3D Printed Building Element With Internal Ducts For Modular Masonry
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Solution Overview
Problem
Existing 3D printing methods for building walls face challenges such as limited size due to stability and precision issues, requirement for eco-unfriendly materials, and the inability to create curved or inclined structures.
Innovation Solution
A 3D printed building element with a block structure featuring internal ducts and connecting elements, allowing for the creation of curved or inclined masonry structures using eco-friendly materials like recycled plastic and wood.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a large-scale 3D printer is used to print large building walls directly, then the wall size and load-bearing capacity are improved, but the device stability and printing precision deteriorate due to the large reciprocating printing movement required
Solution Approach 1:
The building wall is divided into multiple modular blocks that are printed separately using a compact 3D printer. Each block is printed with high precision using smaller, more stable printing movements. The blocks are then assembled together using connecting elements inserted through ducts, achieving large wall sizes while maintaining printing precision through segmentation of the printing process.
2Ease of manufacture
If traditional quick-setting mortar materials are used in 3D printing, then the printing process is simplified, but the environmental friendliness deteriorates
Solution Approach 1:
The patent uses composite materials made from recycled plastic and wood particles mixed with binding agents. These eco-friendly composite materials are extruded layer by layer to form the block structures. The composite nature allows the material to maintain structural integrity while being environmentally sustainable, replacing traditional quick-setting mortars with recyclable content.
3Ease of manufacture
If blocks have flat top and bottom surfaces defining planes parallel to the ground, then the manufacturing process is simplified, but the ability to create curved or inclined structures deteriorates
Solution Approach 1:
The patent introduces ducts running through the blocks in various orientations (not limited to horizontal). These ducts can be angled or curved, allowing connecting elements to transfer forces and maintain stability in non-traditional block arrangements. This enables the construction of curved walls, inclined structures, and complex geometries while maintaining relatively simple block manufacturing processes.
Data Source
AI summary
A 3D printed building element comprises a 3D printed block (20) comprising an upper wall (24), a front wall (26), a rear wall (28) and two lateral walls (29), defining an inner space (27), lower portions of the walls (24, 26, 28, 29) defining an inner edge developing seamlessly to form a bottom edge surface (22). The block (20) further comprises two internal ducts (34) disposed in the inner space (27), each defining a first feedthrough opening (30) provided on the upper wall (24), and an opposite second feedthrough opening (32) facing the bottom edge surface (22). The 3D printed building element further comprises two connecting elements (50), each inserted in a corresponding duct (34) of the block (20), so that a first portion (52) of the connection element (50) is exposed outside the first feedthrough opening (30) provided on the upper wall (24) and is suitable to be inserted in a second feedthrough opening (32) facing the bottom edge surface (22) of a duct (34) of a further block (20) superimposed to the block (20).