Concrete 3D Printing Extruder Nozzle Geometry and Mixture
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Solution Overview
Problem
Existing three-dimensional printing technologies for building production have not achieved significant commercial success.
Innovation Solution
A concrete mixture comprising sand, Portland cement, water, and a workability maintaining compound (such as Viscoflow-2020) is used with an extruder and nozzle system, featuring a funnel, impeller, and motor, along with an applicator for laying a bead of concrete at 50 feet per minute, utilizing a specific geometry and mechanism for precise concrete deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional three-dimensional printing technologies are used for building production, then the process can be automated, but commercial success has not been achieved due to poor manufacturing precision and material control
Solution Approach 1:
The patent changes the physical parameters of the concrete mixture by adding a workability maintaining compound that modifies viscosity and flow characteristics. This enables precise control of the extruded concrete bead, allowing automated deposition with high manufacturing precision while maintaining automation capabilities
Solution Approach 2:
The patent introduces a specialized nozzle as an intermediary device between the extruder and the concrete mixture. This nozzle precisely controls the extrusion of concrete, enabling accurate deposition profiles and shapes while maintaining automated operation
2Productivity
If concrete is extruded at high speed, then productivity increases, but control over the deposited shape and surface quality deteriorates
Solution Approach 1:
The patent modifies the concrete mixture parameters by incorporating a workability maintaining compound that adjusts viscosity and rheology. This allows the concrete to be extruded at high speeds (50 feet per minute) while maintaining control over its shape and surface quality, resolving the contradiction between productivity and precision
Solution Approach 2:
The specialized nozzle acts as an intermediary that controls the extrusion process. Its specific geometry and design enable high-speed deposition while maintaining precise control over the concrete bead shape and surface appearance, achieving both productivity and manufacturing precision
3Ease of manufacture
If standard concrete mixture is used, then material availability is good, but workability and deposit quality are insufficient for high-precision 3D printing
Solution Approach 1:
The patent modifies the concrete mixture parameters by adding a workability maintaining compound (such as Viscoflow-2020) in specific quantities. This enhances the concrete's flow characteristics and workability, enabling high-precision deposition while using readily available base materials like sand, Portland cement, and water
Solution Approach 2:
The patent creates a composite concrete mixture by combining standard materials (sand, Portland cement, water) with a workability maintaining compound. This composite approach maintains material availability while significantly improving deposit quality and workability for 3D printing applications
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 solution enables the creation of a vertical, smooth wall surface with minimal bulges or depressions, allowing for efficient and accurate construction of structures using off-the-shelf components and methods, with high deposit accuracy and speed.
Implementation Method 1
an impeller and a motor. The funnel has: a vertical axis; a length defined by the axis; a frustoconical portion orientated coaxially with the axis and such that it tapers in diameter from top to bottom
Implementation Method 2
the combination of the extruder and a nozzle, the nozzle comprising: an outlet defined by a pair of planar sidewalls, a planar base and a planar top all creating a rectangular channel with a width W and a height H
Implementation Method 3
concrete mixture comprising: sand; Portland cement; water; and workability maintaining compound, wherein the ratio of sand:Portland:water:compound is about 1 cubic foot; 1 cubic foot; 1 cubic foot; 6 oz.
Data Source
AI summary
A concrete mixture is forced through a nozzle by an extruder. An applicator has: a body adapted for vertical movement; a primary arm mounted to the body for movement about a vertical axis, the arm being elongate, having ends, having a vertical axis adjacent one end and having a counterweight adjacent the other end; a secondary arm defining a vertical axis, extending from the vertical axis defined by the primary arm and configured for movement about said vertical axis; a tertiary arm mounted for movement along the secondary arm vertical axis; a rotator carried by the tertiary arm and which carries the nozzle and rotates the nozzle about a vertical axis; a primary rotation mechanism for rotating the primary arm about the primary arm axis; an actuator providing for movement of the secondary arm about the vertical axis; and an elevation mechanism providing for said tertiary arm vertical movement.