Method and system for inclined layer horizontal additive construction

Abstract

Presented is an innovative method and system for in-situ construction using 3D printing technology that involves printing layers at an inclination, with a variable range from 0 to 90 degrees, thereby facilitating the horizontal extension of the structure without the need for additional support structures. This technique involves the deposition of construction material layer-by-layer at variable angles, with each new layer slightly horizontally shifted from the previous one, thereby facilitating the in-situ construction of horizontally extended structures.

Description

Method and System for Inclined Layer Horizontal Additive ConstructionField

[0001] The present invention relates generally to the field of additive construction and, more specifically, to a method and system for constructing elongated structures, such as concrete pipes, by employing a 3D printing technique that utilizes inclined layers.BACKGROUND

[0002] Traditional methods of constructing elongated structures like pipes involve precasting the structures and then shipping them to the construction site. This approach presents logistical and economic challenges due to the significant costs and time associated with shipping. A more efficient method is therefore needed.SUMMARY

[0003] The present invention addresses the aforementioned issues by providing an innovative method and system for in-situ construction using 3D printing technology. This method involves printing layers at an inclination, with a variable range from 0 to 90 degrees, thereby facilitating the horizontal extension of the structure without the need for additional support structures.The disclosure provides methods and system for constructing elongated structures via an inclined layer additive construction technique. This technique involves the deposition of construction material layer-by-layer at variable angles, with each new layer slightly horizontally shifted from the previous one, thereby facilitating the in-situ construction of horizontally extended structures.

[0004] By eliminating the need for shipping and reducing construction time, this innovative method and system provide a more efficient, cost-effective, and environmentally friendly solution for the construction of elongated structures.

[0005] Potential applications for this technology include, but are not limited to, the construction of utility pipelines, bridge spans, or other infrastructure elements requiring the creation of long, continuous structures.

[0006] In one embodiment, provided is a method for constructing an elongated structure via an inclined layer additive construction technique, the method comprising depositing a layer of construction material on a surface at an angle; and depositing one or more successive layers on the surface in a layer-by-layer approach at an angle, wherein each new layer is deposited at a horizontally shifted position from a preceding layer, thereby facilitating construction of the elongated structure. The angle may be an angle of from about 0 to about 90 degrees, wherein, optionally, the angle can vary from layer to layer, and / or wherein, optionally, the elongated structure is constructed without a need for additional support structures.

[0007] In a more specific embodiment, the method involves depositing a first layer at an angle using a 3-D printer with a nozzle, shifting the nozzle horizontally respective to the first layer a first distance, depositing a second layer at an angle, shifting the nozzle horizontally respective to the second layer a second distance, and depositing one or more additional layers until a desired horizontal structure is formed. The first distance and second distance may be the same, about the same, or different distances. In a specific aspect, the method does not require or involve, or both, implementation of reinforcements and / or molds.

[0008] Another embodiment pertains to a method that involves depositing a first layer onto a platform at an angle using a 3-D printer with a nozzle, shifting the platform horizontally respective to the nozzle a first distance, depositing a second layer at an angle in contact with the first layer, shifting the platform horizontally respective to the nozzle a second distance, and depositing one or more additional layers until a desired horizontal structure is formed.

[0009] In a specific example, the material deposited in the described methods is deposited in a circular pattern for at least a plurality of layers such that a lumen is formed within the elongated structure.

[0010] Other embodiments pertain to an elongated structure formed by a method described herein. An elongated structure refers to a structure having a first dimension (e.g. length) that is the same or usually larger than a second dimension (e.g. width).

[0011] The materials used in the construction methods described herein may include concrete and / or thermoplastic materials. A further non-limiting list of suitable materials include those that are described in US Pat. Pub. 20230256650, incorporated herein by reference.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 provides a diagram of a first method embodiment for constructing an elongated structure using construction materials such as concrete.

[0013] FIG. 2 provides a diagram of a second method embodiment for constructing an elongated structure using construction materials such as concrete.

[0014] FIG. 3 provides a diagram of a third method embodiment for constructing an elongated structure using construction materials such as concrete.

[0015] FIG. 4A provides a photograph of a nozzle initiating a layer by layer approach to constructing an elongated structure on a platform.

[0016] FIG. 4B provides a photograph showing the elongated structure started in FIG. 4A with additional layers.DETAILED DESCRIPTION

[0017] The inventive method utilizes an additive construction, where each new layer is slightly horizontally shifted from the previous layer. This slight shift allows the new layer to overlap and naturally bind with the previous layer, resulting in a continuous, horizontally extended structure, also referred to herein as a layer by layer approach.

[0018] In one embodiment, a system for implementing this method comprises a 3D printer capable of depositing construction material at variable angles, ranging from 0 to 90 degrees. The angle can be dynamically adjusted as per the requirements of the structure being built, thereby adding to the versatility of the system.

[0019] The system deposits layers at a selected angle. Each layer is deposited with a slight horizontal shift from the previous layer. This process continues until the required length of the structure is achieved.

[0020] In one embodiment, provided is a method wherein a first layer of a structure is printed at an angle via a nozzle of a 3-D printer. The nozzle or the forming structure, or both, are shifted horizontally relative to one another and then a second layer is deposited at an angle. The forming structure can be shifted such as by moving the platform onto which it is being formed. The successive horizontal shifting and successive layers are printed until a structure of a desired size and configuration is formed. As shown in FIG. 1, a first deposit layer 12a is formed on the platform 20. The nozzle 10 is horizontally shifted, and a second deposit layer 12b is formed onto the initial layer 12a. Subsequent n deposit layers 12c are formed until a final deposit layer 12f is formed to complete the structure. Upon deposition of each layer, the nozzle 10 horizontally shifts to deposit the next layer onto the preceding layer.

[0021] In FIG. 2, a first deposit layer 12a is formed on platform 20 using a nozzle 10’ onto a platform. In this embodiment, the nozzle 10’ remains at its position during the construction of the structure. Instead, after a first layer 12a is formed, the platform 20’ horizontally shifts, and a second deposit layer 12b is formed. Subsequent n deposit layers 12c are formed on the platform where upon deposition of each layer the platform horizontally shifts. A final a final deposit layer 12f is formed to complete the structure. Those skilled in the art will appreciate that a system where both a shifting nozzle 10 and platform 20’ are both implemented may be used to build an elongated structure 14 according to a layer by layer approach.

[0022] FIG. 3 shows construction method similar to that shown in FIG. 1. A first deposit layer 12a is formed on a supporter 22 that rests on the platform 20. The supporter 22 assists in maintaining the angle of the initial deposited layers, which in turn helps hold the forming structure at the desired angle. Upon deposition of the first deposit layer 12a, the nozzle 10 is horizontally shifted, and a second deposit layer 12b is formed. Subsequent n deposit layers 12c are formed until a final deposit layer 12f is formed to complete the structure 14’.

[0023] FIG. 4A shows a photograph of the deposition of a first deposit layer 12a and a second deposit layer 12b onto a platform using a horizontally shifting nozzle 10. FIG. 4B shows the horizontally shifted nozzle 10 that allows for n subsequent deposit layers 12 to be formed on the platform 20.

[0024] Those skilled in the art will appreciate that the platform 20 referred to in FIGs 1 -4 can be any suitable surface onto which an elongated structure can be formed using the methods described herein. In a specific embodiment, the platform 20 is a static or movable planar device, such as a plank or plate.

[0025] The term “about,” as used herein when referring to a measurable value such as an amount of a compound, dose, time, temperature, and the like, is meant to encompass variations of 20%, 10%, 5%, 1 %, 0.5%, or even 0.1% of the specified amount. Unless otherwise defined, all terms, including technical and scientific terms used in the description, have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0026] As used herein, the terms “comprise,” “comprises,” “comprising,” “include,” “includes” and “including” specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0027] As used herein, the term “consists essentially of’ (and grammatical variants thereof), as applied to the compositions and methods of the present invention, means that the compositions / methods may contain additional components so long as the additional components do not materially alter the composition / method. The term “materially alter,” as applied to a composition / method, refers to an increase or decrease in the effectiveness of the composition / method of at least about 20% or more.

[0028] Percentages of the composition are based on mass percent of total solid ingredients. The dosages of chemical additives are expressed as active ingredients and do not include water or inactive carriers that facilitate handling and dispensing.

[0029] All patents, patent applications and publications referred to herein are incorporated by reference in their entirety. In case of a conflict in terminology, the present specification is controlling.

Claims

CLAIMSWhat is claimed is:

1. A method for constructing an elongated structure via an inclined layer additive construction technique, the method comprising depositing a layer of construction material on a surface at an angle; and depositing one or more successive layers on the surface in a layer-by-layer approach at an angle, wherein each new layer is deposited at a horizontally shifted position from a preceding layer, thereby facilitating construction of the elongated structure.

2. This method of claim 1, wherein the angle is an angle of from about 0 to about 90 degrees, wherein, optionally, the angle can vary from layer to layer, and / or wherein, optionally, the elongated structure is constructed without a need for additional support structures.

3. The method of claims 1 or 2, wherein the method comprises depositing a first layer at an angle using a 3-D printer with a nozzle, shifting the nozzle horizontally respective to the first layer a first distance, depositing a second layer at an angle, shifting the nozzle horizontally respective to the second layer a second distance, and depositing one or more additional layers until a desired horizontal structure is formed.

4. The method of claim 2, wherein the first distance and second distance are the same, about the same, or different.

5. The method of any of claims 1-4, wherein the method does not require or involve, or both, implementation of reinforcements or molds.

6. The method of any of claims 1-5, wherein the construction material comprises concrete.

7. The method of claims 1 or 2, wherein the method comprises depositing a first layer onto a platform at an angle using a 3-D printer with a nozzle, shifting the platform horizontally respective to the nozzle a first distance, depositing a second layer at an angle in contact with thefirst layer, shifting the platform horizontally respective to the nozzle a second distance, and depositing one or more additional layers until a desired horizontal structure is formed.

8. The method of claim 7, wherein the first distance and second distance are the same, about the same, or different.

9. The method of claims 7 or 8, wherein the method does not require or involve, or both, implementation of reinforcements or molds.

10. The method of any of claims 7-9, wherein the construction material comprises concrete or a thermoplastic material.

11. The method of any of claims 1-10, wherein the material is deposited in a circular pattern for a plurality of layers such that a lumen is formed within the elongated structure.

12. The method of any of claims 1-4, and 6-8, 10 or 11, wherein at least one layer is deposited onto an angled supporter.

13. The method of any of claims 10 or 11, wherein at least one layer is deposited onto an angled supporter.

14. An elongated structure formed by a method according to any of claims 1-13.

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