GB2509757A

GB2509757A - Reinforced three-dimensionally printed form

Info

Publication number: GB2509757A
Application number: GB1300604.4A
Authority: GB
Inventors: Mark Nicholas Johnson
Original assignee: Stage One Creative Services Ltd
Current assignee: Stage One Creative Services Ltd
Priority date: 2013-01-14
Filing date: 2013-01-14
Publication date: 2014-07-16
Also published as: GB201300604D0

Abstract

A reinforced three-dimensionally printed form 100 comprising a three-dimensional printed form of inert particulate 102 bound by an adhesive and having opposed first and second faces, wherein the first face of the layer is sealed 102B, and a reinforcing layer 114 is provided on the first face. The first face may be sealed with a resin or sealed by a component of the reinforcing layer that has penetrated into the first face of the printed form. The reinforcing layer may comprise matter embedded in a matrix material including reinforcing bars, a layer of aggregate embedded in cementitious material or a composite layer comprising fibres embedded in matrix material. The printed form may have an interior which is substantially filled with the reinforcing layer. The second face may additionally be sealed and provided with a reinforcing layer. The inert particulate is preferably silicone sand and the adhesive may be resin-based or water-based. A method of forming a 3-D printed form is also provided comprising printing the form, sealing the first face and applying a reinforcing layer onto the first face. The form may particularly be a facade panel or unique blocks or panels for use in the construction industry. A building comprising a plurality of reinforced printed forms is further provided.

Description

REINFORCED THREE-DIMENSIONALLY PRINTED FORM

The present invention relates to reinforced three-dimensionally printed forms, particularly architectural construction elements, examples being architectural construction panels, negative moulds, and blocks for the façades of buildings, and sculptures.

BACKGROUND

It is known to build complex architectural structures from large blocks with non-planar exposed outer surfaces (e.g. a 2m x 4m façade block), or to from a structure that is panelled with façade panels (e.g. a 2m x 4m façade panel) having non-planar faces. Manufacturing costs and production timescales typically prevent the use of carved natural stone, and so large architectural blocks and panels are typically formed by a moulding process. However, limitations to the manufacturing process limit the use of façade panels having surfaces with complex three dimensional shapes.

Where costs permit the manufacture of unique blocks and panels, each construction element requires the production of a corresponding bespoke negative mould. Such moulds are typically provided by carving or constructing a positive model, for example from wood, or will be machined from polystyrene or foam blocks. The negative mould is then formed on the positive model, for example, from layers of glass fibre reinforced plastic. Once the positive model has been removed, the moulded object is then formed releasably on or in the mould, e.g. also from glass fibre reinforced plastic. Such a process is common practice in boat-building, where the same mould may then be used to produce many identical boat hulls.

However, such a process is particularly expensive, time consuming and wasteful for the production of one-off objections, e.g. unique façade panels, complex moulds (e.g. formwork such as concrete "shuttering" moulds) and sculptures. Accordingly, complex designs from architects often need to be compromised due to the financial unviability of manufacturing unique construction elements, instead leading to the manufacture of structures without unique façade panels, in which each mould is used several times to produce a small range of panels from which a building façade is constructed.

Further, the shape of construction elements may also be limited by the extra complexity and cost of moulding elements that have constrictions or other shapes that would prevent withdrawal of the element from within a single-part mould, e.g. gargoyles, grotesques or other sculptural building features, blocks/panels faced with elaborate profiles, and free-standing sculptures.

Accordingly, there remains a need for a manufacturing process that enables more financially viable production of unique or elaborately shaped three-dimensional forms.

SUMMARY OF THE DISCLOSURE

A first aspect of the invention provides a reinforced three-dimensionally printed form comprising a three-dimensional printed form of inert particulate bound by an adhesive and having opposed first and second faces, wherein the first face of the layer is sealed, and a reinforcing layer is provided on the first face.

A second aspect of the invention provides a building comprising a plurality of façade panels that are reinforced 3D printed forms according to the first aspect.

A third aspect of the invention provides a mould comprising an interconnected plurality of reinforced three-dimensional printed forms according to the first aspect.

A fourth aspect of the invention provides a method of forming a reinforced 3D printed form comprising a three-dimensional printed form of inert particulate bound by an adhesive and having opposed first and second faces, wherein the first face of the layer is sealed, and a reinforcing layer is provided on the first face, the method comprising printing the 3D printed form, sealing the first face, and applying the reinforcing layer onto the first face.

A fifth aspect of the invention provides a method of moulding a form comprising forming a plurality of reinforced 3D printed forms according to the fourth aspect, and assembling the 3D printed forms to provide a mould, and filling the mould with a moulding material.

Advantageously, the present invention may enable the production of unique construction elements! such as building blocks, building panels, formwork moulds (e.g. concrete shuttering moulds) and sculptures, more quickly, less expensively and with less waste, than known methods. Further, the present invention may enable the production of construction elements and sculptures with three-dimensional surfaces having a greater level of complexity than was possible or viable with known methods.

The face of the reinforced printed form may have an adhesive bonded core, and a first face that is at least 100 times longer and wider than the thickness of the adhesive bonded core.

The face of the reinforced printed form may have an adhesive bonded core having a thickness of at least 5mm. Advantageously, such a bonded core may provide larger three dimensional printed forms with sufficient strength to remain structurally sound whilst being handled and transported. The face of the reinforced printed form may have an adhesive bonded core having a thickness of less than 50mm.

The first face of the printed form may be at least im long and at least im wide.

The first face may be sealed with a resin. The resin may be an epoxy, polyester or acrylic-based resin system, or a polymer based structural concrete.

The first face may be sealed by a component of the reinforcing layer that has penetrated into the first face of the printed form. The first face may be sealed with a gypsum based slurry mix, or a glass strand reinforced material e.g. glass reinforced concrete (GRC) or glass reinforced gypsum (GRG).

The reinforcing layer may be a composite layer comprising matter embedded in a matrix material. Advantageously, such a reinforcing layer may provide greater strength for a given thickness or weight of material applied.

Reinforcing bars may be embedded in the reinforcing layer.

The reinforcing layer may comprise a composite layer of aggregate embedded in a cementitious matrix material.

The reinforcing layer may comprise a composite layer comprising fibres embedded in a matrix material.

The matrix may be a gypsum based slurry mix, or a glass strand reinforced material e.g. glass reinforced concrete (GRC) or glass reinforced gypsum (GRG).

The fibres may be selected from the group consisting of: glass fibres, para-aramid synthetic fibres (e.g. Kevlar®), carbon fibres, and natural hemp fibres.

The matrix material may be a resin. The resin may be an epoxy, polyester or acrylic based resin system, or a polymer based structural concrete.

The first face may be sealed with a sealant that is different to the matrix material.

The reinforcing layer may comprise a plurality of reinforcing sub-layers.

The printed layer may have an interior that is substantially filled with the reinforcing layer.

The second face may be sealed. The second face may be sealed with a resin. The resin may be an epoxy, polyester or acrylic-based resin system, or a polymer based structural concrete.

A further reinforcing layer may be provided on the second face. The second face may be sealed by a component of the further reinforcing layer that has penetrated into the first face of the printed form. The second face may be sealed with a gypsum based slurry mix, or a glass strand reinforced material e.g. glass reinforced concrete (GRC) or glass reinforced gypsum (GRO).

The second face may be sealed by a cementitious finish.

The inert particulate may be silica sand.

The adhesive may be a resin-based or water-based adhesive. The adhesive may be an epoxy, polyester or acrylic-based resin system.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which: * Figures 1A to 1 E show stages in the manufacture of a reinforced three-dimensionally printed form according to a first embodiment of the present invention; * Figure 2 shows a stage in the manufacture of a reinforced three-dimensionally printed form according to a second embodiment of the present invention; and * Figures 3A to 3D show stages in the manufacture of a reinforced three-dimensionally printed form according to a third embodiment of the present invention.

DETAILED DESCRIPTION

In the described embodiments, like features have been identified with like numerals, albeit in some cases having one or more of: increments of integer multiples of 100. For example, in different tigures, 100, 200 and 300 have been used to indicate a three dimensional printed form.

Figures 1A to 1 E show stages in the manufacture of a reinforced three-dimensionally printed form (e.g. a panel) according to an embodiment of the present invention.

Figures 1A shows a partially printed three dimensional form 100 that is being printed in a bed of sand 102 (or other particulate). The sand has been mixed with an adhesive that is curable under the action of heat or under the action of ultraviolet light to bind the sand together. The sand is laid down in a series of thin layers (e.g. a 500pm thick blanket of sand is deposited). Between depositions of successive layers of sand, a patterned layer of adhesive is printed onto the surface of the sand by a print-head 104 (if required, the adhesive may be thermally cured following deposition), and the process is then repeated to build up the three dimensional printed form 100. The enlarged excerpt in Figure 1 B shows the cured adhesive 106, which binds the sand to form a thin permeable core of bonded sand 102B, e.g. a few millimetres thick. Accordingly, by repetition of the deposition and curing steps the three dimensional form 100 is progressively built-up in the bed of sand 102, to provide the full printed three dimensional form shown in Figure lB. The permeable core formed from the adhesive bonded sand 102B, which defines the printed form 100, is supported by loose sand 102A underneath, and covered over with further loose sand 1020 above, which buries and/or fills the printed form.

Once the three-dimensional printing has been completed, the loose sand on the printed form 100 is removed to expose a first face 108. Then, the exposed first face 108 is coated with a sealant 110 (e.g. resin-based sealant) that seals the exposed face 108 and partially penetrates into the bonded sand core 102B of the printed formlOO to form a sealed face layer 112, as shown in Figure 1 C. The sealant does not penetrate all the way through the bound sand core 102B and out the opposite side. The sealant may additionally provide a partial reinforcement of the printed form. The sealant may be a composite, comprising very fine particulate (much finei than the sand or other particulate from which the punted form is formed) that can also permeate the structure of the bonded sand core 102B. The very fine particulate may reinforce the bonded sand by filling the voids between the grains of sand, it may be pigmented to provide an aesthetically pleasing appearance, or may provide a surface that is more suitable for polishing. However, at this stage, the printed form remains weak (e.g. brittle), and may not be sufficiently strong to be lifted out of the sand bed, due to its large length and width, relative to the thinness of the bonded sand core 102B, and is not stuong enough for use in a structurally demanding application. The length and width may be moue than 100 times the thickness of the bonded core (e.g. a façade panel that is 4m long, 2m wide and has a 10mm thick bonded core).

One ou more reinforcing layeus 114 are puovided on the exposed first face 108 of the punted form 100 to form a reinforced three dimensional printed form 150, as shown in Figure 10.

The reinforcing layers are stronger than the printed form 100, and provide a greatly strengthened composite structure 150. The reinforcing layers 114 may be fibre reinforced plastic layers (e.g. glass reinforced plastic), which are successively deposited on the face 108 of the printed form 100 to form a laminate stuucture. Each layer may be formed by permeating a layer of fibre matting (e.g. nonwoven web) with a plastic resin (e.g. two-part epoxy resin). Advantageously permeation of the resin into the fibre glass matting may be enhanced by the use of a "vacuum bagging" technique, in which resin is introduced into a partial vacuum created beneath a membrane that is sealed around the exposed first face 108. The present invention is not limited to the use of glass reinforced plastic, and other reinforcing layers may also be used, e.g. glass reinforced concrete. After application of the reinforcing layer(s) 114, the reinforced three-dimensionally printed form 150 is strong enough to be lifted from the sand bed 102, exposing the second face 116.

Although the first face 108 has been described as being sealed and reinforced in separate steps, alteunatively, the fiust face may be sealed and coated in a single step, by permeation of matrix material into the first face of the porous bonded sand core 102B, when the reinforcing layer 114 is applied to the first face.

The second face 116 may be sealed with sealant (e.g. resin), which penetuates into the second face to form a further sealed face layer 118 on which a further reinforcing layer 120 may be provided. Alternatively, the second face 116 may be sealed and coated in a single step by the application of the reinforcing layer 120 or a surface finish. The sealant applied to the second face 116 penetrates to form a second sealed face layer 118.

In the illustrated embodiment, the second sealed face layer 118 does not penetrate the permeable adhesive bonded sand core 102B sufficiently to meet the first sealed face layer 112. However, in alternative embodiments, the sealant applied to the second face 116 of the printed layer 100 may penetrate the adhesive bonded sand core 102B sufficiently deeply that the second sealed face layer 118 extends to meet the first sealed face layer 112, forming a composite sealed layer throughout the thickness of the bonded sand core 102B.

If further reinforcement of the printed form 100 is not required, the second face 116 may be left bare, or may be coated with an aesthetic finish, e.g. paint.

Alternative methods of three dimensional printing of sand (and other inert particulate) are also known. In a further example, an adhesive may be mixed with the deposited sand that is curable with a catalyst, before patterned deposition of the catalyst.

Although the embodiments are discussed with respect to sand, it will be appreciated that other inert fine particulates may also be printed for use in the present invention.

Although the reinforced printed form 100 in Figure 1 D is shown reinforced with a plurality of reinforcing sub-layers, alternatively, a thick reinforcing layer may be applied. Figure 2 illustrates such an alternative embodiment, in which a thick reinforcing layer 214, comprising reinforcing bars 222 (known as rebars", e.g. metal rods having a profiled surface finish), is applied on the first face 208 of the printed form 200.

Figures 3A to 3D show stages in the manufacture of a reinforced three-dimensionally printed form according to a further embodiment of the present invention.

Figure 3A shows a sculptural three dimensional printed form 300, which is shaped as a hollow vessel, that has been printed with an internal structure 324 that reinforces the form.

After printing, the sand 302 is removed from within the printed form 300, as shown in Figure 3B, and the interior surface 308 of the printed form is sealed, before being filled with a reinforcing material 326, e.g. being filled with cementitious material, as shown in Figure 3C.

Once reinforced, the reinforced three dimensional printed form 350 can be removed from the bed of supportive sand 302. The exterior surface 316 of the reinforced printed form 350 may be sealed and reinforced or treated with an aesthetic finish.

Façade panels and building blocks according to the present invention may be assembled to form parts of buildings. Further, a plurality of reinforced three-dimensional printed forms according to the present invention may be interconnected (e.g. connected together with bolts) to construct a formwork mould (e.g. to provide a concrete shuttering mould into which concrete is poured and sets to form walls, pillars, staircases, etc.).

The figures provided herein are schematic and not to scale.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS1. A reinforced three-dimensionally printed form comprising a three-dimensional printed form of inert particulate bound by an adhesive and having opposed first and second faces, wherein the first face of the layer is sealed, and a reinforcing layer is provided on the first face.
2. A reinforced 3D printed form according to claim 1, wherein the face of the reinforced printed form has an adhesive bound core, and a first face that is at least 100 times longer and wider than the thickness of the adhesive bound core.
3. A reinforced 3D printed form according to claims 1 or 2, wherein the face of the reinforced printed form has an adhesive bonded core having a thickness of at least 5mm.
4. A reinforced 3D printed form according to any one of claims 1, 2 or 3, wherein the first face of the printed form is at least 1 m long and at least 1 m wide.
5. A reinforced 3D printed form according to any preceding claim, wherein the first face is sealed with a resin.
6. A reinforced 3D printed form according to any one of claims 1 to 4, wherein the first face is sealed by a component of the reinforcing layer that has penetrated into the first face of the printed form.
7. A reinforced 3D printed form according to any preceding claim, wherein the reinforcing layer is a composite layer comprising matter embedded in a matrix material.
8. A reinforced 3D printed form according to claim 7, wherein reinforcing bars are embedded in the reinforcing layer.
9. A reinforced 3D printed form according to claims 7 or 8, wherein the reinforcing layer comprises a composite layer of aggregate embedded in a cementitious matrix material.
10. A reinforced 3D printed form according to claim 7, wherein the reinforcing layer comprises a composite layer comprising fibres embedded in a matrix material.
11. A reinforced 3D printed form according to claim 10, wherein the fibres are selected from the group consisting of: glass fibres, para-aramid synthetic fibres, carbon fibres, and natural hemp fibres.
12. A reinforced 3D printed form according to claims 10 or 11, wherein the matrix material is a resin.
13. A reinforced 3D printed form according to any one of claims 7 to 12, wherein the first face is sealed with a sealant that is different to the matrix material.
14. A reinforced 3D printed form according to any preceding claim, wherein the reinforcing layer comprises a plurality of reinforcing sub-layers.
15. A reinforced 3D printed form according to any preceding claim, wherein the printed layer forms has an interior that is substantially filled with the reinforcing layer
16. A reinforced 3D printed form according to any preceding claim, wherein the second face is sealed.
17. A reinforced 3D printed form according to any preceding claim, wherein a further reinforcing layer is provided on the second face.
18. A reinforced 3D printed form according to claim 16, wherein the second face is sealed by a cementitious finish.
19. A reinforced 3D printed form according to any preceding claim, wherein the inert particulate is silicon sand.
20. A reinforced 3D printed form according to any preceding claim, wherein the adhesive is a resin-based or water-based adhesive.
21. A building comprising a plurality of façade panels that are reinforced 3D printed forms according to the first aspect
22. A mould comprising an interconnected plurality of reinforced three-dimensional printed forms according to any preceding claim.
23. A method of forming a reinforced 3D printed form comprising a three-dimensional printed form of inert particulate bound by an adhesive and having opposed first and second faces, wherein the first face of the layer is sealed, and a reinforcing layer is provided on the first face, the method comprising printing the 3D printed form, sealing thefirst face, and applying the reinforcing layer onto the first face.
24. A reinforced 3D printed form substantially as hereinbefore described with reference to the accompanying description and any one of the Figures.
25. A building comprising a plurality of reinforced 3D printed forms substantially as hereinbetore described with reference to the accompanying description and any one of the Figures.