A two-component (2K) cement-based composite material and production method developed for robotic additive manufacturing (3D printing) systems, providing high surface quality and adjustable setting time.

Abstract

The invention relates to a concrete mortar and production method specifically formulated for robotic systems (3DCP) that eliminates the use of formwork in the construction industry. The mortar consists of cement, 0-2 mm crushed stone, fly ash, viscosity regulator, PT, ceramic adhesive, and water. Thanks to the developed two-component (2K) system, the setting time and rheology of the mortar can be instantly adjusted at the printing point according to environmental conditions (temperature, humidity). The formulation, especially with 0-2 mm aggregate and polymer additives, provides significantly higher surface quality (smoothness), sharp geometric details, and strong interlayer adhesion compared to existing techniques. This enables the rapid, economical, and formwork-free production of street furniture, architectural elements, and residential buildings.

Description

FOR ROBOTIC ADDITIVE MANUFACTURING (3D PRINTING) SYSTEMS IMPROVED, HIGH SURFACE QUALITY AND ADJUSTABLE. TWO-COMPONENT (2K) CEMENT-BASED PRODUCT PROVIDING SETTING TIME. COMPOSITE MATERIAL AND PRODUCTION METHOD The invention has implications for the construction and building materials industry, particularly in the computer sector. formworkless construction using controlled robotic systems (3D concrete printers) It relates to the production of its elements. More specifically, the invention includes urban furniture, Architectural elements and residential type structures additive manufacturing used in its production by this method, with enhanced thixotropic properties, environmentally friendly. a two-component (2K) mortar formulation that can adapt to the conditions and this mortar It relates to the method of application. State of the Art (Current Technology) Throughout history, the construction industry has used molds in the production of building elements. It has become dependent on these systems. Traditional concrete pouring methods use wood and steel. or the preparation of composite molds, the pouring of concrete into these molds, and The curing process ultimately requires the removal of the molds. This process is part of the total construction. molding and material costs, which constitute approximately 40-60% of the total cost. This brings with it the possibility of molded production and complex geometric designs. and serious restrictions in realizing original architectural forms. It creates. In recent years, 3D Concrete Printing (3DCP) technologies have developed. It aims to overcome these limitations with its "construction without molds" vision. However The mortar formulations and printing methods used in current technology vary by technique. It contains shortcomings. The vast majority of current practices are "One It is based on "component (1K)" mortar systems. In 1K systems, water and binder The hydration reaction begins the moment the material is mixed. This process causes the material to... pumpability (workability) and interlayer transport capacity (green It creates a "trade-off" between (strength) and the mortar. The mortar can be pumped. It should be fluid, but retain its form without collapsing the moment it exits the nozzle. 1 It must be able to protect this balance. The current 1K fees are insufficient to achieve this balance; either... There are freezing / clogging problems in the pump line or structural issues after printing. Deformations (slump) are observed. Another significant issue in the literature is surface quality. Current 3D printers... Aggregate sizes used in mortars (typically in the 4-8 mm range) and rheological properties The designs have a rough appearance on the printing surface known as the "staircase effect". and results in a rough texture. This situation necessitates an additional plastering process for the manufactured structures. or eliminating the cost advantage by making surface treatment mandatory It removes. Furthermore, the "cold joint" problem is a critical issue in additive manufacturing. This is a risk factor. Prolonged waiting time between layers or the environment. The drying of the substrate surface due to the effects of conditions (temperature, wind), the top This prevents the structure from forming a chemical bond (adhesion) with the surrounding layer. This affects the mechanical properties of the structure. It disrupts its integrity and leads to anisotropic weaknesses. Currently, there are options that offer both high surface quality (high resolution) and stable in varying climatic conditions, with the power supply time controllable during printing. There is no functioning, original, and domestically developed 2K fee system in place. The objective technical problem at this point is the existing single-component (1K) mortar. systems, fluidity during pumping and instantaneous hardening after printing as a result of its inability to strike a balance between them, the fine geometric details and The problem is the inability to achieve a smooth surface texture. Furthermore, the existing mortars... flexibility to adjust the charging time according to changing environmental conditions (temperature, humidity) The lack of this leads to problems of stability and repeatability in production; Mold dependency in traditional methods also increases production time and costs. This appears as an increase. A brief description of the invention. The invention eliminates the need for formwork in the construction industry through robotics. a concrete mortar and production specifically formulated for 3DCP systems It is related to the method. The subject of the invention is mortar; Cement, 0-2 mm crushed stone, fly ash, 2 It contains Viscosity Regulator, PT, Ceramic Adhesive and Water. Two developed. Thanks to the component (2K) system, the setting time and rheology of the mortar are controlled at the printing point. It can be adjusted instantly according to environmental conditions (temperature, humidity). The formulation, especially with 0-2 mm aggregates and polymer additives, is based on existing techniques. Much higher surface quality (smoothness) compared to others, sharp geometric details. and provides strong interlayer adhesion. This allows for the application of this material to urban furniture. The rapid, economical, and formless production of architectural elements and housing becomes possible. It is coming. The Purpose of the Invention and the Technical Problems It Solves The main purpose of the invention is to eliminate the disadvantages mentioned above. A high-performance mortar compatible with the technical capabilities of the robotic system. The goal is to provide the composition and production method. The specific technical problems that the invention solves are as follows: • Dynamic Setting Control: Thanks to its two-component (2K) system structure, the mortar setting control is controlled. The charging time can be instantly controlled at the nozzle. This has been brought about. This ensures stability at different air temperatures and humidity levels. It enables production. • Superior Surface Quality: Aggregate size is limited to 0-2 mm and With the use of special viscosity regulators, compared to traditional systems It is possible to produce products with much smoother, finer details and sharper lines. has been made, • Enhanced Adhesion: Ceramic adhesive added to the formulation / Thanks to polymer modifying agents, chemical bonds between layers are established. reinforced, cold joint risk minimized, and the structure is monolithic. behavior has improved, • Mold-Free and Fast Production: The developed thixotropic mortar does not require any mold. without needing support, it can support its own weight and upper layers. They can transport [the product], thus increasing production speed and reducing costs. is being reduced. Description of the Invention 3 The mortar that is the subject of the invention has rheological properties (yield stress and plasticity). cement-based (viscosity) specifically optimized for layered manufacturing methods. It is a composite. The blend design is based on "Particle Packing Theory". Based on theory, the highest compactness and the lowest void ratio It is designed to provide this. The mortar mixture that is the subject of the invention has the following component ranges by weight: It includes: a) Cement (CEM I) [300 - 850 kg]: Main hydraulic component of the mixture. It is a binder. In the invention, a CEM I type binder with a high rate of early strength gain is used. Portland cement is preferred. The 300-850 kg range is required for 3D printing. the difference between "structural buildability" and "thermal stability" It maintains balance. Uses exceeding 850 kg should be avoided due to the high heat of hydration, affecting microorganisms. While this can lead to cracks, uses below 300 kg can reduce the load-bearing capacity of the layers. It weakens. b) Crushed stone / Fine aggregate (0-2 mm) [500 - 1500 kg]: The most critical aspect of the invention. One of its characteristics is that the maximum particle diameter (Dmax) of the aggregate used is 2 mm. This fine granulometry allows the robotic tool to operate with millimeter precision. This allows the printed surface to be smooth, almost like a ceramic texture. It provides volumetric support by forming the skeleton structure (skeleton) of the mortar in the 500-1500 kg range. It provides stability. c) Fly Ash [150 - 500 kg]: A mineral additive with pozzolanic properties. Thanks to its spherical grain structure, it creates a "ball effect" in the mortar in the pipeline. It reduces friction and increases pumpability. It also improves cement hydration. It reacts with its product, Ca(OH)2, to form CSH gels, and ultimately It increases the impermeability and sulfate resistance of concrete. d) Viscosity Modifier (VMA) [0.5 - 2 kg]: Cellulose ethers or This component, which contains polysaccharide derivatives, increases the water-holding capacity of the mortar and It prevents segregation. It provides "shear-thinning" (sliding) to the material. Thanks to its (subtle) property, the mortar becomes fluid under pump pressure, however When it exits the nozzle and reaches a stationary state, it suddenly increases in viscosity and changes its shape. It protects. e) PT (Activator / Power Supply Accelerator) [0.05 - 1.5 kg]: 2K of the invention 4 It is the "Component B" or accelerating agent in the system. It is included in the mixture at the printing point. This chemical triggers the reaction of the aluminate phases of the cement, causing it to set. It reduces the duration to the order of minutes, even seconds. Usage rate, environment temperature and geometry of the part to be printed (for example, more on curved parts) (high dosage) is dynamically adjusted. f) Ceramic Adhesive (Polymer Binder) [0.05 - 1.5 kg]: Generally This additive, based on styrene-acrylic or vinyl acetate copolymer, is embedded in the cement matrix. It forms flexible polymer bridges. This component is particularly suitable for interlayer adhesion. By increasing the interlayer bond strength, 3D-printed structures can withstand earthquakes or tensile stresses. It improves its performance under stress. g) Water [150 - 450 kg]: Water / cement ratio determines the porosity of the concrete and is the main factor determining its strength. Within the scope of the invention, the amount of water and chemical The additives are optimized with water-reducing effects in the range of 150-450 kg. He was detained. Method of Implementing the Invention The method described in the invention involves the following steps: 1. The dry components (cement, crushed stone, fly ash) must be homogeneous. mixing. 2. Preparing the main mixture (batch) by adding water and viscosity regulator and transfer to the pump. 3. During the transfer of the mortar to the robotic arm or at the nozzle, PT and If necessary, additional water / additives should be dosed and injected into the mixture (2K (The principle). 4. During printing, ambient conditions (temperature, humidity) are monitored via sensors. monitoring and dosing the mortar rheology according to this data. (It automatically revises its viscosity and charging time). 5. Creating the final product by laying the material layer by layer. Thanks to this method, unlike existing systems, the climate... High surface quality and repeatable production, regardless of conditions. standards are met.

Claims

FOR IMPROVED, HIGH SURFACE QUALITY AND ADJUSTABLE. TWO-COMPONENT (2K) CEMENT-BASED PRODUCT PROVIDING SETTING TIME. COMPOSITE MATERIAL AND PRODUCTION METHOD The invention eliminates the need for formwork in the construction industry through robotics. a concrete mortar and production specifically formulated for 3DCP systems It is related to the method. The subject of the invention is mortar; Cement, 0-2 mm crushed stone, fly ash, It contains Viscosity Regulator, PT, Ceramic Adhesive and Water. Two developed. Thanks to the component (2K) system, the setting time and rheology of the mortar are controlled at the printing point. It can be adjusted instantly according to environmental conditions (temperature, humidity). The formulation, especially with 0-2 mm aggregates and polymer additives, is based on existing techniques. Much higher surface quality (smoothness) compared to others, sharp geometric details. and provides strong interlayer adhesion. This allows for the application of this material to urban furniture. The rapid, economical, and formless production of architectural elements and housing becomes possible. It is coming. 7 REQUESTS 1. Formless, layered manufacturing using robotic 3D concrete printers. improved method used in the production of structural elements a mortar composition with thixotropic properties and surface quality and its characteristic is that, in relation to the total mixture weight, it falls within the following ranges: It contains the following components: Between 300 kg and 850 kg of cement, Crushed stone weighing between 500 kg and 1500 kg, with a grain size of 0-2 mm. (Fine Aggregate), between 150 kg and 500 kg of fly ash. Viscosity Regulator between 0.5 kg and 2 kg, PT (Plug Accelerator / Activator) between 0.05 kg and 1.5 kg, Ceramic Adhesive, between 0.05 kg and 1.5 kg, That's between 150 kg and 450 kg of water.

2. A mortar composition conforming to Claim 1; its characteristic is the aforementioned ceramic. The adhesive forms polymer bridges between the superimposed layers. a polymer modification that increases interlayer adhesion (sticking) He is a spy.

3. A mortar composition conforming to Claim 1; its characteristic is the aforementioned crushed stone. the component provides high surface smoothness and detail accuracy. The maximum particle diameter should be 2 mm.

4. The fee applicable to any of the claims 1 through 3. It is a production method for the application of its composition; Its feature is that the mortar components are mixed by means of a two-component (2K) robotic system. processing; here, the main mortar mixture is pumped and mixed with PT and other chemical regulators are incorporated into the mixture at the nozzle, The power supply time is checked at the time of printing.

5. A production method that complies with Claim 4; characterized by its water / binder ratio and the setting accelerator dosage, ambient temperature measured during production, and It can be dynamically adjusted according to humidity conditions. 6