IT202100005480A1 - ADDITIVE MANUFACTURING SYSTEM THROUGH THREE-DIMENSIONAL PRINTING OF A CEMENTITIOUS MATERIAL - Google Patents

Description

Description of the patent application for an industrial invention entitled:

?SYSTEM FOR ADDITIVE MANUFACTURING THROUGH THREE-DIMENSIONAL PRINTING OF A CEMENTITIOUS MATERIAL?

DESCRIPTION

The present invention relates to a system for additive manufacturing by means of three-dimensional printing of a cementitious material according to the preamble of claim 1.

Three-dimensional printing? an additive manufacturing technology that allows you to create an object layer by layer starting directly from a three-dimensional model, usually a CAD model, and following the digitized instructions on a computer control device.

There are several technologies for three-dimensional printing and their main differences are in the way the layers are printed.

Some methods use materials that melt, sintere, or soften with heat, usually produced by radiation from an electromagnetic radiation source or an electron beam, to produce the layers, e.g. Selective Laser Sintering (SLS) and Fused Deposition Modeling (FDM), while others deposit liquid materials which are allowed to cure to an acceptable strength level or value.

In this area, ? the state of the art knows the use of three-dimensional printers that use a cementitious material for the production of products intended for the building/architectural sector.

About that, ? known that with the terms ?Contour Crafting? it is intended to indicate an additive manufacturing technology that uses a cementitious material to create buildings and structures in the construction and civil fields using particular three-dimensional printing machinery, usually such machinery being similar to numerically controlled cranes.

The research on this technology has been conducted with the aim of constructing buildings in a more efficient way. simple, fast and with a reduction of human work compared to traditional technologies. In addition to this, the layered construction typical of additive technologies allows for the creation of buildings with complex shapes, which can integrate water, electricity and ventilation systems.

In essence, the implementation of additive manufacturing technology to create buildings and structures in the building/architectural field allows for greater flexibility, as this technology allows for greater freedom of design. for the architect and for the creator of a project in realizing and personalizing his own ideas and those of the client, even when these ideas are made up of complex shapes, and also combining materials of different nature. Furthermore, the concept of flexibility? is found in ease? to manage construction sites in poorly served areas or in very crowded urban centres.

Another advantage deriving from the implementation of additive manufacturing in the building/architectural sector consists in the fact that it allows to increase sustainability, as it constitutes a sustainable alternative that joins traditional construction methods. In particular, it makes it possible to reduce processing waste, to use a cement material in which recycled and local materials are used, also coming from the same elements made with three-dimensional printing, all in full compliance with the principles of the circular economy. This technology also makes it possible to significantly reduce the quantity? of material used, thanks to specific design approaches and without compromising functionality? of the structural elements.

A further advantage deriving from the implementation of additive manufacturing in the building/architectural sector consists in the fact that it allows to manage a construction site in safety, with reduced noise and dustiness, and with less overlapping of the processing phases and, consequently, with lower risks for the workers.

Three-dimensional printing in the building/architectural sector then allows to increase the accuracy in the realizations, as it offers a direct passage of information from a project (usually consisting of a three-dimensional model) to the construction operations, through a detailed realization of the details and a high reduction of the possibilities? of error. However, alongside the previously listed advantages, known systems for additive manufacturing by means of three-dimensional printing of a cementitious material have some drawbacks and limitations, which are particularly relevant if one wishes to apply the technology in a consolidated urban setting and if one has to intervene in an area characterized by the presence of small villages and cities? high density? building.

In particular, systems of the known type present the need to work in a controlled environment. In fact, since the three-dimensional printing process of a cementitious material is strongly influenced by the environmental conditions, the humidity values? and temperature affect the yield of the cementitious material and can make the difference between a stable structure and a fragile one. Changing the composition of the cement material from time to time to adapt to the environmental conditions of the site's application context would be substantially impossible, therefore in the state of the art the site is entirely covered by a protective superstructure. This practice has a strong impact on construction site times and costs, canceling or at least reducing the advantages inherent in technology in this sense.

In addition to this, the preparation of a building site is often complicated, especially in limited areas and in the case of irregular lots where it is difficult to assemble a superstructure suitable for allowing the three-dimensional printing operations of a cementitious material.

In order to try to at least partially overcome the aforementioned drawbacks, yes? thought of inserting the various equipment for additive manufacturing by means of three-dimensional printing inside transportable modules.

For example, the document published under the no. WO2018/022147A1 relates to a system for additive manufacturing comprising:

- a container substantially in the shape of a parallelepiped and comprising a floor, a ceiling and at least three lateral walls which create an internal space, in which said container is provided with at least one opening for accessing said internal space;

- a head for three-dimensional printing of a cementitious material;

- actuation means for moving said head,

wherein said actuation means and said head are positioned in the internal space of the container.

However, the solution shown in document WO2018/022147A1 also has considerable drawbacks.

In fact, not even such a solution? conceived in such a way as to take into due consideration the humidity values? and temperature that are specific to each place where the system is transported.

? therefore evident that also the solution proposed in the document WO2018/022147A1 ? such that the three-dimensional printing process ? strongly and negatively influenced by the environmental conditions of the place where the system is transported.

In this context, the main purpose of the present invention ? that of indicating a system for additive manufacturing by means of three-dimensional printing of a cementitious material made in such a way as to overcome the drawbacks present in solutions known to the state of the art.

In particular, an object of the present invention ? that of indicating a system for additive manufacturing by means of three-dimensional printing of a cementitious material, in which said system is made in such a way as to allow working in a controlled environment and such as not to have to change the composition of the cementitious material from time to time to adapt to the environmental conditions of the construction site application context.

Another object of the present invention ? to indicate a system for additive manufacturing by means of three-dimensional printing of a cementitious material that is designed in such a way as to take into due consideration the humidity values? and temperature that are specific to each place where the system is transported.

A further object of the present invention ? that of indicating a system for additive manufacturing by means of three-dimensional printing of a cementitious material made in such a way as to provide a highly flexible solution suitable for use in different places, in particular without having to make significant changes to the system itself and/or to the composition of the cement material.

Further objects, characteristics and advantages of the present invention will become clear from the following detailed description and from the annexed figures, provided purely by way of non-limiting explanatory example, in which:

- Fig. 1A and Fig.1B respectively represent a plan view and a side sectional view of a first embodiment of a system for additive manufacturing by means of three-dimensional printing of a cementitious material according to the present invention;

- Fig. 2A and Fig.2B respectively represent a plan view and a side sectional view of a second embodiment of the system for additive manufacturing by means of three-dimensional printing of a cementitious material according to the present invention;

- Fig. 3A and Fig. 3B show side sectional views respectively of a first and a second variant of the system for additive manufacturing by means of three-dimensional printing of a cementitious material according to the present invention.

Moving on to the description of the enclosed figures, the reference number 1 indicates as a whole a system for additive manufacturing by means of three-dimensional printing of a cementitious material according to the present invention.

The system 1 for additive manufacturing comprises a container 10 comprising a lower wall 11, an upper wall 12 and at least three side walls 13 which identify or delimit an internal space, in which the container 10 is equipped with at least one entrance 10A for accessing said internal space.

Preferably, the 10A input? associated with at least one door 14 which allows to selectively obtain the opening or closing of said entrance 10A. It should be noted that the container 10 substantially has the shape of a parallelepiped. In this context and in accordance with a preferred embodiment, the container 10 is consisting of a container, in particular in metal and of the ISO type (acronym of International Organization for Standardization). As known, ISO containers have a dimensional and, therefore, volumetric standardization; compared to a common width of 8 feet (244 cm) and a common height of 8 feet and 6 inches (259 cm), they are mainly diffused in two standard lengths of 20 and 40 feet (610 and 1220 cm) and related variants.

Furthermore, in ISO containers the attachments, present on the corners of the container, are also homogeneous, specific for fixing on the various means of transport. In this way, by means of forklifts, gantries and cranes they are easily transferred between a ship where they can be easily stacked vertically, a wagon or a truck. The characteristics of these attachments, combined with the intrinsic strength of the ISO container, allow them to be stacked on top of each other, improving the utilization of piers, docks and warehouses.

Consequently, also the container 10 according to the present invention ? made according to the aforementioned ISO dimensional/volumetric type standardization and in the standard lengths of 20 or 40 feet, and relative variants; moreover, the container 10 can? be equipped with standard attachments (not shown) present at the corners of said parallelepiped-shaped container 10.

However, ? evident that the container 10 pu? can also be made in a different way, for example being able to be conceived in such a way that the lower wall 11 and/or the upper wall 12 and/or the side walls 13 are made in such a way as not to present elements of discontinuity? designed to determine and identify a clear and appreciable separation of these components.

The system 1 according to the present invention also comprises a head 20 coupled to handling means 31, 32 for handling said head 20, wherein said head 20 and said handling means 31, 32 are driven by a unit? control 21 to carry out the three-dimensional printing of said cementitious material.

In a first possible embodiment, shown in Figures 1A and 1B, said handling means comprise a robotic arm 31 coupled to the head 20 for three-dimensional printing of said cementitious material.

In this embodiment, said robotic arm 31 can be equipped with moving means (for example comprising wheels and/or tracks) to carry out the three-dimensional printing of elements in different points of the internal space of the container 10; in addition or alternatively, the container 10 can? comprise a mobile platform 33 (for example comprising a conveyor belt) associated with the lower wall 11 to allow the movement of the molded elements from the head 20, for example to arrange them in such a way that they are easily accessible from the entrance 10A.

As regards instead a second possible embodiment, shown in figures 2A and 2B, said movement means comprise a portal or bridge crane structure 32; in this embodiment, the container 10 can? comprise a printing plane 34 associated with the lower wall 11 and adapted to receive the printed elements from the head 20.

How can you? note from the attached figures, in both embodiments shown in the figures from 1A to 2B said head 20 and said movement means 31, 32 are positioned in the internal space of the container 10. Preferably, as shown in the attached figures from 1A to 2B, also the unit? control 21 ? positioned in the internal space of the container 10; however, in accordance with the provisions of the present invention, the unit? of control 21 could also be positioned in an external and/or remote place with respect to the container 10.

In both embodiments shown in figures 1A to 2B, the system 1 comprises a feed system 40 suitable for supplying the cementitious material to said head 20, in particular said feed system 40 comprising a unit? 41 for mixing and/or pumping connected to the head 20 by at least one hose 42.

This unit? 41 of mixing and/or pumping pu? be positioned in the internal space of the container 10, as shown in Fig. 3A; this positioning of? unit? 41 mixing and/or pumping ? preferred above all in the case in which the container 10 consists of a container of the ISO type which has a standard length of 40 feet.

Alternatively, this unit? 41 of mixing and/or pumping pu? be positioned outside the container 10 (as shown in Fig. 3B); this positioning of? unit? 41 mixing and/or pumping ? preferred above all in the case in which the container 10 consists of a container of the ISO type which has a standard length of 20 feet.

Furthermore, container 10 can be equipped with at least one opening 15, in particular obtained on a side wall 13, to allow the passage of said at least one hose 42 (as shown in Fig. 3B) suitable for supplying the cementitious material to the head 20 and/or a duct 43, in particular for the water supply to the unit? 41 for mixing and/or pumping (as shown in Fig. 3A). In accordance with the present invention, the system 1 comprises at least one unit? air conditioning system 50 positioned at least partially in the internal space of the container 10 to regulate the environmental values, in particular in terms of temperature and/or humidity, of said internal space.

Furthermore, the system 1 according to the present invention comprises at least one temperature and/or humidity sensor 60? positioned in the internal space of the container 10 to measure the environmental values (in particular, in terms of temperature and/or humidity?) of said internal space, in which said at least one sensor 60 ? connected to that at least one unit? air conditioning system 50 to regulate its operation on the basis of the measurement of the environmental values measured in the internal space of the container 10.

In accordance with a preferred embodiment, the system 1 comprises a plurality? of sensors 60 of temperature and/or humidity? positioned in different points of the internal space of the container 10.

It should be noted that the system 1 preferably comprises a control unit (not shown in the figures) connected to said at least one unit? conditioning unit 50 and connected to said at least one sensor 60 to drive the operation of said at least one unit? conditioning system 50 based on the measurement of the environmental values measured by said at least one sensor 60 in the internal space of the container 10.

? it is clear that the container 10 comprises electrical power supply means 16 for powering the various components of the system 1 according to the present invention, in particular for supplying a power necessary to operate the head 20 and/or the unit? control unit 21 and/or the movement means 31, 32 and/or said at least one unit? conditioning system 50 and/or said at least one sensor 60.

Furthermore, at least part of the walls 11, 12, 13 of the container 10 are made in such a way as to comprise an insulating material suitable for insulating the internal space of the container 10 with respect to the external environment. Preferably, the container 10 ? made in such a way that the lower wall 11, the upper wall 12 and the side walls 13 are all made in such a way as to include said insulating material.

From the description given, the characteristics of the system 1 for additive manufacturing by means of three-dimensional printing of a cementitious material according to the present invention are therefore clear. how clear are its advantages.

In particular, the particular characteristics object of the present invention allow to indicate a system 1 conceived in such a way as to overcome the drawbacks present in the solutions known to the state of the art.

In fact, the solution object of the present invention allows to indicate a system 1 conceived in such a way as to allow to work in a controlled environment and such as not to have to change the composition of the cement material from time to time to adapt to the environmental conditions of the context of construction site application.

Another advantage of system 1 consists in the fact that it ? conceived in such a way as to take into due consideration the values of humidity? and temperature that are specific to each place where the system is transported.

Indeed, the system 1 according to the present invention ? made in such a way that the container 10 can? be transported in the construction site area where it will become? immediately operational; in particular, following its connection to the electric supply means 16 and to the supply system 40 suitable for supplying the cementitious material, the head 20 will be able to immediately and without delay, start printing the architectural and/or furnishing elements in a controlled environment using said at least one unit? conditioning sensor 50 and/or said at least one temperature and/or humidity sensor 60; ? it is therefore clear that the three-dimensional printing operations carried out by the system 1 according to the present invention can be carried out without having to modify the composition of the cementitious material each time in such a way as to adapt to the environmental conditions of the construction site application context.

? therefore evident that the system 1 according to the present invention ? made in such a way as to provide a highly flexible solution suitable for being used in different places, in particular without having to make significant changes to said system 1 and/or to the composition of the cement material which is used to carry out the three-dimensional printing.

There are numerous possible variants to system 1 described as an example, without departing from the principles of novelty? inherent in the inventive idea, cos? as ? it is clear that in its practical implementation the forms of the illustrated details may be different, and they may be replaced with technically equivalent elements.

So, ? easily understandable that the present invention is not limited to the system 1 previously described but ? subject to various modifications, improvements, replacements of parts and equivalent elements without for? move away from the idea of the invention, so? as ? better specified in the following claims.

Claims (15)

1. System (1) for the additive manufacturing by means of three-dimensional printing of a cementitious material, said system (1) comprising: - a container (10) comprising a lower wall (11), an upper wall (12) and at least three side walls (10) which define an internal space, in which the container (10) is equipped with at least one entrance (10A) to access said internal space; - a head (20) coupled to movement means (31, 32) for movement of said head (20), wherein said head (20) and said movement means (31, 32) are driven by a unit? control (21) to carry out the three-dimensional printing of said cement material, and wherein said head (20) and said movement means (31, 32) are positioned in the internal space of the container (10); said system (1) being characterized in that it comprises at least one unit? air conditioning system (50) positioned at least partially in the internal space of the container (10) to regulate the environmental values, in particular in terms of temperature and/or humidity, of said internal space. 2. System (1) according to claim 1, characterized in that it comprises at least one sensor (60) for temperature and/or humidity? positioned in the internal space of the container (10) to measure the environmental values of said internal space, in which said at least one sensor (60) ? connected to that at least one unit? air conditioning (50) to regulate its operation based on the measurement of the environmental values measured in the internal space of the container (10). 3. System (1) according to one or more? of the preceding claims, characterized in that it comprises a control unit connected to said at least one unit? conditioning system (50) and connected to said at least one sensor (60) to drive the operation of said at least one unit? climate control (50) based on the measurement of the environmental values measured by said at least one sensor (60) in the internal space of the container (10). 4. System (1) according to one or more? of the preceding claims, characterized in that at least part of the walls (11, 12, 13) of the container (10) are made in such a way as to include an insulating material suitable for insulating the internal space of the container 10 with respect to the external environment. 5. System (1) according to one or more? of the preceding claims, characterized in that said handling means (31; 32) comprise a robotic arm (31) coupled to the head (20) for three-dimensional printing of said cementitious material. 6. System (1) according to claim 5, characterized in that the container (10) comprises a mobile platform (33) associated with the lower wall (11) to allow the movement of the molded elements from the head (20). 7. System (1) according to one or more? of claims from 1 to 4, characterized in that said movement means (31; 32) comprise a portal or bridge crane structure (32). 8. System (1) according to one or more? of the preceding claims, characterized in that it comprises a feed system (40) capable of supplying the cementitious material to said head (20), in particular said feed system (40) comprising a unit? (41) for mixing and/or pumping connected to the head (20) by at least one hose (42). 9. System (1) according to claim 8, characterized in that said unit? (41) mixing and/or pumping ? positioned in the internal space of the container (10). 10. System (1) according to claim 8, characterized in that said unit? (41) mixing and/or pumping ? positioned outside the container (10). 11. System (1) according to one or more? of the preceding claims, characterized in that the container (10) is equipped with at least one opening (15), in particular obtained on a side wall (13), to allow the passage of at least one hose (42) suitable for supplying the cement material to the head (20) and/or to allow the passage of a conduit (43), in particular for feeding water to a unit? (41) for mixing and/or pumping of the cementitious material. 12. System (1) according to one or more? of the preceding claims, characterized in that said container (10) comprises electrical power supply means (16) for powering the various components of the system (1). 13. System (1) according to one or more? of the preceding claims, characterized in that said container (10) substantially has the shape of a parallelepiped. 14. System (1) according to claim 13, characterized in that said container (10) is consisting of a container, in particular in metal and of the ISO type. 15. System (1) according to claim 14, characterized in that said container (10) is made in the standard lengths of 20 or 40 feet and relative variants, in particular said container (10) being equipped with standard connections present at the corners of said container (10).