METHOD AND APPARATUS FOR DELIVERY AND FEEDING OF MATERIAL AND ELECTRICITY FOR CONSTRUCTION 3D PRINTING

Abstract

Systems described herein relate to a mobile material transport system for 3D printing construction. Embodiments of the mobile material transport system include a portable container configured to store a granular material, such as a dry mix mortar. The system also includes a feed system coupled to the portable container that may continuously expel the granular material through a material output valve at a steady feed rate that may be controlled to adjust the feed rate up or down. Additionally, the system may include a power supply that powers the feed system, as well as any additional construction equipment, such as a material mixer or 3D printer.

Claims

1. A mobile material transport system comprising: a portable container configured to store a granular material; a feed system coupled to the portable container and configured to continuously expel the granular material through a material output valve at a steady feed rate; a controller for adjusting the feed rate; and a power supply configured to power the feed system and provide 3-phase power to construction equipment.

2. The system of claim 1 wherein granular material is a dry mix mortar for construction 3-D printing.

3. The system of claim 2 wherein the feed system is further configured to expel the granular material to a material mixing unit.

4. The system of claim 3 wherein the controller is further configured to communicate with the material mixing unit to coordinate the feed rate with an output rate of the material mixing unit.

5. The system of claim 4 wherein the system further includes a second portable container configured to store a liquid; a second feed system coupled to the second portable container and configured to expel the liquid through a liquid output valve at a liquid feed rate; and wherein the controller is further configured to control the liquid feed rate and communicate with the material mixing unit to coordinate the liquid feed rate with the output rate of the material mixing unit.

6. The system of claim 1 wherein the construction equipment is a construction 3-D printer.

7. The system of claim 1 wherein the construction equipment is a material mixer.

8. The system of claim 1 further comprising a user interface configured to allow a user to operate the controller to increase or decrease the feed rate of the granular material.

9. A 3D printing construction system comprising: a mobile material transport system including: i. a portable container configured to store a granular material; ii. a feed system coupled to the portable container and configured to continuously expel the granular material through a material output valve at a steady feed rate; iii. a controller for adjusting the feed rate; and iv. a power supply configured to power the feed system; a material mixing unit coupled to the material output valve of the mobile material unit and configured to receive granular material for mixing into construction build material; and a 3D printer coupled to the material mixing unit and configured to receive build material used to form structures by extruding successive layers of build material under computer control.

10. The 3D printing construction system of claim 9 wherein the material mixing unit and 3D printer are coupled to receive power from the power supply of the mobile material transport system.

11. The system of claim 10 wherein granular material is a dry mix mortar for construction 3-D printing.

12. The system of claim 11 wherein the controller is further configured to communicate with the material mixing unit to coordinate the feed rate with an output rate of the material mixing unit.

13. The system of claim 12 wherein the system further includes a second portable container configured to store a liquid; a second feed system coupled to the second portable container and configured to expel the liquid through a liquid output valve at a liquid feed rate; and wherein the controller is further configured to control the liquid feed rate and communicate with the material mixing unit to coordinate the liquid feed rate with the output rate of the material mixing unit.

14. The system of claim 1 wherein the construction equipment is a construction 3-D printer.

15. The system of claim 1 wherein the construction equipment is a material mixer.

16. The system of claim 1 further comprising a user interface configured to allow a user to operate the controller to increase or decrease the feed rate of the granular material.

17. The system of claim 1 wherein the 3D printer is a polar coordinate based deposition printer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The foregoing will be apparent from the following more particular description of example embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments.

[0014] FIG. 1 is an example portable silo for delivery at a construction site of the prior art;

[0015] FIG. 2 is mobile material transport system consistent with some aspects of the present concepts; and

[0016] FIG. 3 is a 3-D printing construction system employing a mobile material transport system consistent with some aspects of the present concepts.

DETAILED DESCRIPTION

[0017] A description of example embodiments follows.

[0018] At traditional large-scale construction sites, where significant amounts of cement or plaster may be used over the course of a month or longer, the powered or granular building material is typically stored in silos set up at the construction site. Construction 3D printers may use the same or similar dry mix mortar materials, so similar silos may be used. However, when using 3D printing in a construction process, as mentioned above, the building process typically involves a continuous of extruding construction material layer by layer to build structural components. As the layers of material are deposited, the construction material must be managed such that lower layers are given time to settle and harden enough to bear the load of later layers, while still remaining fresh and fluid enough to allow the successive layers to appropriately bond. Consumption of building material for 3D printing construction can occur over the course of several days, as structures are planned and built as continuous builds with managing the material with the rheology in mind.

[0019] As shown in FIG. 2, embodiments of a mobile material transport system 200 consistent with some aspects of the present concepts eliminate the need for the traditional pre-construction site prep involving the delivery and installation of a dry material silo, as the mobile material transport system takes advantage of the 3D printing construction process where material is consumed quickly and can be advantageously managed.

[0020] The mobile material transport system 200 includes a container 220 that has a top hatch 222 that provides an opening in the container 220 for loading granular material. Due to the weight of the granular material, the material may collect at the bottom of the container 220. Coupled to the container is a feed system that includes a material transfer line 230 that provides an output valve 260 to expel the granular material. Along the bottom of container, valve openings 224 allow granular material to feed into a material transfer line 230. While the weight of the material may naturally push the material through the valve openings 224 into the material transfer line 230, in some embodiments as shown in FIG. 2, the feed system may include an airline 250 that uses air pressure to expel the granular material through the transfer line 230 and out of the output valve 260. A control valve 240 may be used to adjust the air pressure, and thus the feed rate of the granular material from the material transfer line. A controller (not shown) may be used to control the control valve 240. The controller may also be used to control the valve openings 224 and the output valve 260.

[0021] In some alternative embodiments not shown in FIG. 2, the system may include a second portable container configured to store a liquid, where a second feed system is coupled to the second portable container and configured to expel the liquid through a liquid output valve at a liquid feed rate.

[0022] In the mobile material transport system 200, a power supply 280 may be used to provide power to the controller and power the feed system. At a construction site, access to 3-phase electricity may be limited (especially for private housing construction). The power supply 280 can also be equipped with a connector 285 that may be used to provide power to construction equipment that may be part of an overall construction 3D printing system, such as a material mixer or construction 3D printer. The connector 285 may be a proprietary connector unit, or simply a 3-phase power outlet. The entire system may be placed on a wheeled platform, and coupled to a vehicle 210. The mobility of the system allows it to be advantageously positioned with ease on a construction as needed to supply the granular material.

[0023] As shown in FIG. 3, a construction 3D printing system 300 may include the material transport system 320, a material mixer 340, and a 3D printer 360. The power provided by power supply can be sufficient to convey all of the material from the material transport system to the construction equipment, while also powering the consumption of that material by the material mixer and 3D printer. When the material in the material transport system runs out, a new material transport system arrives loaded with new material and a fully charged power supply. The first material transport system can then return to the factory to refuel the material and charge the power supply.

[0024] In embodiments of the material transport system 320, the feed system may be further configured with an interface 325 to expel the granular material to the material mixing unit 340. A controller the material transport system 320 may be configured to communicate with the material mixing unit to coordinate the feed rate with an output rate of the material mixing unit 340 as the printer build material is consumed by the 3D printer 360 in the build process. The material mixing unit 340 may include sensors (not shown) to determine the amount of construction build material is available, and the rate of consumption of that build material.

[0025] As the build rate changes due to the output speed of the 3D printer, the material mixing unit 340 can provide that information to the material transport system 320 through a wired or a wireless communication, or simply send a request for additional feed of granular material. The controller in the material transport system 320 may then increase the feed rate of dry mix material into the mixing unit. In alternate embodiments where the material transport system 320 includes a second portable container configured to store a liquid, a controller may also control the liquid feed rate and communicate with the material mixing unit 340 to coordinate the liquid feed rate with an output rate of the material mixing unit 340.

[0026] One of skill in the art will appreciate that different types of construction 3D printers that may be used in connection with a construction 3D printing system 300 having the material transport system and the material mixer. As an example, the 3D printer may be a polar coordinate based deposition printer such as those described in U.S. Pat. No. 10,780,637 titled “3D Printer in Polar Coordinates.” Construction 3D printing systems as described here, provide connections between the material transport system and the 3D printer allowing for the smooth supply and processing of the granular material directly to 3D printing equipment, and a controller for controlling the flow and gating of the material supply through the system. Because the material is consumed by the 3D printer directly from the mixer and material transport system, there is better control over the quality and consistency of the material used. Without the need for on-site unloading of material into a silo, the is less concern of contaminants or environmental factors (humidity or rain) that might affect the material quality.

[0027] The teachings of all patents, published applications and references cited herein are incorporated by reference in their entirety.

[0028] While example embodiments have been particularly shown and described, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the embodiments encompassed by the appended claims.