3D Printed Construction Element With Filled Air-Pocket Matrix
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Solution Overview
Problem
Conventional construction methods using 3D printing face issues with weak interlayer bonding, lack of accurate material fillings, high thermal conductivity leading to increased energy costs, and excessive construction waste, which affect structural integrity and environmental sustainability.
Innovation Solution
A construction element is produced through additive manufacturing with an outer layer and inner matrix formed by successive layers, featuring air pockets infused with filler material, and optionally incorporating insulating inserts, using a system with a sensor module and mechanism for reinforcement and thermal regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional 3D printing process is used for construction, then construction speed is improved and labor requirement is decreased, but structural integrity deteriorates due to weak interlayer bonding and inaccurate material filling
Solution Approach 1:
The patent employs composite materials by combining construction material with reinforcement elements (such as fibers, meshes, or other structural components) to create a hybrid material system. This composite approach maintains the rapid layer-by-layer deposition capability of 3D printing while significantly enhancing interlayer bonding strength and overall structural integrity, directly addressing the weakness of conventional 3D printed construction elements
Solution Approach 2:
The patent modifies key process parameters of the 3D printing system, including extrusion temperature, layer thickness, deposition rate, and material composition ratios. By optimizing these parameters, the process achieves both high construction speed and improved material filling accuracy, thereby maintaining productivity while enhancing structural reliability
2Strength
If conventional construction materials (bricks, concrete) are used, then structural strength is achieved, but thermal insulation deteriorates due to high thermal conductivity leading to increased energy costs
Solution Approach 1:
The patent incorporates porous structures within the construction element, creating controlled voids or cellular patterns in the material matrix. These porous features reduce thermal conductivity by introducing air pockets (which have low thermal conductivity) while maintaining structural strength through the optimized pore distribution and wall thickness, thereby achieving both strength and thermal insulation requirements
Solution Approach 2:
The patent uses composite materials combining construction material with insulation materials (such as foam, aerogel, or reflective barriers). This composite structure provides both structural strength from the construction material and thermal insulation from the insulation material, effectively resolving the contradiction between strength and energy efficiency
3Ease of manufacture
If conventional construction methods are used, then building structures are formed, but construction waste increases leading to environmental hazards and increased carbon footprint
Solution Approach 1:
The patent applies preliminary action by using digital modeling and simulation before actual construction. The entire construction element is designed, analyzed, and optimized in virtual space first, allowing for precise material quantity calculation and waste minimization strategies to be implemented before physical manufacturing begins, thereby reducing construction waste while maintaining ease of manufacture
Solution Approach 2:
The additive manufacturing process inherently exhibits self-service characteristics by depositing material only where needed layer by layer. This eliminates the need for formwork, reduces excess material usage, and minimizes construction waste generation, while the automated nature of the process maintains ease of manufacture and construction feasibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances structural integrity, reduces thermal conductivity, and minimizes waste by improving thermal insulation and structural stability while reducing energy consumption and environmental impact.
Implementation Method 1
The outer layer and the inner matrix are integrally formed by depositing successive layers using an additive manufacturing system
Implementation Method 2
a filler material is infused into at least some air pockets of the plurality of air pockets
Data Source
AI summary
The present disclosure is directed to a construction element produced by additive manufacturing, an additive manufacturing system for producing the construction element and a method for manufacturing the construction element. The construction element includes an outer layer. The outer layer is configured to define or form an enclosure. The construction element further includes an inner matrix. The inner matrix is formed within the enclosure. The outer layer and the inner matrix are formed integrally, by depositing successive layers using an additive manufacturing system. The inner matrix is defined by a first layup and a second layup. The first layup is laid along a first direction and across the enclosure. The second layup is laid juxtaposing the first layup. The first layup and the second layup define a plurality of air pockets in the inner matrix. Further, a filler material is infused into at least some air pockets of the plurality of air pockets.