Additive Concrete Printing Speed and Strength Coordination
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Solution Overview
Problem
Current generative manufacturing processes for producing concrete moldings are limited by the physical and chemical properties of concrete mixtures, leading to slow production speeds due to kinetics and thixotropic properties, which result in reduced quality and increased complexity.
Innovation Solution
A method for producing shaped bodies from mineral binder compositions using a print head that applies curable material in layers, coordinating application rate and temporal strength development, adjusting movement speed based on strength development, and potentially using hardening accelerators to optimize production efficiency and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If concrete mixture is applied layer by layer using conventional additive manufacturing processes, then molded bodies can be produced, but production speed is severely limited due to kinetics and thixotropic properties
Solution Approach 1:
The patent changes the chemical parameters of the concrete mixture by adding specific additives that modify the kinetics of the cement hydration reaction. These additives accelerate the strength development without compromising the thixotropic properties, allowing faster layer application while maintaining quality and strength requirements.
Solution Approach 2:
The patent introduces chemical intermediaries (additives) that mediate between the cement and water interaction. These intermediaries control the reaction rate and strengthen development, enabling the system to achieve both high productivity and reliable quality by optimizing the chemical interaction dynamics.
2Productivity
If application rate of curable material is increased to improve production speed, then productivity increases, but adhesion between layers may be compromised
Solution Approach 1:
The patent modifies the rheological and chemical parameters of the curable material through additive incorporation. This changes the material's strength development kinetics and thixotropic behavior, allowing faster application rates while maintaining sufficient adhesion between layers through optimized chemical reaction characteristics.
Solution Approach 2:
The patent makes the material properties dynamic by controlling the time-dependent strength development through chemical additives. The material transitions from a state suitable for rapid application to a state providing sufficient adhesion, with the transition timing controlled by the chemical composition and reaction kinetics.
3Reliability
If waiting time between layers is increased to ensure strength development, then quality improves, but production time increases
Solution Approach 1:
The patent changes the temporal parameters of strength development by introducing chemical additives that accelerate the cement hydration reaction. This modifies the time course of strength acquisition, allowing reduced waiting times between layers while still achieving the necessary quality and strength, thereby reducing overall production time.
Solution Approach 2:
The patent performs preliminary chemical preparation by incorporating strength-enhancing additives into the mixture before application. This preliminary action ensures that the material has optimized strength development characteristics from the start, reducing the need for extended waiting periods and accelerating the overall production process.
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
This method enables efficient, reliable, and rapid production of high-quality moldings by synchronizing application rate with strength development, reducing waiting times, and maintaining adhesion between layers, thus overcoming the limitations of conventional systems.
Implementation Method 1
The binder liquid is polymerized due to an activator incorporated into the particles
Implementation Method 2
the curable material is applied layer by layer in a generative free-space process... coordinating application rate and temporal strength development
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a method for producing a molded body from a curable material, in particular from a mineral binder composition, wherein the curable material is applied layer by layer in an additive process, in particular in an additive free-space process, by means of a print head movable in at least one spatial direction, and wherein an application rate of the curable material and the strength development over time of the curable material are coordinated.