Additive Concrete Wall Structures with Segmented Reinforcement
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Solution Overview
Problem
Existing additive manufacturing methods for concrete construction elements face challenges in achieving both good mechanical strength and thermal insulation, particularly due to thermal bridges formed by zigzag reinforcement structures that connect opposite wall surfaces.
Innovation Solution
The method involves depositing superposed mortar layers to create two opposite wall surfaces with reinforcement elements extending towards a cavity, ensuring these elements are not in contact with the opposite wall surface or other reinforcement elements, thereby forming a single cavity that can be filled with insulating material to enhance thermal insulation while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If zigzag reinforcement structures are used to connect opposite wall surfaces, then mechanical strength is improved, but thermal insulation deteriorates due to thermal bridges
Solution Approach 1:
The reinforcement structure is segmented into discrete reinforcement elements extending from each wall surface toward the cavity, rather than continuous zigzag connections. This segmentation prevents thermal bridges while maintaining mechanical strength through distributed reinforcement points.
Solution Approach 2:
The cavity acts as an intermediary space that prevents direct thermal contact between opposite wall surfaces. By eliminating continuous reinforcement paths and using the cavity as a thermal barrier, thermal bridges are interrupted while structural integrity is maintained through the reinforcement elements.
2Strength
If multiple cavities are created by zigzag structures, then mechanical reinforcement is achieved, but thermal insulation deteriorates and manufacturing complexity increases
Solution Approach 1:
Multiple potential cavities are merged into a single continuous cavity space extending between opposite wall surfaces. This unified cavity structure simplifies manufacturing while providing effective thermal insulation, eliminating the need for complex multi-cavity configurations.
3Strength
If reinforcement elements are in contact with opposite wall surfaces, then mechanical strength is maximized, but thermal bridges are created
Solution Approach 1:
Reinforcement elements are positioned to extend toward the cavity from each wall surface, creating local reinforcement zones without establishing continuous thermal paths. This local quality approach provides mechanical strength where needed while maintaining thermal insulation properties.
Data Source
AI summary
A method for obtaining a concrete construction element by additive manufacturing, in which superposed mortar layers are successively deposited so as to form two wall surfaces, opposite one another, so as to form a cavity, as well as a plurality of reinforcement elements each extending from one of the wall surfaces toward the cavity, each reinforcement element being in contact with neither the wall surface opposite to that from which it extends, nor with a reinforcement element extending from the opposite wall surface to that from which it extends.