RU2739244C2 - Device and method for production of heat-insulating walls from polysterel-concrete using 3d-printer - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: disclosed group of inventions is intended for making heat-insulating walls of buildings using 3D printer. Device for making heat-insulating walls from polystyrene concrete using 3D printer includes 3D printer with a printing head in form of an extruder with a system for feeding binder, extruding binding material through nozzle and spatulas made with possibility of shaping material extruded with extruder. Extruder is equipped with system for preliminary heating of binding material, as well as upper pressure trowel and side spatula-electrodes, having in the head part process bends and connected to the mains by cables.

EFFECT: technical result of the invention is to obtain in a single pass of the printing head a homogeneous layer of material which does not spread under the pressure of the layers being laid.

2 cl, 2 dwg

Description

The invention relates to the field of construction and is intended for the device of heat-insulating walls of buildings, manufactured using a 3D printer.

A known method of manufacturing building structures by layer-by-layer extrusion using a 3D printer [Lunev DA, Kozhevnikova EO, Kaloshin SV. The use of 3D printing in construction and the prospects for its development. / Bulletin of PNRPU. Construction and architecture, v. 8, No. 1 (2017), p. 90-101]. In the manufacture of walls, the extruder, which is the working body of the 3D printer, squeezes out the fast-hardening concrete mixture layer by layer, forming the outer and inner versts, which are fixed to each other with concrete, also layer-by-layer extruded or pre-made metal or fiberglass bonds. The cavities between versts can be filled with structural reinforced concrete or thermal insulation.

The disadvantages of this method are:

- cold bridges, which are the connections between the outer and inner versts, which reduce the thermal insulation capabilities of the wall; the presence of several technological redistributions (printing of the wall frame, filling some cavities with heat-insulating material, installing reinforcement and laying structural concrete in others) in the manufacture of one structural element;

- the need for manual operations included in the robotic process.

The closest in technical essence to the claimed method is "Robotic systems for automated construction / Robotic systems for automated construction" (US Patent No. 7641461 B2, class В29С 64/106 from 2004) - a prototype containing a 3D printer with a binder supply system material and a print head in the form of an extruder that squeezes out the binder through three nozzles to form an outer verst, an inner verst of the wall and then fill the space between them with another binder, as well as two spatulas made with the possibility of shaping the material of the outer and inner versts, extruded by the extruder.

The disadvantages of this solution are:

- two-stage performance of work. First, using side nozzles, it is necessary to form the outer and inner versts of the wall layer by layer with one binding material. Then, after waiting for the loss of its mobility, fill the cavity formed between the outer and inner versts of the wall with another binding material (Fig. 5);

- the need to include in the device and the operation of two systems for supplying different binding materials;

- the need for a sufficiently fast curing of the binder for the outer and inner versts so that it can withstand the weight of the layers of binder laid on top and the lateral pressure of the binder filling the cavity between the versts. However, it should not cure too quickly because this can lead to its hardening inside the storage and delivery systems.

The objective of the claimed invention is the layer-by-layer production of building walls with the necessary thermal insulation and structural properties, performed simultaneously for their entire thickness, in one pass of the printhead-extruder, squeezing out the binder from one nozzle by means of one binder material supply system.

The task is solved by the fact that in the "Device and method for the manufacture of heat-insulating walls from polystyrene concrete using a 3D printer":

- a device containing a 3D printer with a print head in the form of an extruder with a binder material supply system that squeezes out the binder material through nozzles and two spatulas configured to shape the material squeezed out by the extruder, according to the invention, the extruder is equipped with a binder material preheating system, one nozzle, a clamping spatula and side spatula-electrodes having technological bends at the head and connected to the electrical network by cables;

- a manufacturing method, including feeding a binder from an extruder through nozzles to form first a structural and then a heat-insulating part of the wall, according to the invention, polystyrene concrete with non-foamed polystyrene is used as a binder, which is preheated in an extruder, squeezed out through a nozzle onto the surface of a previously laid layer over its entire width, after which it is heated by an electric current that penetrates it, supplied to the side spatula electrodes to the temperature of foaming polystyrene and is formed into a new layer using the upper pressing spatula and spatula electrodes.

Evenly distributed throughout the volume, polystyrene granules reduce heat loss from the structure to the environment, increasing the duration of high temperatures, and thereby providing an intensive increase in strength. By changing the polystyrene content in the formulation of the binder, depending on the need, it is possible to increase or decrease the thermal insulation or structural properties of the wall.

A device for manufacturing heat-insulating walls made of polystyrene concrete using a 3D printer is shown in Fig. 1 and FIG. 2. The print head of the 3D printer includes an extruder 1 equipped with a preheating system 2 of a binder 9 with non-foamed polystyrene granules connected to the electrical network 7, a supply system 3 of a binder 9 and an outlet nozzle 4, through which the binder - polystyrene concrete 9 is squeezed out on the surface of the previously molded and lost mobility layer of polystyrene concrete 11. The width of the outlet nozzle 4 is equal to the width of the erected wall 12. Side spatula-electrodes 5 with technological bends are rigidly fixed to the outlet nozzle 4. The spatula-electrodes 5 are connected to the electrical network by means of cables 6 7. Between the spatula-electrodes 5, in their upper part, a pressing spatula 8 is fixed, together they form a new layer of binding material 10 with foamed polystyrene granules. The outlet nozzle 4 and the pressing spatula 8 are made of current-insulating material.

The method and the device function as follows. The polystyrene concrete mixture 9 with non-foamed polystyrene granules enters the extruder 1 through the feed system 3 of the binder material, where it is heated by means of the preheating system 2 to a temperature not higher than 80 ° C and from there, through the outlet nozzle 4, it is squeezed onto the surface of the previously molded and lost mobility layer of polystyrene concrete 11 The outlet nozzle 4 has a transverse dimension equal to the width of the previously formed layer of polystyrene concrete 11. The polystyrene concrete mixture 9 fills the space between the side spatula-electrodes 5, which, being part of the print head of the 3D printer, slowly move along the wall. An electric current, with a voltage of 380 V, coming from the electrical network 7 through cables 6 to the spatula-electrodes 5, passes through the polystyrene-concrete mixture 9, quickly heating it. Upon reaching a temperature of more than 90 ° C, the polystyrene granules soften and, under the action of the boiling isopentane contained in them, foamed, multiplying in volume. In this case, the mixture 9 with non-foamed polystyrene granules turns into a mixture 10 with foamed polystyrene granules and changes its quality, acquiring thermal insulation properties. In the process of heating and swelling of polystyrene granules, the volume of polystyrene concrete mixture 9 increases, turning into polystyrene concrete mixture 10, and occupies the entire space between the side spatula-electrodes 5, the surface of the previously laid layer of the erected wall 12 and the pressure spatula 8, partially compacted. Side spatula-electrodes 5 and a pressing spatula 8 form the next layer of the wall 11 of polystyrene concrete 10 with foamed polystyrene granules obtained as a result of electric heat treatment. Possessing a high temperature, the polystyrene concrete mixture 10 quickly, even in the space between the spatula-electrodes 5, loses its mobility and begins to harden intensively. Foamed polystyrene granules uniformly distributed throughout the volume, which are insulation, reduce heat loss from the structure to the environment. The duration of action of high temperatures inside the material increases, which ensures an intensive increase in the strength of polystyrene concrete.

The use of the method and device for the manufacture of heat-insulating walls of polystyrene concrete using a 3D printer makes it possible, in one pass of the print head, to obtain a layer of fast-hardening, non-spreading under pressure of the above-laid layers, homogeneous heat-insulating and structural concrete, changing its properties as needed.

Claims (2)

1. A device for the production of heat-insulating walls of polystyrene concrete using a 3D printer, containing a 3D printer with a print head in the form of an extruder with a binder feed system that squeezes out the binder through a nozzle and spatulas made with the ability to shape the material extruded by an extruder equipped with a binder material preheating system, characterized in that the extruder is equipped with an upper pressing spatula and lateral spatula-electrodes having technological bends at the head and connected to the electrical network by cables. 2. A method of manufacturing heat-insulating walls made of polystyrene concrete using a 3D printer, including feeding a binder material from an extruder preheated in it through a nozzle to form a structural and heat-insulating part of the wall, characterized in that polystyrene concrete with non-foamed polystyrene is used as a binder material, which is squeezed out through the nozzle onto the surface of the previously laid layer over its entire width, after which it is heated by a penetrating electric current supplied to the side spatula-electrodes to the temperature of foaming polystyrene and is formed into a new layer using the upper pressing spatula and spatula-electrodes.

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