Retractable Nozzle Walls for Grout-Free Adjacent Brick Deposition
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Solution Overview
Problem
The process of laying bricks, pavers, or tiles is labor-intensive, requires heavy materials transport, and involves the use of grout or cement, which can cause structural issues due to differential expansion and contraction.
Innovation Solution
A large-scale 3D printing nozzle deposits bricks or pavers directly adjacent to each other without grout or cement, using a semi-solid or semi-liquid material that melds together as it cools, and a movable nozzle wall mechanism ensures precise placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bricks are made and transported to the job site, then brick production can be standardized, but transportation time and energy increase significantly
Solution Approach 1:
The patent applies preliminary action by preparing brick-making materials (dirt, dust, clay) directly at the job site before they are needed, eliminating the need to transport finished bricks. The 3D printing system is pre-configured with local materials and can immediately begin constructing bricks as needed, reversing the traditional approach of producing and storing bricks before transport.
Solution Approach 2:
The system applies self-service by using locally available materials at the job site to create bricks, rather than relying on external brick production and delivery systems. The apparatus autonomously mixes, forms, and deposits bricks using on-site resources, making the system self-sufficient and eliminating dependency on brick transportation infrastructure.
2Ease of manufacture
If grout or cement is used between bricks, then gaps can be filled, but structural problems arise due to differential expansion and contraction
Solution Approach 1:
The patent applies the taking out principle by completely removing grout and cement from the brick-laying system. Instead of filling gaps with separate materials that cause structural issues, the system deposits bricks in direct contact with each other, eliminating the need for intermediary filling materials and their associated expansion/contraction problems.
Solution Approach 2:
The system merges the brick deposition process with the gap-filling function by depositing bricks directly adjacent to each other without any intervening material. The bricks themselves form the continuous structure, eliminating the need for separate grout or cement applications and their associated structural complications.
3Productivity
If automated bricklaying is implemented, then labor intensity is reduced, but the system becomes more complex
Solution Approach 1:
The 3D printing apparatus applies universality by performing multiple functions within a single integrated system: it mixes materials, forms bricks, transports them, and deposits them in precise locations. This multi-functional design consolidates what would otherwise require separate machines and operations into one automated system, reducing overall complexity while maintaining high productivity.
Solution Approach 2:
The system applies parameter changes by using a large-scale nozzle with adjustable wall positions that can dynamically adapt to different brick deposition scenarios. The nozzle walls can move between extended and retracted positions, allowing the same apparatus to handle various brick sizes, shapes, and deposition patterns without requiring multiple specialized tools.
4Reliability
If a large-scale nozzle deposits bricks directly adjacent to each other, then grout is eliminated, but precise wall positioning is required
Solution Approach 1:
The patent applies dynamics by making the nozzle walls movable rather than fixed. The walls can dynamically adjust their position between extended and retracted states during the brick deposition process, allowing real-time compensation for positioning variations and ensuring precise brick placement for seamless adhesion without requiring static high-precision manufacturing.
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 automates bricklaying, reduces human intervention, eliminates material transport, and prevents structural issues by ensuring seamless adhesion.
Implementation Method 1
brick material added to the nozzle through the inlet opening flows through the conduit and exits the nozzle through the outlet opening
Implementation Method 2
brick material added to the nozzle through the inlet opening flows through the conduit
Implementation Method 3
The material of the bricks or pavers is preferably in a semi-solid, semi-liquid, or molten state so that the bricks or pavers meld together as they cool or cure
Implementation Method 4
the bricks or pavers meld together as they cool or cure
Implementation Method 5
at least one of the walls is configured to lift up relative to the other walls
Data Source
AI summary
An apparatus for making and depositing bricks includes a nozzle having an inlet opening, an outlet opening, and a plurality of walls surrounding the outlet opening. At least one of the walls is configured to retract relative to the other walls. When a first brick is deposited, all of the nozzle walls are in the extended position. When subsequent bricks are deposited, one or more of the nozzle walls are retracted so that the form for the subsequent bricks is provided by the walls that are in the extended position and the sides of the already-deposited bricks. In this manner, the nozzle is configured to deposit the bricks directly adjacent to each other without any space or intervening material between them. The bricks may be deposited in a heated state and they meld together as they cool. The nozzle is particularly advantageous for paving autonomously in otherwise inaccessible locations, such as surfaces on the moon or other planets.