided by reducing the relevant dimensions, typically length, width, and height, of the individual components accordingly.

[0081] Fig. 5A shows the additively manufactured component, Fig. Figure 5B shows the "virtual" component 120 stored in the corresponding control data record using the associated STL file. The one in the Fig. The recognizable and familiar "network structure" shown in Figure 5B makes it easier for the viewer to distinguish the installation channel section 1 from the gyroidal structure 20 that supports it. In both partial views, it is evident that the gyroidal structure is involved in forming the cover surface 11 and the mounting surface 10. The cavities 21 formed by the gyroidal structure 20 allow for complete powder coating of each component when the component is additively manufactured using a powder-based process 1000. Conversely, the cavities 21 advantageously allow for material savings when the component 120 is manufactured, for example, using a filament-based manufacturing process 1040. The relatively simple knobs 18.1 and 18.2, the curved side walls 12 and 13, and the gyroidal structures 20 associated with the cover surface 11 are clearly visible. The cavities 21 formed between channel section 1 and the gyroidal structure 20, which are also shown in Figure 5B, are clearly visible. Fig. 5A and in Fig. 5B continuous cavities 21 allow complete isolation, e.g. by depowdering, if the component 120 is powder-based, i.e. manufactured in a powder bed or in a slurry bed.

[0082] Similar to the preceding figure, it shows Fig. 6 a side surface 15 of the two narrow side surfaces 14, 15 of an embodiment 120 of the component. It is evident that the installation channel section 1 runs essentially horizontally and at a substantially constant distance to the outer walls 13 and 12 (not marked). Again, the Fig. 6A the real, additively manufactured component 120, while Fig. 6B represents the corresponding view of the “virtual” component 120 stored in the control data set by means of the associated STL file.

[0083] Fig. Figure 7 shows a view of one of the previously discussed embodiments of the component 120 in its "virtual" form, as stored in the corresponding STL file, from its base 10, or rather, from the base surface 10 serving as the mounting surface 10 in the wall to be erected. Here, the installation channel section 1 is more clearly visible than before in relation to the underside 30 of the gyroidal structure 30. The rectangular cross-section of the recesses 18.1 and 18.2 (not shown here) on the mounting surface 10 for the two adjacent components is also clearly visible. The recesses 18.1 and 18.2 of the laterally adjacent components 120 are held or enclosed by the rectangular frame 18' shown. This increases the stability of the wall constructed from the corresponding components.

[0084] Fig. Figure 8 shows a structure 300, or part of a wall 300, comprising individual components 120, 130, 150 with interlocking elements 25.1, 25.2, each having studs 18.1, 18.2 or raised areas or stubs 18.1 and 18.2. The installation channel 1, or its section 1, which is not visible from the outside, runs in the middle layer or position of the structure 300, which includes the components 120 and 130. The components 300 in the lowest and uppermost layers do not have any installation channel sections, but, as can be seen, also have an internal gyroidal structure 30, which enables depowdering in powder-based manufacturing and thus material savings and sustainability independent of the specific additive manufacturing process.

[0085] Fig. Figure 9 shows the same section of a wall 300, formed from individual building elements comprising interlocking structures 25.1, 25.2 and respective studs or stubs 18.1, 18.2, which, in the assembled state of the assembly, are each held together by corresponding recesses 18' on the undersides 10 of adjacent building elements, as well as the gyroidal structure 30 inside the building elements of the assembly 300. The building elements of the wall 300 or wall section 300 shown each have a convexly curved outer surface 13.

[0086] Fig. Figure 10 is a detailed view of a side surface 25 (flank) of a building element in its assembled state in a wall / in a structure with an interlocking element 25.1 and a channel opening 1 arranged in the interlocking element 25.1. The first interlocking element 25 shown has a first protrusion 18.1 on the upper surface of the first anchoring element 25.1, which, together with the protrusion of the adjacent building element (not shown) facing forward in the same layer, engages with a recess 18' in the mounting surface 10 of the building element (not shown) that bridges both building elements above. As can already be seen from the preceding figures, the side surfaces 12, 13 of the building element 300, 300a are curved.

[0087] Fig. Figure 11 shows a unit 300 of a wall section composed of nine building elements, viewed from the inside 12 of the building elements. The previously shown laterally curved building element 120 with the opening 1b of the channel section 1 is arranged in the middle position of the unit 300.

[0088] Fig. Figure 12 illustrates the proposed process chain, or the proposed procedure 1000, for the construction of a wall using the building elements described here. The individual steps of process 1000 comprise the computer-aided design 1010 of the wall, the subsequent computer-aided disassembly 1020 into individual components, followed by the creation of the control data set 1030, which is used in the additive manufacturing step 1040 in / with a suitable device, e.g. a 3D printer of a suitable design and corresponding auxiliary elements (e.g. workspace, work platform, material storage container, filament, filament melting nozzle, powder, granules, slurry, possibly a doctor blade, possibly a laser, possibly a binder metering valve, etc.) for the additive assembly of the component 100, 110, 120, 130, 140, 150, 160.... or of its blank 100, 110, 120, 130, 140, 150, 160....The next step, 1050, involves removing the product from the manufacturing device, which can optionally be followed by a post-treatment step, 1060.

[0089] Thus, following the additive manufacturing (1040) or post-processing (1050) of the additively manufactured component (100, 110, 120, 130, 140, 150, 160...), the process step of individual packaging (1070) of the components takes place. In the subsequent step (1080), the packaged components can be placed directly onto a transport vehicle or in an intermediate storage area in an orderly manner. The transport (1090) of the packaged components (100, 110, 120, 130, 140, 150, 160...) to the construction site then follows. Here, at least two basic options arise: The building elements 100, 110, 120, 130, 140, 150, 160... are either immediately arranged in an orderly fashion from the truck's loading platform / cargo space onto a foundation, for example, the footing of the wall to be erected, thereby directly constructing the previously planned wall. Alternatively, the building elements can also be stored in an orderly fashion on a construction site storage area, so that later, if necessary,After the foundation has been fully formed, the construction of the wall (200, 300, 300a) or even a complete shell building is started using a shell construction process (5000).

[0090] As in Fig. 12, represented by the dashed rectangle, may comprise a computer-aided manufacturing process according to one embodiment: - Construct 1010 at least one part of a structure, in particular a wall, wherein the at least one part 200, 300, 300a has an installation channel 1, - Disassembling 1020 of the constructed at least one part 200, 300, 300a into typically at least substantially extruded body-shaped components 100, 110, 120, 130, 140, 150, 160...., wherein at least two, typically a plurality of at least pairwise adjacent components 100, 110, 120, 130, 140, 150, 160.... have at least one respective section of the installation channel 1; - Create 1030 a control data set for controlling a device 500 for additive manufacturing, which is configured to individually provide the multitude of components 100, 110, 120, 130, 140, 150, 160... from at least one building material; and - Manufacture 1040 of the multitude of components 100, 110, 120, 130, 140, 150, 160.... using the device 500 for additive manufacturing using the control data set.

[0091] Fig. 13 is a block diagram of the building manufacturing process 5000, which includes the process steps “Making the wall” 2000 and “Erecting a shell” 3000, encompassing the wall 200, 300, 300a.

[0092] The additive manufacturing process described at the beginning and explained above involves a typically self-sustaining solidification of the immediately preceding manufactured components 100, 110, 120, 130, 140, 150, 160... to a specified final strength. This can be achieved by one or more of the following: curing, cooling, solidifying, setting and / or drying, through-polymerization or sintering of the respective material used and, if applicable – as described above, possibly only locally treated – and / or removing the powder bed component 100, 110, 120, 130, 140, 150, 160.... Here, "removing" refers, as is customary in the industry, to the removal of the powder that has not solidified into a component of the component.The aforementioned curing, cooling, solidifying, setting and / or drying, through-polymerization and / or sintering of the component directly removed from the manufacturing device is carried out, according to typical embodiments, by leaving the component or its blank on the work platform. "Through-polymerization" here refers to the complete polymerization of the component material, which may initially have only been polymerized externally. The freshly manufactured component 100, 110, 120, 130, 140, 150, 160... is removed from the device together with the work platform. This has the advantage of allowing the uncured, still hot, not yet solidified, not yet fully set, not yet through-polymerized, still moist, or still unsintered component 100, 110, 120, 130, 140, 150, 160... to be transported or easily transferred without contact.

[0093] In other words, the component 100, 110, 120, 130, 140, 150, 160... removed from the device – depending on the material used – may not be ready for immediate use. If necessary, the component 100, 110, 120, 130, 140, 150, 160... may therefore undergo post-processing 1060 or post-treatment 1060. Such post-processing 1060 typically involves sintering, particularly if it has been previously removed from a powder bed. Furthermore, the post-treatment or post-processing may also involve at least partial, partial, or complete wetting, for example, with a paint, a weatherproofing agent, or impregnation with a water-repellent impregnating agent or a binder to increase strength. Impregnating agents and binders can be applied in both liquid and gaseous form.The described impregnation can, for example, make an outer surface or a pore space water- and / or dirt-repellent, or, for example, make the installation channel section 1 of the component 100, 110, 120, 130, 140, 150, 160... impermeable to a medium to be transported within it. In this way, the relevant installation channel section 1 of the component 100, 110, 120, 130, 140, 150, 160... is made usable as a pipe section 1 for conveying a fluid in the resulting installation channel 1.

[0094] Additionally, post-processing includes marking or coding each individual building block so that it is assigned a unique position in the wall or building, even if it is not yet in its actual position in the wall.

[0095] The sintering process previously described for powder-based components 100, 110, 120, 130, 140, 150, 160 ... may be preceded, if necessary, by a so-called "depowdering" and / or debinding process. This removes unsolidified components of a powder bed and / or substances used as binders that remain in the component blank 100, 110, 120, 130, 140, 150, 160 .... Debinding can be achieved, for example, by pyrolysis or by the action of binder solvents.

[0096] The described sintering of a blank (e.g., "green body") of component 100, 110, 120, 130, 140, 150, 160... can be carried out, as is standard practice, by passing the blank through a continuous furnace or a roller furnace. In this process, a long, narrow furnace, which may have zones at different temperatures, is continuously traversed by a succession of component blanks produced one after the other on a conveyor belt / rollers or similar device. The components 100, 110, 120, 130, 140, 150, 160... are, for example, still arranged on their respective work platforms. The furnace can be designed to continuously perform drying, debinding, sintering, and / or other steps that lead to the achievement of the final strength of component 100, 110, 120, 130, 140, 150, 160... and thus to its intended use. The steps just described are, of course, carried out prior to individual packaging of the components.During these post-treatment steps, the unambiguous identification of the various components 100, 110, 120, 130, 140, 150, 160.... can be ensured by marking their respective working platforms.

[0097] Although specific embodiments have been presented and described herein, it is within the scope of the present invention to modify the illustrated embodiments appropriately without deviating from the scope of protection of the present invention. The following claims represent a first, non-binding attempt to define the invention in general terms. Reference symbol list 1 channel, channel section 1b Channel section opening, circular cross-section 10 Base, footprint 11 Cover area 12 first side surface 13 second side surface 14 first end face, third side face 15 second end face, fourth side face 18 studs, elevation, blunt 18' Recess to accommodate 18 18.1 first pimple, first elevation, first stump 18.1' Recess for receiving corresponding 18.1 of an adjacent component 18.2 second pimple, ...raisedness, ...blunt, ...projection, ...protrusion 18.2' Recess for receiving corresponding 18.2 of an adjacent component 18.3 third pimple, ...raisedness, ...blunt, ...projection, ...protrusion 18.3' Recess for receiving corresponding 18.3 of an adjacent component 18.4 fourth pimple, ...raisedness, ...blunt, ...projection, ...protrusion 18.4' Recess for receiving corresponding 18.4 of an adjacent component 18.5 fifth pimple, ...elevation, ...stump, ...projection, ...protrusion 18.5' Recess for receiving corresponding 18.5 of an adjacent component 20, 21, 30 internal support structure, e.g. here gyroid structure 25 Interlocking element forming an engagement, e.g. dovetail ... 25.1 First entanglement element, e.g. “spring” 25.2 second interlocking element, e.g. “groove” 50 Supply line, external; e.g. pipe stub 100, 110, 120, 130, 140, 150, 160 Component of different designs 200 Association / wall cutout / with connected supply line 50 300 building element assembly, section of a wall, Fig. 8: Frontal view / e.g., exterior view; Fig. 9: Top view 300a Building component assembly, section of a wall, Fig. 10 Detail of a side view / e.g., interior view of the (future) shell building 500 Device for additive component manufacturing 1000 methods for manufacturing or erecting a wall 1010 Process step: computer-aided construction of the wall 1020 Process step: computer-aided decomposition of the constructed wall into virtual building elements 1030 Procedure step: Creating tax data records 1040 Process step: additive manufacturing of the individual wall components 1050 Process step: Removing the components from the manufacturing device 1060 Process step Post-treatment, e.g.: thermal, mechanical, setting, solidifying, through-polymerization, drying, sintering, impregnation, coloring, coating, polishing.... 1070 Process step Individual packaging of components 1080 Process step Orderly depositing of building components 1090 Process step: Transporting components 1100 Process step: Forming a group of components 2000 Erection of the wall, assembly of the building elements to the wall, possibly with grouting. 3000 Shell construction methods using at least one wall 4000 building kit comprising components for a wall or a building shell, kit 5000 building manufacturing processes x 10 , y 10 outer contours of the mounting surface of a component x 10 , y 10 outer contours of the top surface of a building element z vertical direction

Claims

[1] Method (1000) for producing a wall (200, 300, 3000a), comprising the processes: - computer-aided design (1010) of the wall (200, 300, 300a), wherein the wall (200, 300, 300a) has an installation channel (1), - computer-aided disassembly (1020) of the constructed wall (200, 300, 300a) into building elements (100, 110, 120, 130, 140, 150, 160....), wherein a plurality of adjacent building elements (100, 110, 120, 130, 140, 150, 160....) comprise at least one section of the installation duct (1); - computer-aided creation (1030) of a control data set for controlling a device (500) for additive manufacturing, which is configured to individually provide the plurality of components (100, 110, 120, 130, 140, 150, 160...) from at least one building material; - additive manufacturing (1040) of the plurality of components (100, 110, 120, 130, 140, 150, 160....) for the wall (200, 300, 300a) with the additive manufacturing device (500) using the control data set; and typically - Erecting the wall (1100) by an orderly joining of the multitude of manufactured building elements (100, 110, 120, 130, 140, 150, 160....) comprising forming a bond (200, 300, 300a) of the building elements 100, 110, 120, 130, 140, 150, 160....). [2] Method (1000) according to claim 1, wherein the computer-aided dissection (1020) of the constructed wall (200, 300, 300a) into building elements (100, 110, 120, 130, 140, 150, 160....) is carried out layer by layer into adjacent layers, and a subsequent division (1025) of each of these layers into a sequence of building elements (100, 110, 120, 130, 140, 150, 160....) comprising the plurality of adjacent building elements (100, 110, 120, 130, 140, 150, 160....). [3] Method (1000) according to claim 2, wherein the division (1025) of the adjacent layers into building elements (100, 110, 120, 130, 140, 150, 160...) is carried out such that substantially vertically arranged surfaces (14, 15) of the building elements (100, 110, 120, 130, 140, 150, 160...) of adjacent layers, which form a wall surface, are offset from each other. [4] Method (1000) according to one of the preceding claims, wherein the computer-aided creation (1030) of the control data set and the additive manufacturing (1040) are adapted to provide the section of the installation channel (1) with at least two openings, wherein a plane of a first cross-sectional end surface of the section of the installation channel (1) is oriented substantially parallel or substantially orthogonal to a plane of a second cross-sectional end surface of the section of the installation channel (1) of the manufactured component (100, 110, 120, 130, 140, 150, 160....). [5] Method (1000) according to any one of the preceding claims - wherein, when forming the bond (1100), adjacent components (100, 110, 120, 130, 140, 150, 160...) are fixed with an adhesive. [6] Method (1000) according to any of the preceding claims, wherein the installation channel (1) is configured for the installation of a cable, a pipe and / or for the transport of a fluid. [7] Method (1000) according to one of the preceding claims, wherein the plurality of components (100, 110, 120, 130, 140, 150, 160....) comprises at least 3, preferably 3 to 1 million, more preferably 10 to 50,000 pieces. [8] Method (1000) according to any one of the preceding claims, wherein the manufactured components (100, 110, 120, 130, 140, 150, 160....) are essentially cuboid in shape and / or can be traced back to one or more cuboid basic shapes, and wherein the manufactured building elements (100, 110, 120, 130, 140, 150, 160...) typically have anchoring structures (25.1, 25.2) on opposite sides which are configured by their respective size, shape and position such that at least sectionally an engagement can be formed between a first anchoring structure (25.1) of a first building element (100, 110, 120, 130, 140, 150, 160...) and a second anchoring structure (25.2) of a second building element (100, 110, 120, 130, 140, 150, 160...) adjacent in the wall (200, 300, 300a). [9] Method (1000) according to any one of the preceding claims, further comprising: - individual packaging (1070) of all or at least the majority of the components (100, 110, 120, 130, 140, 150, 160....) with a packaging material. [10] Method (1000) according to one of the preceding claims, wherein the computer-aided disassembly (1020) of the constructed wall (200, 300, 300a) into the building elements (100, 110, 120, 130, 140, 150, 160...) is carried out such that their respective mass is between 1 kg and 25 kg, preferably between 5 kg and 10 kg. [11] Method (1000) according to any one of the preceding claims, further comprising: - Marking (1200) the building elements (100, 110, 120, 130, 140, 150, 160....) with an individual code indicating their respective position in the wall (200, 300, 300a). [12] Method (1000) according to any of the preceding claims, wherein the additive manufacturing (1040) is carried out with a building material, comprising: a concrete, a mortar, a loam, a clay, an aluminosilicate, a silica-containing compound, a metakaolin, an organic polymer, a crosslinkable monomer, a pozzolan and / or a mixture of materials suitable for geopolymer formation. [13] Method (1000) according to one of the preceding claims, wherein in the additive manufacturing (1040) a gradient of a relative concentration of a building material type, a building material density, a porosity, a pigmentation, a wettability, a thermal conductivity, and / or a sound insulation effect is generated in the building elements (100, 110, 120, 130, 140, 150, 160....), wherein the gradient is oriented substantially orthogonally to a surface of the wall (200, 300, 300a). [14] Method (1000) according to any one of claims 11 to 13, further comprising the processes: - automatic picking up and arranging of the large number of components (100, 110, 120, 130, 140, 150, 160....) on a means of transport; - Transporting (1090) the multitude of building elements (100, 110, 120, 130, 140, 150, 160....) arranged on the means of transport to a construction site; - Unloading the means of transport comprising the orderly placement of the numerous building elements (100, 110, 120, 130, 140, 150, 160....) on a storage area according to their position in the wall (200, 300, 300a) as specified by the respective code and / or - Arranging the numerous components (100, 110, 120, 130, 140, 150, 160...) as intended on a suitable base in a sequence determined by the code, for example on a foundation, and optionally fixing adjacent components (100, 110, 120, 130, 140, 150, 160...) with an adhesive. [15] Component (100, 110, 120, 130, 140, 150, 160....) for constructing a wall (200, 300, 300a), comprising a lower support surface (10), an upper connection surface (11) substantially parallel to the lower support surface (10), and a side surface (12, 13, 14, 15) which has an outer contour (x 10 , y 10 ) the lower mounting surface (10) with an outer contour of the upper connection surface (x 11 , y 11 ) connects each other in a substantially vertical direction (z), wherein the component has a marking in which the position of the component in the wall is encoded, wherein typically at least two or even at least three adjacent components (100, 110, 120, 130, 140, 150, 160....) in the wall (200, 300, 300a) form at least one section of an installation duct (1) arranged in the wall (200, 300, 300a). [16] Component (100, 110, 120, 130, 140, 150, 160....) according to claim 15, wherein the section of the installation channel (1) comprises at least two openings and a plane of a first cross-sectional end surface (1b) of the section of the installation channel (1) is oriented substantially parallel or substantially orthogonal to a plane of a second cross-sectional end surface (1b) of the section of the installation channel (1). [17] Component (100, 110, 120, 130, 140, 150, 160....) according to claim 15 or 16, wherein the component (100, 110, 120, 130, 140, 150, 160....) is essentially cuboid and preferably surface-filling and / or has anchoring structures (25.1, 25.2) on opposite sides which are individually configured by their respective size, shape and position depending on their position in the wall (200, 300, 300a) such that at least sectionally an engagement can be formed of a first anchoring structure (25.1) of a first component (100, 110, 120, 130, 140, 150, 160....) with a second anchoring structure (25.2) of a second building element (100, 110, 120, 130, 140, 150, 160....) adjacent in the wall (200, 300, 300a) and an anchoring structure (25.1, 25.2) of a third building element (100, 110, 120, 130, 140, 150, 160....) adjacent in the wall. [18] Component (100, 110, 120, 130, 140, 150, 160....) according to one of claims 15 to 17, wherein an orientation of the installation channel (1) deviates at least sectionally from an orientation orthogonal to the lower mounting surface (10). [19] Component (100, 110, 120, 130, 140, 150, 160....) according to one of claims 15 to 18, wherein a first opening (1b) of the installation channel (1) is arranged on a side surface (14, 15) of the component (100, 110, 120, 130, 140, 150, 160....) and the second channel opening (1b) is arranged on the lower mounting surface (10) or on the upper connection surface (11). [20] Component (100, 110, 120, 130, 140, 150, 160....) according to one of claims 15 to 19, wherein the installation channel section (1) runs at a constant distance to an inner or an outer side surface (10, 11, 12, 13, 14, 15) or lateral surface of the component (100, 110, 120, 130, 140, 150, 160....). [21] Component (100, 110, 120, 130, 140, 150, 160....) according to any one of claims 15 to 20, wherein a cross-sectional area of ​​the installation duct section (1) is a geometric area selected from a circle, an ellipse, a triangle, a rectangle, a square, a trapezoid, a trapezoid, a star and a polygon, [22] Component (100, 110, 120, 130, 140, 150, 160...) according to one of claims 15 to 21, wherein the installation channel section (1) in the component is a self-supporting structure and an installation channel wall is at least partially adjacent to a cavity of the component (100, 110, 120, 130, 140, 150, 160...) [23] Component (100, 110, 120, 130, 140, 150, 160....) according to any one of claims 15 to 22, wherein the section of the installation channel (1) opens into, encompasses and / or forms part of an opening for a switch, socket, valve or junction box. [24] Kit (4000) for constructing a wall (200, 300, 300a) comprising an installation channel (1) comprising a plurality of components (100, 110, 120, 130, 140, 150, 160....) according to any one of claims 15 to 22, which are configured to form a section of the installation channel (1) in a projected arrangement in the wall (200, 300, 300a). [25] Building shell (3000), comprising at least one wall (200, 300, 300a) constructed from a plurality of building elements (100, 110, 120, 130, 140, 150, 160....) manufactured according to a method (1000) of claims 1-14; comprising building elements (100, 110, 120, 130, 140, 150, 160....) according to one of claims 15 to 22 and / or a kit (4000) according to claim 24.

Images