Carbon-Infused Cementitious 3D Printing for Low-Emission Structures
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Solution Overview
Problem
Existing construction techniques are limited in forming structures of various dimensions and fail to effectively incorporate carbon-related materials to mitigate gaseous emissions affecting global climate, while being susceptible to environmental factors.
Innovation Solution
A system and method for additive manufacturing that combines carbon-based materials with cementitious materials using a base mixer unit and nozzle unit to form 3D structures, incorporating carbon dioxide and additives to enhance structural reliability and reduce carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional construction techniques are used to form structures, then structures can be built with traditional materials and methods, but the structures have limited dimensional flexibility and fail to incorporate carbon-related materials to mitigate gaseous emissions
Solution Approach 1:
The patent changes the chemical composition parameters of construction materials by incorporating carbon-related materials (such as carbon dioxide, carbon black, or other carbon-containing compounds) into the cementitious material formulation. This allows the material to maintain its structural function while sequestering carbon, thereby reducing carbon emissions from construction activities.
Solution Approach 2:
The patent creates composite cementitious materials by combining traditional cement components with carbon-related materials. This composite approach enables the material to simultaneously provide structural integrity and carbon sequestration functionality, addressing both dimensional flexibility and emissions reduction requirements.
2Object-generated harmful factors
If carbon-related materials are incorporated into cementitious materials to reduce carbon footprint, then environmental benefits are achieved, but the structural integrity and reliability may be compromised
Solution Approach 1:
The patent optimizes the concentration and distribution parameters of carbon-related materials within the cementitious matrix. By carefully controlling these parameters, the material maintains adequate strength and structural integrity while achieving meaningful carbon sequestration. The system adjusts material composition parameters to balance environmental benefits with structural requirements.
3Object-generated harmful factors
If additive manufacturing is used to form 3D structures with carbon-infused materials, then carbon sequestration is achieved, but the process complexity and material deposition precision requirements increase
Solution Approach 1:
The patent designs the material deposition system to perform multiple functions: depositing cementitious material, incorporating carbon-related materials, and achieving precise 3D structural formation. By making the system multi-functional, the patent reduces overall system complexity compared to having separate systems for each function, while still achieving carbon sequestration in 3D printed structures.
4Ease of manufacture
If conventional construction methods are used, then materials can be placed with traditional equipment, but environmental factors such as wind, temperature, and humidity cause displacement and reduce placement success
Solution Approach 1:
The patent formulates the carbon-infused cementitious material to have self-leveling or self-adjusting properties that compensate for environmental disturbances. The material composition is designed to maintain workability and placement accuracy despite variations in temperature, humidity, or wind conditions, reducing the need for complex environmental control systems.
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
The system enables the formation of 3D structures with reduced carbon emissions and improved structural integrity by sequestering carbon dioxide, achieving a carbon footprint of 280 kg CO2 per cubic yard or less, while maintaining structural integrity and environmental resilience.
Implementation Method 1
sequestration, capture, and implementation of carbon-based materials in association with cementitous materials
Implementation Method 2
deposit the material including carbon-based materials and carbon-based captured elements in a cementitious material to form an additively constructed structure
Data Source
AI summary
Various embodiments relate generally to additive manufacturing and construction techniques to form structures with embodiments including computer software and systems, and control systems, and, more specifically, to a computing and a mechanical platform configured to receive a material with which to form a structure of programmable dimensions and deposit the material including carbon-based materials and carbon-based captured elements in a cementitious material to form an additively constructed structure, such as a three-dimensional (“3D”) formed structure.