Multi-Component Mortar Composition for 3D Printing
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Solution Overview
Problem
Existing 3D printing mortars face challenges in achieving a balance between flowability, rapid curing, and maintaining high final strength, while also ensuring that the curing accelerator does not significantly impact the viscosity of the composition.
Innovation Solution
A multi-component composition comprising a mortar base component with Portland cement, an amine-glyoxylic acid condensate as a hydration retarder, a polyhydroxy compound, water, and an accelerator component with alkali metal aluminate, which allows for independent adjustment of viscosity and provides rapid setting without compromising final strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Portland cement is used as the primary binder for 3D printing mortar, then high final strength is achieved, but rapid hydration prevents the mortar from maintaining flowability during printing
Solution Approach 1:
The patent applies preliminary action by incorporating a hydration retarder into the mortar composition before printing. This retarder pre-conditions the Portland cement to delay its hydration reaction, allowing the mortar to maintain flowability throughout the printing process while still achieving high final strength once printing is complete. The retarder is removed or becomes inactive after deposition, allowing normal hydration to proceed.
Solution Approach 2:
The patent uses a hydration retarder as an intermediary substance that mediates between the Portland cement and water interaction. This intermediary temporarily inhibits the hydration reaction, preventing premature stiffening during handling and printing, while allowing the cement to later hydrate normally to develop full strength. The retarder acts as a temporary buffer in the cement-water system.
2Productivity
If an accelerator is added to enable rapid setting and hardening for fast construction progress, then layer build-up speed is improved, but the accelerator significantly impacts the viscosity of the composition
Solution Approach 1:
The patent segments the additives into two distinct functional components: a hydration retarder that controls flowability duration and a separate accelerator that enables rapid setting. This segmentation allows each component to be optimized for its specific function without interfering with the other, enabling independent control of viscosity during printing and setting speed after deposition.
Solution Approach 2:
The patent applies parameter changes by using specific types of accelerators (alkali metal aluminates or calcium-silicate-hydrate) that accelerate setting through chemical mechanisms that do not significantly alter the rheological parameters of the mortar. This allows the viscosity and flowability parameters to remain relatively unchanged while the setting time parameter is dramatically reduced.
3Speed
If CAC and sulphate source are used as binders to achieve fast hardening, then early strength is improved, but costs increase and final strength may be reduced
Solution Approach 1:
The patent applies preliminary action by using a hydration retarder to delay the hydration of Portland cement, creating a time window that allows for fast construction progress without needing expensive CAC-sulphate systems. The retarder pre-conditions the system to maintain workability longer, eliminating the need for costly alternative binders to achieve the same construction speed.
Solution Approach 2:
The patent uses small, controlled amounts of chemical additives (retarders and accelerators) that are inexpensive compared to replacing the entire binder system with CAC. These small quantities of chemicals provide the necessary time control functions without the high material costs associated with CAC-based formulations.
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 proposed solution enables the production of mortars that can be processed efficiently in 3D printing equipment, with rapid initial setting and high early and final strength, while maintaining adjustable viscosity independent of the accelerator's influence.
Implementation Method 1
an amine-glyoxylic acid condensate which acts as a setting retarder for the Portland cement
Implementation Method 2
an accelerator component, which comprises an alkali metal aluminate
Implementation Method 3
a polyhydroxy compound or a salt or ester thereof
Data Source
AI summary
Multi-component compositions for the preparation of extrudable mortars, which include a mortar base component including Portland cement, an additive for hydration control, a polyhydroxy compound and water and an accelerator component, which includes an alkali metal aluminate. The multi-component compositions enable a simple processing in conventional 3D mortal extrusion printing devices, where the viscosity can be adjusted independent from the accelerator. Also included are cementitious compositions prepared from such multi-component compositions, a 3D printing process using such mixed compositions as a printing material, as well as 3D structures which have been prepared via a corresponding printing process.