Artificial reef and method of manufacturing an artificial reef

Abstract

The present invention relates to providing a strategy for cutting and developing a path for a 3D printing tool, using a suitable building material, following a single polyline and allowing slopes greater than 60° with the possibility of including openings and tunnels. The invention belongs to the technical field of the manufacturing of three-dimensional objects (artificial reef) by means of additive deposition. The problem that the inventor aims to solve is the lack of available filling patterns for 3D printing using building materials (description: page 1, lines 25-29). The solution to the problem addressed consists of a method that generates a path without distinction between the outside and the inside, alternating layers on top of each other, the deposition directions of which are perpendicular to each other, and using materials with a viscosity such that they allow implementing plans with a 60° slope (description).

Description

[0001] DESCRIPTION

[0002] ARTIFICIAL REEF AND ARTIFICIAL REEF MANUFACTURING PROCESS

[0003] The present invention relates to an artificial reef, and its manufacturing process, with a lateral exterior surface and a base, comprising at least one polyline printed in a construction material suitable for 3D printing or additive manufacturing, such as cement, concrete, clay, other materials such as geopolymers or the like, biochart-based biomaterials or the like, as well as mixtures of the above, in a succession of superimposed layers, as described in claim 1, also incorporating notable innovations and advantages.

[0004] BACKGROUND OF THE INVENTION

[0005] Various manufacturing processes are known for materials such as cement and / or concrete and concrete and / or clay mixtures, and / or other materials such as geopolymers or similar, as well as mixtures of biochart-based biomaterials or similar, through the automated generation of deposition trajectories. Specifically, 3D printing typically requires a slicing method to translate a 3D model into printable data. The 3D printing tool based on a 3D model does this through a set of instructions that provide precise details on how the 3D printer nozzle should move to create the desired object.

[0006] A 3D model can be divided into two parts: the exterior or shell, and the interior or infill. With conventional methods, software developed for 3D printing of plastics and ceramics creates cuts and generates infill patterns in a defined manner, such as triangular, hexagonal, or square beams, etc. However, in the case of printing construction materials, the available software does not provide many options for infill patterns.

[0007] The conventional strategy for 3D printing, or additive manufacturing, in a 3D-printable building material minimizes infill because the structures printed using this technique are morphologically simpler, such as beams and walls. To achieve this, they prefer to keep weight and material usage to a minimum, with minimal or no infill. This limits the ability to print complex shapes with greater degrees of tilt and overhang. It is worth mentioning that the tilt and overhang in 3D printing of an unfilled 3D-printable building material depend on the height of the printing layer and the percentage of overlap within each layer. In the case of 3D-printed artificial reefs, this approach does not work well because the morphology of an artificial reef requires a great deal of complexity to integrate bionomic requirements such as vaults, domes, cavities, tunnels, etc.Therefore, there is no solution available to integrate the infill, while printing in a 3D printing-friendly build material. On the other hand, the fact that the 3D printed body has a higher weight is a beneficial aspect in the case of artificial reefs, since more weight means more stability underwater when placed on the seabed.

[0008] Therefore, there is currently no strategy available for generating a toolpath that provides complete infill during 3D printing. The available options simplify complex designs to near-vertical extrusions and manually pouring concrete between the walls after printing.

[0009] It is also known from the prior art, as described in document CN117088676A, a method for repairing an oyster reef body by 3D printing comprises steps of: pretreating materials such as a pore-forming agent, silicate, dredging mud, and an adhesive; uniformly mixing the pretreated materials according to a certain proportion to prepare a preprinting material; adding the preprinted material to a 3D printer of a clay material to prepare a wet reef body; aging the wet reef body at normal temperature; and drying and roasting.The method is characterized in that waste materials such as dredged mud, glass waste, spartina alterniflora, and corn straw are reasonably utilized to prepare a green and environmentally friendly reef body, so that the ecological balance based mainly on the oyster reef is restored, improving the ecological environment of oyster reefs.

[0010] In view of all this, there is a need to achieve 3D printed designs consisting of inclinations of more than 60 degrees, including openings and tunnels, which is not possible today with the conventional strategy known for 3D printing with a tool path only for the exterior, leaving the interior empty. This is because the outer casing will not have support when printing in parts where the inclination of the face is greater than 60 degrees with respect to the normal face. DESCRIPTION OF THE INVENTION

[0011] The objective of the present invention is to provide a strategy for slicing and developing a 3D printing tool path for a 3D printable construction material as a single polyline that can be translated into a programming code, so that the movement of the robotic arm can be controlled, making it possible to generate inclinations of more than 60 degrees, comprising openings and tunnels.

[0012] There are many construction materials suitable for 3D printing. For example, to build an artificial reef using 3D printing, you can use cement, concrete, clay, other materials such as geopolymers or similar, biochart-based biomaterials or similar, as well as mixtures of the above.

[0013] To achieve this performance, a strategy was developed that generates a path without differentiating between exterior and interior. Thus, the 3D shape is first cut according to the required layer thickness based on the material density. Once cut, these layers are divided into two sections: even layers and odd layers. The even and odd layers are processed accordingly on the X and Y axes, respectively. The next step, which is optional, is to join the separate islands in each layer to create a single polyline for each layer, so that each layer consists of a single polyline. All consecutive layers are then superimposed, thus creating a woven structure that provides strength and stability. It should be noted that, once superimposed, the individual polylines in each layer are preferably connected with the shortest possible connection length, thus converting the entire model into a single polyline.

[0014] More specifically, the artificial reef has a lateral exterior surface and a base, and comprises at least one polyline printed in a construction material suitable for 3D printing in a succession of superimposed layers. Said 3D printing makes it possible to achieve complex morphologies, including openings and tunnels, for example, in cement, and / or concrete, and / or clay, and / or other materials such as geopolymers or the like, as well as mixtures of biomaterials based on biochart or the like, through what is known as additive manufacturing, through said succession of superimposed layers in a single polyline.

[0015] Preferably, the artificial reef comprises a vertical succession of horizontal layers with a plurality of polylines, such that 3D printing is simpler and more stable, without material displacement after printing, as there is no slope on which the printed material can slip and slide. More specifically, the artificial reef comprises at least a first layer with a first polyline printed substantially in a first direction, said first layer corresponding to one of the so-called odd-numbered layers, such that there is a possibility of a mesh-like interlacing.

[0016] In addition, the artificial reef comprises at least a second layer with a second polyline printed substantially in a second direction, said second layer corresponding to one of the so-called even layers, so that there is a possibility of interlacing in the form of a net fabric.

[0017] In a preferred embodiment of the invention, the first direction and the second direction are perpendicular or substantially perpendicular, so that an interlaced mesh can be formed in the net fabric.

[0018] According to another aspect of the invention, the artificial reef comprises at least one connection printed in material of the first polyline with the second polyline, such that an interlaced mesh is effectively formed in the net fabric, which allows a filling texture in the interior, and to achieve complex morphologies, comprising openings and tunnels,

[0019] It's worth mentioning that the artificial reef comprises at least one cavity, so it resembles a natural one and is compatible with the settlement of marine fauna and flora, offering protection from currents and predators.

[0020] Additionally, the artificial reef comprises at least one tunnel, with an entrance on the lateral outer surface and an exit on the lateral outer surface, such that it resembles a natural one and is compatible with the settlement of marine fauna and flora, by offering increased protection against currents and predators.

[0021] It should be noted that the process for manufacturing an artificial reef comprises the steps of i) printing a first layer with a first polyline oriented substantially in a first direction; i) printing a second layer with a second polyline oriented substantially in a second direction;

[0022] The process for manufacturing an artificial reef may comprise the step of printing a connection of the first polyline with the second polyline, such that the manufactured artificial reef is obtained in a single polyline. In a preferred embodiment, the first direction and the second direction of the process for manufacturing an artificial reef are perpendicular or substantially perpendicular.

[0023] Additionally, the manufacturing process of an artificial reef comprises the step of printing a succession of superimposed layers with a plurality of polylines joined together by a plurality of connections, where the first direction corresponds to the odd layers and the second direction corresponds to the even layers.

[0024] Preferably, the manufacturing process of an artificial reef comprises the step of printing a vertical succession of horizontally superimposed layers.

[0025] The height of the horizontal layers can vary and may depend on the type of software used in the additive or 3D printing machine and the complexity of the reef design. In one embodiment of the invention, each layer (3) has a height of 10 mm.

[0026] The viscosity of the printing material is also a characteristic that can affect the final geometry of the reef. In one embodiment of the invention, the viscosity of the material is such that, once printed to create a layer, it deforms and eventually spills, at least partially, over the sides of the polyline.

[0027] While the fact that a polyline's material deforms after printing is a characteristic considered negative in most 3D manufacturing processes, in the manufacture of artificial reefs it is a characteristic that can be considered positive by generating geometries or textures that favor colonization of the artificial reef by fauna and flora.

[0028] In summary, the present invention offers several advantages over currently available technical solutions. First, it allows for greater morphological freedom and therefore a better translation of bionomic parameters, while also allowing for the generation of suitable textures on exposed surfaces to promote colonization. It adds or allows for the possibility of increasing the specific weight of the parts while maintaining their cohesion. This is especially appropriate in the case of manufactured elements for use as artificial reefs. It also overcomes the limitation existing with conventional strategies using extrusion machines, given that with them it is not possible to achieve certain degrees of formal complexity and therefore the shapes are limited.The novel 3D printing strategy of the present invention requires the machine to be used in a different manner, allowing for the printing of complex geometries such as tunnels, holes, and greater degrees of inclination. The accompanying drawings show, by way of non-limiting example, an artificial reef constructed in accordance with the invention. Other features and advantages of said artificial reef, object of the present invention, will become apparent from the description of a preferred, but not exclusive, embodiment, which is illustrated by way of non-limiting example in the accompanying drawings.

[0029] BRIEF DESCRIPTION OF THE FIGURES

[0030] For a better understanding of what has been explained, some drawings are attached which, schematically and solely as a non-limiting example, represent a practical case of implementation.

[0031] Figure 1 is a perspective view of the artificial reef, according to the present invention;

[0032] Figure 2 is a perspective view of a representation of the artificial reef, in accordance with the present invention;

[0033] Figure 3A is a plan view of a first layer of the artificial reef with a separated island area, according to the present invention;

[0034] Figure 3B is a plan view of a second layer of the artificial reef with a separated island area, in accordance with the present invention;

[0035] Figure 4A is a plan view of a first layer of the artificial reef with an island area attached, in accordance with the present invention;

[0036] Figure 4B is a plan view of a first layer and a second layer of the artificial reef with an island area attached, in accordance with the present invention;

[0037] Figure 5 is a perspective view of an artificial reef halfway through its manufacturing process, in accordance with the present invention;

[0038] DESCRIPTION OF A PREFERRED EMBODIMENT

[0039] Although reference has been made to a specific embodiment of the invention, it is evident to a person skilled in the art that the artificial reef described is susceptible to numerous variations and modifications, and that all the details mentioned may be replaced by other technically equivalent ones, without departing from the scope of protection defined by the claims attached in the following section.

[0040] Figure 1 shows a perspective view of the artificial reef, with an outer surface (21) and a base (22), showing the presence of a cavity (23) and a tunnel (24) with an entrance (24a) and an exit (24b). Figure 2 shows a perspective view of a representation of the artificial reef, showing the outer surface (21) with a cavity (23) and a tunnel (24) with an entrance (24a) and an exit (24b), and below it the base (22).

[0041] In Figure 3A, a plan view of a first layer (31) of the artificial reef with a separated island area can be seen. The plan view of a cavity (23) is shown, and the first layer (31) is formed by a polyline (4), and specifically by a first polyline (41) in a first direction (41a).

[0042] In Figure 3B, a plan view of a second layer (32) of the artificial reef with a separated island area can be seen, showing a cavity (23) in plan. The formation of a second layer (32) can be seen by means of a polyline (4), specifically a second polyline (42) in a second direction (42a).

[0043] In Figure 4A a plan view of a first layer (31) of the artificial reef with an island area connected by a connection (43) can be seen, also showing a cavity (23) in plan. The formation of a first layer (31) can be seen by means of a polyline (4), specifically a first polyline (41) in a first direction (41a).

[0044] In Figure 4B a plan view of a first layer (31) and a second layer (32) of the artificial reef with an island area connected by a connection (43) can be seen, also showing a cavity (23) in plan. The formation of a first layer (31) and a second layer (32) can be seen by means of a polyline (4), specifically a first polyline (41) in a first direction (41a), and a second polyline (42) in a second direction (42a).

[0045] Figure 5 is a perspective view of an artificial reef halfway through its manufacturing process in a material (1), for example cement, including the base (22), where it rests, and a tunnel (24) with an entrance (24a) and an exit (24b). The body of the artificial reef is formed by a polyline (4) composed of a first polyline (41) intertwined with a second polyline (42).

[0046] More particularly, as can be seen in Figures 2 and 5, the artificial reef with a lateral outer surface (21) and a base (22), comprises at least one polyline (4) printed in a material (1), for example cement, in a succession of superimposed layers (3).

[0047] Preferably, as seen in Figures 4B and 5, the artificial reef comprises a vertical succession of horizontal layers (3) with a plurality of polylines (4).

[0048] More specifically, as seen in Figures 3A and 4A, the artificial reef comprises at least a first layer (31) with a first polyline (41) printed substantially in a first direction (41a).

[0049] Additionally, as seen in Figure 3B, the artificial reef comprises at least a second layer (32) with a second polyline (42) printed substantially in a second direction (42a).

[0050] In a preferred embodiment of the invention, as seen in Figures 3A and 3B, the first direction (41a) and the second direction (42a) are perpendicular or substantially perpendicular.

[0051] More specifically, as seen in Figures 4A and 4B, the artificial reef comprises at least one connection (43) printed in a material (1), for example cement, of the first polyline (41) with the second polyline (42).

[0052] According to another aspect of the invention, as seen in Figures 1 and 4A, the artificial reef comprises at least one cavity (23).

[0053] Additionally, as seen in Figures 1 and 5, the artificial reef comprises at least one tunnel (24), with an entrance (24a) on the lateral outer surface (21) and an exit (24b) on the lateral outer surface (21).

[0054] It is worth mentioning that, as can be seen in Figures 4B and 5, the manufacturing process of an artificial reef comprises the steps of i) printing on a material (1), for example cement, a first layer (31) with a first polyline (41) oriented substantially in a first direction (41a); i) printing on a material (1), for example cement, a second layer (32) with a second polyline (42) oriented substantially in a second direction (42a);

[0055] Optionally, the manufacturing process of an artificial reef also comprises the step of printing on a material (1), for example cement, a connection (43) of the first polyline (41) with the second polyline (42).

[0056] Optionally, as shown in Figures 3A and 3B, the first direction (41a) and the second direction (42a) are perpendicular or substantially perpendicular. Additionally, as shown in Figures 4B and 5, the manufacturing process of an artificial reef comprises the step of printing a succession of superimposed layers (3) with a plurality of polylines (4) connected to each other by a plurality of connections (43).

[0057] It should be noted that, as can be seen in figures 2 and 5, the manufacturing process of an artificial reef includes the stage of printing a vertical succession of horizontally superimposed layers (3).

[0058] The details, shapes, dimensions and other accessory elements, as well as the components used in the implementation of the artificial reef may be conveniently replaced by others that are technically equivalent, and do not deviate from the essence of the invention or the scope defined by the claims included below the following list.

[0059] LIST OF NUMERICAL REFERENCES:

[0060] 1 material used in printing

[0061] 21 exterior surface

[0062] 22 base

[0063] 23 cavity

[0064] 24 tunnel

[0065] 24th entry

[0066] 24b exit

[0067] 3 layer

[0068] 31 first layer

[0069] 32 second layer

[0070] 4 polyline

[0071] 41 first polyline

[0072] 41st first address

[0073] 42 second polyline

[0074] 42nd second address

[0075] 43 connection

Claims

CLAIMS 1- Artificial reef with a lateral outer surface (21) and a base (22) comprising at least two polylines (4) printed on a material (1) in a succession of superimposed layers (3) characterized by comprising: • at least a first layer (31) with a first polyline (41) printed substantially in a first direction (41a), and • a second layer (32) with a second polyline (42) printed substantially in a second direction (42a) different from the first direction (41a). 2- Artificial reef, according to claim 1, characterized in that the first direction (41a) and the second direction (42a) are substantially perpendicular. 3- Artificial reef, according to any of the preceding claims, characterized in that it comprises a vertical succession of horizontal layers (3) with a plurality of polylines (4). 4- Artificial reef, according to any of the preceding claims, characterized in that it comprises at least one connection (43) of the first polyline (41) with the second polyline (42). 5- Artificial reef, according to any of the preceding claims, characterized in that it comprises at least one cavity (23). 6- Artificial reef, according to any of the preceding claims, characterized in that it comprises at least one tunnel (24), with an entrance (24a) on the lateral outer surface (21) and an exit (24b) on the lateral outer surface (21). 7- Artificial reef, according to any of the preceding claims, characterized in that the material (1) has a viscosity such that once printed to generate a polyline (41, 42) it deforms and spills, at least partially, over the sides of the polyline. 8- Manufacturing process of an artificial reef with a lateral outer surface (21) and a base (22) characterized by comprising the following stages: • printing a first layer (31) with a first polyline (41) oriented substantially in a first direction (41a); • printing a second layer (32) with a second polyline (42) oriented substantially in a second direction (42a) different from the first direction (41a). 9- Manufacturing process of an artificial reef according to claim 8, characterized in that it additionally comprises the step of • printing a connection (43) of the first polyline (41) with the second polyline (42). 10- Manufacturing process of an artificial reef according to claim 8 or 9 characterized in that the first direction (41a) of the first polyline (41) and the second direction (42a) of the second polyline (42) are substantially perpendicular.

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