METHOD FOR 3D PRINTING OF MINERAL BINDER COMPOSITIONS

Description

Technical area

[0001] The invention relates to a method for 3D printing mineral binder compositions and molded bodies produced therewith. State of the art

[0002] Structural concrete is typically poured into formwork for shaping and allowed to cure. Formwork production incurs material costs and is time-consuming, the molding options are limited, and the formwork is often treated with environmentally harmful formwork oils.

[0003] The problem of high costs and limited shaping options when using formwork, for example, has been partially solved for thermoplastics through the use of 3D printing processes.

[0004] The 3D printing process is also known as freeform construction. Typical materials for 3D printing are thermoplastics, which are heated and then applied in a plastic state, dot by dot or layer by layer. The material is usually applied using a movable print head controlled by a computer. Upon cooling, the polymers gain sufficient strength to hold their given shape.

[0005] However, 3D printing building materials, especially cementitious materials, is significantly more difficult. Cement achieves its strength by reacting with water in a chemical process known as cement hydration. Typically, the time from mixing the cement with water to achieving sufficient strength to be self-supporting is several hours. However, 3D printing requires rapid strength development or at least good dimensional stability of the applied material.

[0006] Some users therefore use concrete or mortar mixes that contain very little water and are therefore very stiff. Such mixes can only be pumped over short distances and at high pump pressure, and the resulting molded body often contains defects, such as air pockets, is visually inhomogeneous, and / or exhibits poor bonding between the individual applied layers.

[0007] Another problem is the transport of the mortar or concrete mix to the printing device, especially for printing larger structures. Only easily conveyable mixes can be conveyed over a long distance from the mixer to the printing head. However, such mixes are typically not self-supporting and are therefore unsuitable for printing.

[0008] CN 203357623 describes a process in which, shortly before the concrete is applied, some of the water is removed through a vacuum to create a rigid, self-supporting material. Such installations are expensive, complex, and undesirably increase the weight of the print head. The resulting material is often not homogeneous, which can lead to visual defects and even cracking.

[0009] WO 2013 / 064826 describes a method for applying a cementitious material layer by layer. It describes the addition of an accelerator via a separate inlet located near the nozzle used to dispense the cementitious material, without using a mixing device for mixing the accelerator with the cementitious material. The described arrangement is not suitable for effectively mixing the cementitious material with the accelerator.

[0010] CN 104310918 describes a cementitious mixture for 3D printing in which a premix of accelerator and retarder is prepared and then added to the cementitious dry mix before mixing with water. Cementitious mixtures that already contain the accelerator when mixed with water, even if they contain a retarder, are very difficult to control in their curing behavior.

[0011] JP H02 62205 A describes a device for continuously stirring, mixing, and discharging a hydraulic material mixed with an accelerator. The discharged material is poured into a fixed or movable formwork.

[0012] DE 29 47 913 A1 describes a machine for spraying wet concrete. Dry concrete is pumped, and water and admixtures, such as setting accelerators, are added and mixed immediately upstream of the spray hose and nozzle. The concrete is pumped from the nozzle using compressed air and sprayed onto the wall to be coated.

[0013] JP 3 080627 B2 describes a device for the continuous mixing of aggregates, hardener, and resin. The hardener is first mixed with the aggregates and then the resin is added.

[0014] CN 106 988 535 A describes a 3D print head in which printing material and additive are mixed.

[0015] CN 204 354 263 U describes a device for mixing and extruding multi-component Bingham fluids.

[0016] Current processes do not solve the problem satisfactorily: the production speed is slow, the production costs are high, the optical appearance is poor, and / or the strength of the molded body is insufficient. Therefore, there is a need for improved processes for 3D printing mineral binder compositions that overcome the aforementioned disadvantages as far as possible. Description of the invention

[0017] The object of the present invention is therefore to provide an improved process for the 3D printing of mineral binder compositions. In particular, the process should enable efficient, reliable, and as rapid as possible application of the mineral binder composition. This should, if possible, be achieved with high-quality applied layers in terms of strength development and optical uniformity. Surprisingly, this object is achieved by a process as described in claim 1.

[0018] The separation of the steps "providing the water-based mineral binder composition" and "mixing the water-based accelerator with the water-based binder composition" significantly increases the flexibility of the process. The water-based mineral binder composition remains readily processable over a longer period of time because the water-based accelerator is only mixed in with the continuous mixer. This prevents high pressure in the conveying device, especially in a hose between the pump and the continuous mixer, as well as premature stiffening or hardening of the binder composition and thus a possible blockage of the printing device, especially during unplanned waiting times. Furthermore, the location of the water-based binder composition and the location of application can be spatially separated, which is advantageous given the often tight space conditions at the printing point.

[0019] By using the continuous mixer with at least one dynamic mixing element, the aqueous accelerator is mixed very well and effectively with the water-based binder composition, whereby the applied layers cure uniformly and quickly.

[0020] Surprisingly, the material output from the continuous mixer is very consistent, even though the pumping performance fluctuates when conveying the water-based mineral binder composition to the mixer, which is often the case with normal concrete or mortar pumps.

[0021] The quality of the accelerated mineral binder composition emerging from the mixer is also very consistent, even if the quality of the water-based mineral binder composition exhibits fluctuations. These fluctuations can result from quality variations, particularly in the particle size distribution of the fillers, or fluctuations in the composition of the mineral binder and / or slight deviations in the dosage of the components. Furthermore, the accelerated binder composition leaving the continuous mixer is free of large air pockets and very homogeneous, and the shape of the applied layers is very uniform and visually appealing, with no imperfections.

[0022] The process allows the accelerated binder composition to be applied quickly and reliably in homogeneous layers, allowing large molded articles to be produced easily, with minimal time expenditure, and in an aesthetically pleasing manner. Particularly preferred embodiments of the invention are the subject of the dependent claims. Ways to implement the invention

[0023] The invention relates to a method for applying a mineral binder composition by means of 3D printing, according to claim 1.

[0024] 3D printing is a formwork-free molding process. The material is applied layer by layer to create three-dimensional objects. The layered construction is computer-controlled, using one or more liquid or solid materials according to specified masses and shapes.

[0025] "3D printing," also referred to as "freeform construction," is defined in this document as a process for producing molded bodies in which a deformable material is applied in multiple layers or smaller portions, forming a solid molded body after curing. The layers are not applied by spraying.

[0026] In this document, "mineral binder" means in particular a binder which reacts in the presence of water in a hydration reaction to form solid hydrates or hydrate phases.

[0027] In this document, "mineral binder composition" is understood to mean a composition containing at least one mineral binder. This composition contains, in particular, the binder, fillers, and optionally one or more additives.

[0028] In this document, "water-based mineral binder composition" means a mineral binder composition mixed with water, in particular in fluid form.

[0029] In this document, "cementitious binder" is understood to mean, in particular, a binder containing at least 5% by weight, in particular at least 20% by weight, preferably at least 35% by weight, especially at least 65% by weight, with a maximum content of 100% by weight, of cement clinker. The cement clinker preferably comprises a Portland cement clinker, a calcium aluminate clinker, or a calcium sulfoaluminate clinker. In this document, cement clinker refers, in particular, to ground cement clinker.

[0030] In this document, "mortar" or "concrete" refers to aqueous dispersions containing at least one cement and at least one mineral filler, capable of hardening into a solid form after the cement has hydrated. "Mortar" refers to dispersions containing fillers with particle sizes up to a maximum of approximately 8 mm, and "concrete" refers to dispersions containing fillers with particle sizes larger than 8 mm.

[0031] In this document, "fresh mortar" or "fresh concrete" means mortar or concrete immediately after the components have been mixed with water.

[0032] In this document, "self-supporting" is defined as a material property in which the material changes its individual dimensions by a maximum of 10% after forming, provided no external force is applied. This means that an extruded strand with a square cross-section and a side length of 10 mm has a height of 9 to 10 mm and a width of 10 to 11 mm after curing.

[0033] In this document, "dynamic mixing element" is understood to mean a component that comprises movable elements and is suitable for mixing solid and / or liquid components.

[0034] The process provides a water-containing mineral binder composition. This contains at least one mineral binder. A suitable mineral binder is, in particular, a mineral binder that reacts in the presence of water in a hydration reaction to form solid hydrates or hydrate phases. This can be, in particular, a hydraulic binder that hardens with water, even underwater, such as, in particular, cement or hydraulic lime, or a latently hydraulic binder that hardens with water under the action of additives, such as, in particular, slag, or a pozzolanic binder, such as, in particular, fly ash, or a non-hydraulic binder, such as, in particular, gypsum in the form of anhydrite or hemihydrate gypsum.

[0035] Preferably, the mineral binder is selected from the group consisting of cement, gypsum, burnt lime, slag and fly ash and mixtures thereof.

[0036] Preferably, the mineral binder composition comprises at least one hydraulic binder, preferably a cementitious binder.

[0037] Preferably, the hydraulic binder is selected from the group consisting of Portland cement, calcium aluminate cement, calcium sulfoaluminate cement and mixtures thereof.

[0038] Any available cement type or a mixture of two or more cement types can be used, for example, the cements classified under DIN EN 197-1: Portland cement (CEM I), Portland composite cement (CEM II), blast furnace slag cement (CEM III), pozzolanic cement (CEM IV), and composite cement (CEM V). Of course, cements produced according to an alternative standard, such as the ASTM standard or the Indian standard, are equally suitable.

[0039] Particularly preferred is a cement according to DIN EN 197-1, a calcium sulfoaluminate cement, a calcium aluminate cement, or mixtures thereof, optionally in a mixture with calcium sulfate.

[0040] Portland cement or a cement containing Portland cement according to DIN EN 197-1 is most preferred. Portland cement is particularly readily available and enables mortar with good properties.

[0041] Mixtures of cement, calcium aluminate cement, and calcium sulfate, or mixtures of cement and calcium sulfoaluminate cement, are also particularly suitable. Such binder mixtures enable short setting times and high early strengths.

[0042] Preferably, the proportion of the hydraulic binder in the total mineral binder is at least 5% by weight, in particular at least 20% by weight, more preferably at least 35% by weight, especially at least 65% by weight, with a maximum proportion of 100% by weight. According to a further advantageous embodiment, the mineral binder consists of 95 to 100% by weight of hydraulic binder, in particular cement clinker.

[0043] It may also be advantageous if the binder composition contains other binders in addition to or instead of a hydraulic binder. These are, in particular, latent hydraulic binders and / or pozzolanic binders. Suitable latent hydraulic and / or pozzolanic binders are, in particular, slag, granulated blast furnace slag, fly ash, and / or silica fume.

[0044] The mineral binder composition preferably also contains fillers, especially mineral fillers. Fillers are chemically inert, solid particulate materials and are available in various shapes, sizes, and materials, ranging from the finest sand particles to large, coarse stones. In principle, all fillers commonly used for concrete and mortar are suitable. Examples of particularly suitable fillers include aggregates, gravel, sand, especially quartz sand and limestone sand, crushed stones, calcined pebbles, or lightweight fillers such as expanded clay, expanded glass, foam glass, pumice, perlite, and vermiculite. Other advantageous fillers are calcium carbonate, aluminum oxide, amorphous silica (silica fume), or crystalline silica (quartz flour).

[0045] The particle size depends on the application and ranges from 0.1 µm to 32 mm and larger. It is preferable to mix different particle sizes to optimally adjust the properties of the water-based mineral binder composition. Fillers made of different materials can also be mixed. The particle size can be determined using sieve analysis.

[0046] Preferred fillers are those with particle sizes of a maximum of 8 mm, more preferably a maximum of 5 mm, even more preferably a maximum of 3.5 mm, most preferably a maximum of 2.2 mm.

[0047] Preferably, the mineral binder composition contains fillers of which at least 30% by weight, more preferably at least 40% by weight, most preferably at least 50% by weight, are smaller than 2 mm, preferably smaller than 1 mm, more preferably smaller than 0.5 mm, based on a total amount of 100% by weight of all fillers in the Binder composition. Suitable fillers with small particle size are especially fine quartz sand or calcium carbonate powder

[0048] Binder compositions with such particle sizes are easy to convey, can be easily mixed with the aqueous accelerator in the continuous mixer and result in a very homogeneous surface after application.

[0049] In special applications, fillers with particle sizes up to 32 mm, more preferably up to 20 mm, most preferably up to 16 mm can also be used.

[0050] Optionally, the water-based mineral binder composition may contain at least one additive, for example, a concrete admixture and / or a mortar admixture and / or process chemicals. The at least one additive comprises, in particular, a defoamer, a wetting agent, a dye, a preservative, a flow agent, a retarder, other accelerators, a polymer, an air entraining agent, a rheology aid, a viscosity modifier, a pumping aid, a shrinkage reducer, or a corrosion inhibitor, or combinations thereof.

[0051] The use of a flow agent or plasticizer in the water-containing mineral binder composition improves the flowability of the composition. Examples of suitable flow agents include lignosulfonates, sulfonated naphthalene-formaldehyde condensates, sulfonated melamine-formaldehyde condensates, sulfonated vinyl copolymers, polyalkylene glycols with phosphonate groups, polyalkylene glycols with phosphate groups, polycarboxylates or polycarboxylate ethers, or mixtures of the aforementioned flow agents. Polycarboxylate ethers are understood to mean comb polymers with anionic groups on the polymer backbone and polyalkylene oxide side chains, the anionic groups being selected in particular from carboxylate groups, sulfonate groups, phosphonate groups, or phosphate groups.

[0052] The flow agent preferably contains a polycarboxylate ether. In particular, the flow agent is a comb polymer comprising a polycarboxylate backbone with attached polyalkylene oxide side chains, particularly polyethylene oxide side chains. The side chains are bonded to the polycarboxylate backbone, in particular via ester, ether, imide, and / or amide groups. Corresponding comb polymers are also marketed commercially by Sika Schweiz AG under the Sika ® ViscoCrete ® range of trade names.

[0053] The use of setting retarders can be advantageous because it extends the processing time of the water-based binder composition. The setting retarder is preferably a hydroxycarboxylic acid, especially tartaric acid, citric acid, or gluconic acid, a sugar, especially sucrose, a phosphate or a phosphonate, or their salts or mixtures thereof.

[0054] The use of rheology aids can be advantageous because they can improve the cohesion of the composition. Preferred rheology aids are natural or modified polysaccharides, especially cellulose ethers or esters, starch, modified starch, xanthan gum, welan, diutan, or carrageenan.

[0055] Particularly preferred is the rheology aid methylcellulose, hydroxyethylcellulose, methylhydroxyethylcellulose or xanthan gum, or mixtures thereof.

[0056] The use of pumping aids can be advantageous because they improve the internal cohesion, suppleness, and lubricity of the composition. The pumping aid preferably contains water-soluble polymers, such as SikaPump® from Sika.

[0057] In a preferred embodiment, the binder composition contains a polymer, especially a water-insoluble, film-forming polymer. Film-forming polymers, when present as a dispersion in a liquid, can coagulate to form films upon drying. The polymer is preferably a homopolymer or copolymer of acrylic esters, a copolymer of styrene and butadiene, a copolymer of styrene and acrylic esters, or a homopolymer or copolymer of vinyl acetate.

[0058] Aqueous dispersions of such polymers are commercially available, for example under the trade names Acronal ®< (BASF), Primal ™< (DOW) or Revacryl (Synthomer).

[0059] However, redispersible polymer powders, which form dispersions when mixed with water, can also be used. Such polymer powders are commercially available, for example, under the trade names Vinnapas ® (Wacker) or Elotex ® (AkzoNobel).

[0060] In particular, the mineral binder composition comprises or consists of a hydraulic binder composition, preferably a mortar or concrete composition.

[0061] The water-based mineral binder composition is preferably prepared by mixing a dry mineral binder composition with water. The water may further contain additives in dissolved or dispersed form. However, the additives may also be mixed with the water-based mineral binder composition after the addition of the water, either as solids or in dissolved form.

[0062] The provision and manufacture of such mixtures is known to the person skilled in the art from the provision of mortars or concrete mixtures.

[0063] The production can be carried out in a batch mixer or in a continuous mixer.

[0064] The water-containing mineral binder composition is preferably a fresh mortar with a slump of at least 170 mm, preferably from 200 to 380 mm, particularly preferably from 250 to 350 mm, determined according to DIN EN 1015-3 after lifting the slump hopper without lifting the slump table.

[0065] Furthermore, the water-containing mineral binder composition is preferably a fresh concrete with a slump of at least 100 mm, preferably 200 to 295 mm, most preferably 250 to 280 mm, determined according to DIN EN 12350-2.

[0066] Water-based mineral binder compositions with such a consistency are particularly easy to pump and convey, and can be mixed very well with the aqueous accelerator in the continuous mixer.

[0067] The water-based mineral binder composition preferably comprises the following components: 15-50 wt% Portland cement, 40-65 wt% fillers, 0.01-5 wt% additives and 8-25 wt% water, based on 100 wt% water-containing mineral binder composition.

[0068] Furthermore, the water-containing mineral binder composition preferably comprises the following components: 10-30 wt% Portland cement, 5-20 wt% calcium aluminate cement, 0-4 wt% calcium sulfate, preferably calcium sulfate hemihydrate, 40-65 wt% fillers, 0.1-10 wt% additives and 8-25 wt% water, based on 100 wt% water-containing mineral binder composition.

[0069] The water-based mineral binder composition preferably comprises the following components: 20-40% by weight Portland cement, in particular Portland cement CEM I, 40-65% by weight fillers with a particle size of maximum 2.2 mm, wherein preferably at least 50% by weight of the fillers have a particle size of less than 0.5 mm, 0-2% by weight plasticizer, in particular a polycarboxylate ether, 0-8% by weight water-insoluble polymer, 0-2% by weight thickener, 0-1% by weight defoamer, 0-5% by weight further additives and 8-22% by weight water, based on 100% by weight water-containing mineral binder composition.

[0070] Another particularly preferred water-based mineral binder composition comprises the following components: 15-28% by weight Portland cement, especially Portland cement CEM I,7-15% by weight calcium aluminate cement or calcium sulfoaluminate cement 0-4% by weight calcium sulfate hemihydrate, 40-65% by weight fillers with a particle size of less than 2.2 mm, wherein preferably at least 50% by weight of the fillers have a particle size of less than 0.5 mm, 0.1-5% by weight retarder comprising in particular tartaric acid and / or citric acid and / or salts thereof, 0-2% by weight plasticizer, in particular a polycarboxylate ether, 0-2% by weight thickener, 0-1% by weight defoamer, 0-5% by weight further additives and 8-24% by weight water, based on 100% by weight water-containing mineral binder composition.

[0071] The water-containing mineral binder composition is fed from the point of supply to the continuous mixer, preferably by means of a pump and a delivery line, in particular a hose. The water-containing mineral binder composition is preferably easy to convey. Good conveyability is important for 3D printing because it is a prerequisite for homogeneous application. Especially for the printing of large molded parts, the length of a delivery line between the pump and the continuous mixer can reach up to 50 m or more, which can lead to high pressure in the delivery line. High pressure, especially in a hose, is disadvantageous because the material is subjected to considerable stress and can burst if overloaded. Easily conveyable compositions can prevent excessive pressure buildup. The pressure in the delivery line between the pump and the continuous mixer is preferably below 40 bar, more preferably below 25 bar.

[0072] Preferably, a so-called "lubricating mixture" can be pumped through the delivery line and pressure device before the water-containing mineral binder composition is fed to the continuous mixer. The "lubricating mixture" is not applied; it is typically disposed of in a waste container. Suitable lubricating mixtures are, in particular, aqueous solutions of an organic polymer, in particular SikaPump®< Start 1, or a low-viscosity mixture of water and cement and / or fine filler, in particular limestone. Preferably, an aqueous polymer solution is first pumped through the delivery line and pressure device, followed by a low-viscosity mixture of water and cement and / or fine filler, before the water-containing mineral binder composition is pumped.

[0073] The water-based mineral binder composition is mixed with an aqueous accelerator. The accelerator is preferably a setting accelerator and / or a hardening accelerator, or a mixture thereof.

[0074] A variety of substances known to those skilled in the art can be used as accelerators.

[0075] The aqueous accelerator preferably contains at least one compound selected from the group consisting of amino alcohols, alkali and alkaline earth nitrates, alkali and alkaline earth nitrites, alkali and alkaline earth thiocyanates, alkali and alkaline earth halides, alkali and alkaline earth carbonates, glycerol, glycerol derivatives, glycols, glycol derivatives, aluminum salts, aluminum hydroxides, alkali and alkaline earth hydroxides, alkali and alkaline earth silicates, alkali and alkaline earth oxides, crystallization nuclei, in particular calcium silicate hydrate compounds in finely divided form, and mixtures thereof.

[0076] The aqueous accelerator particularly preferably contains an aluminum salt or aluminum hydroxide, in particular sodium aluminate, potassium aluminate, aluminum sulfate, aluminum hydroxysulfate, aluminum hydroxide or mixtures thereof.

[0077] Such aluminum compounds accelerate the setting of a hydraulic binder particularly well.

[0078] Preferably, several aqueous accelerators which differ in composition can also be added together or separately.

[0079] This allows, for example, flexible adaptation to a wide variety of applications.

[0080] The dosage of the accelerator depends on the composition of the water-based mineral binder composition, in particular on the type and quantity of the hydraulic binder, the type and quantity of the retarder, if present, and the quantity of water, as well as on the ambient temperature and the temperature of the water-based binder composition.

[0081] The accelerator is preferably added in such a quantity that the accelerated composition remains readily moldable for several seconds to several minutes. This allows the layers to be applied homogeneously, form a strong bond, and the surface of the molded article can be further treated, for example, smoothed, if desired.

[0082] If the accelerator is applied in insufficient quantities, the accelerated binder composition applied in layers will only reach the necessary strength late for another layer to be applied. This requires a significant reduction in printing speed or waiting times, which delays the completion of the molded part.

[0083] If the accelerator dosage is too high, it may happen that the accelerated mineral binder composition already hardens, at least partially, in the mixer, which can lead to blockage of the mixer, or the partial hardening occurs shortly after the mixer before or during application, which can lead to the applied layer being inhomogeneous and crumbly and the bond with a later applied layer being inadequate.

[0084] Preferably, the mineral binder composition is mixed with the aqueous accelerator shortly before the application of the accelerated mineral binder composition.

[0085] Preferably, the aqueous accelerator is dosed in an amount in the range of 0.3 to 8 parts by weight, more preferably 0.4 to 5 parts by weight, even more preferably 0.5 to 2.5 parts by weight, calculated as solid without water, based on 100 parts by weight of mineral binder.

[0086] In addition to the accelerator, other additives can be mixed with the water-based mineral binder composition using the continuous mixer.

[0087] The at least one aqueous accelerator and optionally further additives are preferably dosed via dosing devices in the area of ​​the continuous mixer.

[0088] The conveyance of the water-based mineral binder composition and the aqueous accelerator, and optionally other additives, to the mixer can be achieved, for example, via one or more conveying devices, in particular pumps and conveying lines. The conveying devices can be controlled, in particular, via a control unit, and in particular independently of one another.

[0089] Preferably, the continuous mixer is mounted on a movable print head.

[0090] Preferably, the print head has a discharge nozzle for the layer-by-layer application of the accelerated mineral binder composition.

[0091] Preferably, the continuous mixer is mounted on the movable print head directly next to this discharge nozzle. This allows the temporal strength development of the mineral binder to be precisely adjusted. In particular, the addition of an accelerator can significantly accelerate the overall application.

[0092] Preferably, the dimensions and weight of the continuous mixer are adapted to the size of the printing head. Thus, it is advantageous if the mixer in a printing system for smaller molded parts is also smaller than the mixer in a printing system for larger molded parts such as house parts or walls.

[0093] Thus, the continuous mixer can have a weight of 20 to 100 kg or more for printing molded parts in the order of several meters, or a weight of about 1 to 20 kg for printing molded parts in the order of about 5 cm to 1 m.

[0094] With the continuous mixer, the accelerator is mixed very quickly, efficiently and homogeneously into the mineral binder composition.

[0095] This is important so that the composition is homogeneous when applied layer by layer and hardens evenly and quickly.

[0096] In an exemplary embodiment, the mixer comprises more than one inlet, in particular two, three, four, five, six, seven, or eight inlets.

[0097] The provision of several inlets offers the advantage that components which react with each other or are not stable together can be fed into the mixing area of ​​the mixer through separate inlets.

[0098] Particularly suitable mixers are described in the international application with the application number PCT / EP2017 / 054824.

[0099] Preferably, the mixing of the water-containing mineral binder composition with the aqueous accelerator takes place in the mixing area at a rotational speed of the agitator shaft of 500 to 3000 revolutions per minute, more preferably of 650 to 2500 revolutions per minute, even more preferably of 800 to 2000 revolutions per minute, most preferably of 1000 to 1500 revolutions per minute.

[0100] Mixing at high speed ensures rapid and efficient mixing of the binder composition with the accelerator, which is especially important because a poorly distributed accelerator in the aqueous mineral binder composition can quickly lead to very high viscosity and / or hardening of the binder, which can cause blockage and / or damage to the mixer. However, if the accelerator is mixed very quickly and efficiently with the aqueous mineral binder composition, the viscosity increase and hardening occur homogeneously and controllably, without blockage of the mixer, and the accelerated mineral binder composition can be applied without disruption.

[0101] Preferably, the residence time of the water-containing mineral binder composition in the mixer is less than 10 s, more preferably less than 7 s, particularly preferably less than 4 s.

[0102] The average residence time of the binder composition in the mixing device is the average time a particle spends in the mixing device, from the inlet to the outlet.

[0103] The continuous mixer, especially in the preferred form, ensures a very good distribution of the accelerator in the binder composition, which leads to a homogeneous curing of the accelerated binder composition, without the formation of lumps or poor bonding of the components.

[0104] Surprisingly, the use of the aqueous accelerator in combination with the use of the continuous mixer can compensate for the usual fluctuations in the composition of the water-containing mineral binder composition, such as fluctuations in water content, in the particle size distribution of the fillers or in the cement quality, thus making the properties of the accelerated binder composition very constant and the process very robust, which is extremely advantageous.

[0105] The accelerated binder composition is readily deformable immediately after mixing in the accelerator and can be applied in homogeneous layers using the print head. These layers become self-supporting after a short time and exhibit rapid strength development. Subsequent layers can therefore be easily applied to the underlying layers at short intervals and in heights of several centimeters.

[0106] A further unclaimed subject matter is therefore an accelerated binder composition obtained from the described process, which immediately after mixing the water-containing mineral binder composition with the aqueous accelerator has a penetrometer resistance of at most 0.03 MPa for at least 10 seconds, and after at most 10 minutes, preferably after at most 6 minutes, even more preferably after at most 4 minutes, has a penetrometer resistance of more than 0.03 MPa, wherein the penetrometer resistance is determined at 21°C with a penetrometer according to ASTM C-403 with a needle of 1 mm diameter.

[0107] The accelerated binder composition is preferably applied via a movable print head.

[0108] In particular, the print head has at least one discharge opening, which can be identical to the outlet of the continuous mixer, through which the curable material can be discharged.

[0109] The good stability of the applied layers eliminates the need to carry formwork panels at the discharge opening of the print head.

[0110] However, in special applications it can be advantageous if formwork panels are carried directly at the discharge opening.

[0111] Preferably, a discharge nozzle is located at the discharge opening to shape the discharged material. The shape is not limited, but should be adapted to the maximum particle size of the material to be discharged. The discharge nozzle is preferably rectangular, square, or round. Additional shaping elements can be mounted in the discharge nozzle.

[0112] In a preferred variant, the print head is movable in one, two, or three spatial directions. A print head that is movable in three spatial directions is particularly preferred. This allows molded bodies of almost any shape to be produced in a particularly simple manner.

[0113] The movement of the print head can be realized in particular by mounting the print head on a conventional robot arm which is movable in one, two or three spatial directions.

[0114] The print head is preferably located on a 3-axis gantry robot system. This enables rapid printing even of large molded parts with flexible shapes.

[0115] It is also possible to realize movements in one, two, or three spatial directions by correspondingly moving the build space. The build space is the area, for example, a surface, on which the molded body is built.

[0116] Preferably, the accelerated mineral binder composition, when provided and applied at 21°C, has a compressive strength of at least 10 MPa 8 hours, more preferably 4 hours, most preferably 1 hour, after mixing with the aqueous accelerator, the compressive strength being determined according to EN 196-1.

[0117] With the method according to the invention, shaped bodies can be produced surprisingly quickly by layer-by-layer application.

[0118] The height of an individual layer, typically measured in a direction substantially perpendicular to the planes formed by individual layers, in particular in the vertical direction, is preferably 1 mm to 200 mm, more preferably 5 mm to 100 mm, in particular 10 mm to 50 mm.

[0119] The total height of the shaped body or the thickness of all individual layers of the shaped body taken together is preferably 0.01 m to 100 m or more, more preferably 0.1 m to 80 m, even more preferably 0.3 m to 30 m, in particular 0.5 m to 10 m. This is particularly the case if the mineral binder composition comprises or consists of a mortar or concrete composition.

[0120] The surface of the molded body can be smoothed, repaired, or specially shaped using suitable tools, as long as it is still workable. This can be done as part of the machine production process or manually as a separate step. The surface can also be given a functional or decorative coating, such as paint.

[0121] The molded body can also be cut with suitable tools as long as it is still workable. This allows holes to be made in the molded body, particularly for window openings, door openings, and cable entry points, or even cuts, especially for later processing steps.

[0122] The molded body produced using the process according to the invention can have virtually any desired shape. The molded body is, for example, a building, a prefabricated part for a building, a construction element, a masonry structure, a bridge, a column, a decorative element such as artificial mountains, reefs, or sculptures, a basin, a fountain, or a tub. The molded body can be solid or hollow, with or without a base. The molded body can be created directly on site and cannot be moved after application. However, the molded body can also be created elsewhere, particularly in a factory. This is preferably done on a non-adherent base. After curing, the molded body can be transported to the desired location. Examples

[0123] The following are exemplary embodiments intended to further illustrate the described invention. Of course, the invention is not limited to these described exemplary embodiments. Materials used

[0124] Sigunit ®< -L53 AF (CC) is an aqueous alkali-free accelerator based on aluminum sulfate with a solids content of approximately 52% by weight, available from Sika.

[0125] Betoflow ®< D is a fine calcium carbonate powder with a particle size of 1-5 µm, available from Omya.

[0126] Nekafill ®< 15 is a limestone powder available from Kalkfabrik Netstal.

[0127] Sika ®< ViscoCrete ®< -3088 S is an aqueous retarder / plasticizer based on a polycarboxylate ether, available from Sika.

[0128] Carbowet ®< 4000 is a defoamer available from Air Products Chemicals Europe.

[0129] SikaPump ®< is a pumping aid containing water-soluble polymers, available from Sika. Description of the printing process

[0130] A 3-axis gantry robot was used for 3D printing.

[0131] The gantry robot was equipped with a print head that could be moved in all three spatial directions. A dynamic continuous mixer weighing approximately 60 kg was integrated into the print head. The mixer was designed as shown in Fig. 1shown. It had an inlet for the mortar, an inlet for the aqueous accelerator, and an outlet for the accelerated mortar. The drum contained the mixing section and the conveying section and had a diameter of approximately 100 mm. In the mixing section, there was a pin-driven agitator shaft, and in the conveying section, a six-turn conveyor screw. The agitator shaft and the conveyor screw were arranged on the same axis. The inlets were located near the agitator shaft, and the outlet was located at the end of the conveyor screw. A round nozzle with a diameter of 40 mm was attached to the outlet.

[0132] A forced-action mixer was used to prepare the fresh mortar. The dry mortar components were first mixed for 1 minute, then the water and aqueous components were added and thoroughly mixed within 3 minutes.

[0133] Using a screw pump, the mortar was pumped through a hose with an inner diameter of 35 mm and a total length of 32 m to the first inlet of the mixer.

[0134] The aqueous accelerator was pumped from a storage container through a hose to the second inlet of the mixer.

[0135] In the mixer, the mortar mixture was continuously mixed with the aqueous accelerator and the accelerated mortar was applied in layers via the outlet and nozzle of the print head.

[0136] The conveying of the mortar mixture, the dosage of the accelerator, the rotation speed of the continuous mixer and the movement of the pressure head were controlled by a computer program.

[0137] Before the first mortar mix, a mixture of 1 bag of SikaPump ®< Start 1 and 30 l of water and then a mixture of 15 kg of Nekafill ®< 15 and 15 kg of water was pumped through the pressure device, i.e. through the hose, the mixer and the pressure head, into a waste trough.

[0138] The temperature of the water-containing mortar mixture was about 19°C, that of the ambient air about 21°C. Example 1

[0139] A fresh mortar was prepared from 120 kg Portland cement CEM I 52.5, 92 kg quartz sand of 0-1 mm with a moisture content of 2.2 wt%, 33 kg Betoflow ®< -D, 80 kg Nekafill ®< 15, 1.1 kg Sika ®< Viscocrete ®< -3088 S, 0.004 kg Carbowet ®< 4000 and 56.8 kg water.

[0140] The fresh mortar had a slump of 260 mm, measured according to DIN EN 1015-3 after lifting the slump hopper without lifting the spreading table.

[0141] The fresh mortar was conveyed to the continuous mixer at a conveying rate of approximately 33 kg / min.

[0142] Pre-diluted Sigunit ®< -L53 AF (CC) (75 wt% Sigunit ®< -L53 AF (CC) and 25 wt% water) was fed to the continuous mixer as accelerator at a feed rate of approximately 350-400 ml / min.

[0143] The fresh mortar and accelerator were continuously mixed in the mixer at approximately 1200 revolutions per minute. The accelerated mortar mixture was applied to a plastic sheet laid on a concrete floor using a print head, in layers approximately 50 mm wide and 10 mm high. The print head speed was 20–30 meters per minute. A conical, elongated, curved hollow frame in the shape of a bathtub with an open bottom, approximately 800 mm high, was printed in several layers. The long sides were parallel, the wide sides were rounded, and the slope of the walls on the wide sides was approximately 30°. The finished molded body had a bottom and top width of approximately 590 mm, a bottom length of approximately 720 mm, and an top length of approximately 1670 mm. The molded body took approximately 15 minutes to print. The height of the lower and upper layers differed by no more than 5%.The printed molded body had a wavy, very uniform surface without any visible defects.

[0144] During the entire printing process, the pressure in the hose for delivering the fresh mortar was in the range of 3-5 bar.

[0145] Approximately 16 hours after the application of the last layer, the hollow body was lifted onto a transport pallet using carrying straps and a crane without causing any damage to the printed body.

[0146] After about four days, the mold was broken using a heavy hammer, and the fragments were optically analyzed. The fracture surfaces exhibited a uniform surface, free of air pockets or defects. The fracture surfaces showed no preferred orientation, meaning that the applied layers exhibited equally good bonding between each other as within the same layer. Comparison example 1

[0147] Example 1 was repeated, but without the addition of an accelerator. The mortar flowed from the discharge nozzle and could not be applied in layers. The test was subsequently discontinued. Comparison example 2

[0148] Example 1 was repeated, but without using a mixer to mix the accelerator with the mortar mixture. The accelerator dosing line was mounted so that the accelerator was dosed just before the discharge nozzle in the center of the hose through which the mortar was conveyed. The accelerator dosage was the same as in Example 1. The mortar discharged from the discharge nozzle was very inhomogeneous. A buildup of multiple superimposed layers was not possible with this mortar. Comparison example 3

[0149] Example 1 was repeated, but the aqueous accelerator was added and mixed directly after the aqueous mortar mixture was prepared. After a few seconds, the mortar stiffened, and it was no longer possible to convey it to the print head. Short description of the drawings

[0150] In the following, embodiments of the invention are explained in more detail with reference to the drawing.

[0151] Fig. 1 shows: schematic representation of an example mixer.

[0152] Only the elements essential for a direct understanding of the invention are shown.

[0153] In Fig. 1 An exemplary mixer 1 is shown. The mixer 1 has a drive 3 and a drum 2 with a mixing area 10 and a conveying area 11. In the mixing area there is an agitator shaft 4 and two inlets 6, and in the conveying area 11 there is a conveying device 5 and an outlet 7.

[0154] The conveying device 5 is arranged directly adjacent to the agitator shaft 4, so that the accelerated mineral binder composition mixed by the agitator shaft 4 can be directly captured by the conveying device 5 and conveyed out of the drum 2 through the outlet 7.

[0155] In this illustration, the conveying device 5 is designed as a screw conveyor. The screw conveyor in this illustration has two complete turns 9. Depending on the desired conveying capacity, the screw conveyor can be dimensioned or designed differently. The conveying device 5 and the agitator shaft 4 are arranged on the same axis in the drum 2. In this illustration, the agitator shaft 4 is equipped with pins 8, so that when the agitator shaft rotates, the water-containing binder composition in the drum is moved by the pins 8.

[0156] In this illustration, two inlets 6 are arranged on the drum 2. In an alternative variant not shown, however, the drum 2 has only one inlet. In this case, the components to be mixed can already be brought together before being conveyed into the drum 2 via the inlet.

[0157] Such mixers are particularly well suited to mixing the aqueous accelerator with the water-containing mineral binder composition homogeneously and quickly.

[0158] Preferred is a mixer 1 which additionally comprises a drive 3, and the dynamic mixing element comprises a stirring shaft 4 with stirring elements 8 for mixing the water-containing mineral binder composition with the aqueous accelerator, wherein the mixing area 10 and the conveying area 11 are arranged in a same drum 2.

[0159] Preferably, the agitator shaft 4 and the conveying device 5 are arranged on the same axis, wherein the conveying device 5 comprises in particular a conveyor screw.

Claims

1. Method for applying a mineral binder composition by 3D printing, comprising the steps of - providing a hydrous mineral binder composition, - feeding the hydrous mineral binder composition, especially by a pump, to a continuous mixer (1) comprising • a mixing region (10) comprising at least one dynamic mixing element and at least one inlet (6), • a conveying region (11) connected to the mixing region (10) and comprising at least one conveying device (5) and an outlet (7), the hydrous mineral binder composition being conveyed through the at least one inlet (6) into the mixing region (10), - feeding at least one aqueous accelerator for the setting of the hydrous mineral binder composition into the mixing region (10) of the continuous mixer (1), - mixing the at least one aqueous accelerator with the hydrous binder composition in the mixing region (10) of the continuous mixer (1) to give an accelerated binder composition, - conveying the accelerated binder composition by the conveying device (5) to the outlet (7), and - applying the accelerated binder composition layer by layer, in particular by way of a movable printing head, characterized in that the method is a method for producing shaped bodies by applying a formable material in a plurality of layers or relatively small portions, where a solid shaped body is formed after curing and where the layers in this case are not applied by spraying.

2. Method according to Claim 1, characterized in that the hydrous mineral binder composition comprises at least one hydraulic binder, preferably a cementitious binder.

3. Method according to Claim 2, characterized in that the hydraulic binder is selected from the group consisting of Portland cement, calcium aluminate cement, calcium sulfoaluminate cement, and mixtures thereof.

4. Method according to any of the preceding claims, characterized in that the mineral binder composition comprises fillers of which at least 30 wt%, preferably at least 40 wt%, most preferably at least 50 wt% are smaller than 2 mm, preferably smaller than 1 mm, more preferably smaller than 0.5 mm, based on a total amount of 100 wt% of all fillers in the binder composition.

5. Method according to any of the preceding claims, characterized in that the hydrous mineral binder composition is a fresh mortar having a slump of at least 170 mm, preferably of 200 to 380 mm, more preferably of 250 to 350 mm, determined according to DIN EN 1015-3 after the raising of the slump cone without lifts of the flow table.

6. Method according to any of the preceding claims, characterized in that the aqueous accelerator comprises at least one compound selected from the group consisting of amino alcohols, alkali metal and alkaline earth metal nitrates, alkali metal and alkaline earth metal nitrites, alkali metal and alkaline earth metal thiocyanates, alkali metal and alkaline earth metal halides, alkali metal and alkaline earth metal carbonates, glycerol, glycerol derivatives, glycols, glycol derivatives, aluminium salts, aluminium hydroxides, alkali metal and alkaline earth metal hydroxides, alkali metal and alkaline earth metal silicates, alkali metal and alkaline earth metal oxides, crystallization nuclei, especially calcium silicate hydrate compounds in finely divided form, and mixtures thereof.

7. Method according to any of the preceding claims, characterized in that the aqueous accelerator comprises an aluminium salt or aluminium hydroxide, especially sodium aluminate, potassium aluminate, aluminium sulfate, aluminium hydroxysulfate, aluminium hydroxide, or mixtures thereof.

8. Method according to any of the preceding claims, characterized in that the aqueous accelerator is metered in an amount in the range from 0.3 to 8 parts by weight, preferably 0.4 to 5 parts by weight, more preferably 0.5 to 2.5 parts by weight, calculated as solid without water, based on 100 parts by weight of mineral binder.

9. Method according to any of the preceding claims, characterized in that the continuous mixer is mounted on a movable printing head.

10. Method according to any of the preceding claims, characterized in that the mixer (1) additionally comprises a drive (3), and in that the dynamic mixing element comprises a stirring shaft (4) having stirring elements (8), for mixing the hydrous mineral binder composition with the aqueous accelerator, the mixing region (10) and the conveying region (11) being arranged in one and the same drum (2).

11. Method according to Claim 10, characterized in that the stirring shaft (4) and the conveying device (5) are arranged on one and the same axis, the conveying device (5) more particularly comprising a screw conveyor.

12. Method according to any of the preceding claims, characterized in that the hydrous mineral binder composition is mixed with the aqueous accelerator in the mixing region at a stirring shaft speed of 500 to 3000 revolutions per minute, preferably of 650 to 2500 revolutions per minute, more preferably still of 800 to 2000 revolutions per minute, most preferably of 1000 to 1500 revolutions per minute.