Multi-Component Mortar System for 3D Printing with Set Inhibition
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Solution Overview
Problem
Existing two-component mortar systems for 3D printing face challenges such as corrosive dust, complex powder dosing, and short storage stability due to Portland cement's rapid hydration, while aluminous cement-based systems are costly and corrosive, and current set-inhibited aluminous cement suspensions have high calcium aluminate content and toxicity concerns.
Innovation Solution
A multi-component mortar system comprising a liquid or paste-like component A with aluminous cement, set inhibitors, and mineral fillers, and a component B with an initiator system for the set-inhibited aluminous cement, allowing for safe handling, extended storage, and reduced alkaline content, enabling immediate self-supporting structures with high strength and low shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If Portland cement is used in powder form, then the mortar can be stored and handled, but corrosive dust is generated and powder dosing is complex
Solution Approach 1:
The patent converts the powder cement into a liquid suspension form, using hydraulic principles to deliver the cement through pumps and nozzles. This eliminates dust generation during handling and dosing, while maintaining the ability to store and transport the mortar component. The liquid suspension is pumped through the printing system, replacing complex powder dosing mechanisms with simpler liquid delivery systems.
2Object-affected harmful factors
If Portland cement suspension is used with water, then dust is eliminated, but hydration starts immediately causing short storage stability
Solution Approach 1:
The patent extracts the harmful element (water) from the cement suspension temporarily. Instead of using water as the suspending medium, the invention uses an organic solvent that does not trigger cement hydration. This allows the cement to remain in suspension form without setting, enabling long-term storage stability while maintaining the dust-free liquid form. The water is reintroduced only at the point of application.
3Duration of action of stationary object
If organic solvents are used instead of water, then storage stability is improved, but inflammability and health concerns increase
Solution Approach 1:
The patent changes the chemical parameters of the suspending medium by selecting specific organic solvents with favorable properties. Instead of using flammable solvents like alcohol, the invention employs solvents such as glycol or glycerol that have high boiling points, low volatility, and non-flammable characteristics. This parameter change maintains storage stability while eliminating the harmful effects of inflammability and health risks associated with traditional organic solvents.
4Stability of the object's composition
If high calcium aluminate content is used in aluminous cement, then setting inhibition is improved, but costs and corrosiveness increase
Solution Approach 1:
The patent changes the chemical composition parameters of the aluminous cement by reducing the calcium aluminate content to lower levels. Instead of relying on high calcium aluminate content for setting inhibition, the invention uses optimized combinations of lower cement content with specific additives and pH control mechanisms. This parameter reduction directly decreases the corrosiveness of the mortar while maintaining adequate setting inhibition through alternative chemical mechanisms.
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 provides a cost-effective, safe, and durable mortar for 3D printing with reduced porosity and toxicity, enabling immediate self-supporting structures that harden quickly, suitable for robotic systems with enhanced storage stability and reduced environmental impact.
Implementation Method 1
The hydration of set-inhibited aluminous cement can be initiated by pH increase
Implementation Method 2
when cement is in contact with water hydration starts leading to setting and hardening of the cement
Implementation Method 3
The hydration of set-inhibited aluminous cement can be initiated by pH increase
Implementation Method 4
by mixing the components, the cement in the powder component can form a corrosive dust
Data Source
AI summary
The present invention relates to a multi-component mortar system comprising a component A and a component B wherein - component A comprises aluminous cement, at least one set inhibitor, at least one mineral filler and water, and - component B comprises an initiator system for the set-inhibited aluminous cement, at least one mineral filler and water. The multi-component mortar system is easy to use and suitable for repair and refurbishment and particularly for printing 3D structures.