Abstract
The invention relates to a method and a device for producing a paving area from paving elements, wherein the paving elements are printed in situ from a printable material onto a surface in a 3D printing method using a 3D printing device.
Claims
1. A method for producing a paving area (1) from paving elements, particularly from paving stones (2) or paving slabs, characterized in that the paving elements are printed onto a surface in situ from a printable material (6) in a 3D printing process using a 3D printing device (5).
2. The method according to claim 1, characterized in that the 3D printing device (5) comprises an extruder (9), through which the printable material (6) is applied onto the surface.
3. The method according to claim 1 or 2, characterized in that the paving elements are respectively produced by forming at least one first layer and one second layer of the printable material (6).
4. The method according to claim 3, characterized in that the first layers of the paving elements are initially produced prior to the production of the second layers of the paving elements.
5. The method according to one of claims 1 to 4, characterized in that the cover layers (17) of the paving elements are printed with a higher resolution than the subjacent layers.
6. The method according to one of claims 1 to 5, characterized in that the paving elements are printed with an internal structure (31) containing hollow spaces.
7. The method according to claim 6, characterized in that the internal structure (31) is printed onto at least one full-surface bottom layer.
8. The method according to one of claims 1 to 7, characterized in that the paving elements are provided with reinforcing elements.
9. The method according to one of claims 1 to 8, characterized in that temperature sensors, precipitation sensors and/or acceleration sensors are incorporated into the paving elements.
10. The method according to one of claims 1 to 9, characterized in that heating elements are incorporated into the paving elements.
11. The method according to one of claims 1 to 10, characterized in that pressure sensors are incorporated into the paving elements in order to detect a load exerted upon the paving elements.
12. The method according to one of claims 1 to 11, characterized in that solar cells or piezoelectric elements are incorporated into the paving elements in order to generate power.
13. The method according to one of claims 1 to 12, characterized in that the paving elements are provided with lighting elements, especially LED elements and particularly on their upper sides.
14. The method according to one of claims 1 to 13, characterized in that a bedding layer (4a), onto which the printable material (6) is printed, is produced by means of the 3D printing device (5), particularly from at least one of the materials stone chips, sand or mortar.
15. The method according to one of claims 1 to 14, characterized in that the environment of the surface, particularly the structure of the surface, is surveyed with a sensor (29) before the surface is printed.
16. A device (30) for producing a paving area (1) from paving elements, particularly from paving stones (2) or paving slabs, characterized by a 3D printing device (5) for printing the paving elements onto a surface in situ in a 3D printing process.
17. The device (30) according to claim 16, characterized in that the 3D printing device (5) comprises an extruder (9) with an extrusion die (10), which comprises an outlet opening (26) that preferably can be closed.
18. The device (30) according to claim 17, characterized in that the diameter of the outlet opening (26) of the extrusion die (10) preferably can be adjusted between 0.01 and 20 cm, particularly between 0.1 and 1 cm.
19. The device (30) according to one of claims 16 to 18, characterized in that the 3D printing device (5) comprises at least one supply line (7; 7a, 7b, 7c) for dry material and one supply line (7; 7a, 7b, 7c) for water.
20. The device (30) according to one of claims 16 to 19, characterized in that the 3D printing device (5), preferably the extrusion die (10), comprises a supply line (7; 7a, 7b, 7c) for dyes and/or additives.
21. The device (30) according to one of claims 16 to 20, characterized in that the 3D printing device (5) comprises a pivotable robotic arm (11), wherein the extrusion die (10) preferably is arranged on one end of the robotic arm (11) in a pivotable manner.
22. The device (30) according to one of claims 16 to 21, characterized in that the 3D printing device (5) comprises at least one sensor (29), by means of which the structure of the surface to be printed can be surveyed.
23. The device (30) according to one of claims 16 to 22, characterized in that the 3D printing device comprises a mobile substructure (23).
Description
[0058] The invention is described in greater detail below with reference to preferred exemplary embodiments, but is not limited to these exemplary embodiments. In the drawings:
[0059] FIG. 1 shows a schematic view of an inventive 3D printing device during the production of a paving area;
[0060] FIG. 2 shows a schematic view of an alternative embodiment of the 3D printing device;
[0061] FIG. 3A shows the steps for the production of an individual paving stone according to one design variation;
[0062] FIG. 3B shows the steps for the production of an individual paving stone according to another design variation;
[0063] FIG. 3C shows the steps for the production of an individual paving stone according to yet another design variation;
[0064] FIGS. 4a-4i show different views of the 3D printing device during the production of the pavement surface;
[0065] FIGS. 5a-5e show different embodiments of the mobile 3D printing device;
[0066] FIG. 6 shows a view of a 3D printing device with a rail system;
[0067] FIG. 7 shows a flow chart of a first variation of the production method;
[0068] FIG. 8 shows a flow chart of a second variation of the production method;
[0069] FIG. 9 shows a schematic view of a first design variation of the 3D printing device with an extruder;
[0070] FIG. 10 shows a schematic view of a second design variation of the 3D printing device with an extruder;
[0071] FIG. 11 schematically shows different cross sections of paving stones with an internal structure; and
[0072] FIG. 12 schematically shows a model of a paving stone with an internal hollow space, which is obtained by means of topology optimization.
[0073] FIG. 1 schematically shows a method for producing a paving area 1 from paving elements, particularly from paving stones 2, by means of 3D printing. A 3D printing device 5 is arranged on an upper bearing layer 3 with a formation 4 and prints the paving stones 2 onto the exposed surface in situ from a printable material 6 in a 3D printing process. The 3D printing device 5 can be moved in all directions on the formation 4. The 3D printing device 5 is supplied with dry material (e.g. cement, sand, aggregates, dye pigments) via a supply line 7. The dry starting materials are mixed with water in order to obtain the printable material 6. The printable material may alternatively be transported to the 3D printing device in a viscous state, particularly by means of an eccentric screw pump. A bearing layer 8 is produced on the formation 4 prior to printing the paving stones 2. The bearing layer 8 preferably is also produced by means of the 3D printing device 5. The paving stones 2 preferably are printed onto the bearing layer 8 in accordance with a preprogrammed route, for example corresponding to a desired pattern. The 3D printing device 5 comprises an extruder 9 with an extrusion die 10, through which the printable material 6 is applied onto the bearing layer 8. The discharge of material from the extrusion die 10 can be stopped. The extrusion die 10 has a variable diameter. In the embodiment shown, the 3D printing device 5 comprises a robotic arm 11, wherein the robotic arm 11 is on one end connected to the mobile substructure of the 3D printing device 5 in an articulated manner. The extrusion die 10 is arranged on the other end of the robotic arm 11. In this way, the extrusion die 10 can be precisely controlled during the printing process.
[0074] The 3D printing device 5 accordingly is positioned in the region of the surface to be paved. For example, the 3D printing device may be respectively positioned on a road, a sidewalk or a pedestrian zone, namely on the substructure, on the upper bearing layer, on the anti-frost layer or on the ground or even on building walls. The 3D printing device 5 may also be suspended with cables. The cables may be fastened on existing structures or on specially erected structures.
[0075] The paving stones 2 are produced in layers in the form of at least one first layer and one second layer of the printable material 6, wherein the first layers of the paving stones 2 are initially produced prior to the production of the second layers of the paving stones 2. Once printing of a paving stone 2 or a group of paving stones 2 is completed, the 3D printing device 5 is repositioned and a new printing process is started. For this purpose, the 3D printing device 5 comprises a mobile substructure 12, which is realized in the form of a track drive in the exemplary embodiment according to FIG. 1. The control is realized by means of control software. After the paving stones 2 have been printed, the gaps 13 between the paving stones 2 are filled with a grouting material. The gaps can be filled with grouting material by means of the 3D printing device.
[0076] FIG. 2 shows an alternative embodiment of the 3D printing device 5, which preferably can be moved horizontally and vertically. A rail system 14 is provided laterally and above the upper bearing layer 3 or the formation 4, wherein the entire surface of the formation 4 is accessible via two transverse rails 14a and a longitudinal rail 14b supported thereon in a sliding manner. The 3D printing device 5 is suspended on the longitudinal rail 14b such that a motion along the surface to be printed can be realized in a horizontal and a vertical plane. The supply with printable material 6 takes place via the supply line 7, wherein the materials are either mixed prior to being supplied to the 3D printing device 5 or directly in the 3D printing device 5. This is also controlled by means of control software such that the 3D printing device 5 can carry out the printing process in a fully automated and autonomous manner.
[0077] FIG. 3A shows the step-by-step printing process of a paving stone 2 according to a first design variation, wherein the contours (outer peripheries) 15 of the paving stones 2 are initially printedpreferably after the production of one or more horizontal layersand the contours 15 are then completely filled or provided with an internal structure 31 containing hollow spaces (see FIG. 11, FIG. 12), and wherein the surfaces of the paving stones 2 are subsequently printed, preferably with a higher resolution than the contours 15. The contours 15 therefore comprise a layer-like structure, in which multiple identical layers are printed on top of one another. The interior 16 is filled with a filling or provided with the internal structure 31 as soon as the last layer of the contour 15 has been printed. A cover layer 17 is printed after the contour 15 has been filled or provided with the internal structure. The cover layer, as well as the filling, may be produced from a different material than the contour 15. The diameter of the extrusion die 10 can be reduced when the cover layer 17 is printed in order to achieve a higher resolution.
[0078] FIG. 3B shows an alternative embodiment of the printing process, in which the contours (outer peripheries) 15 are produced up to a predefined partial height of the paving stone 2, preferably after the production of one or more horizontal layers. The interior 16 is then filled or provided with the internal structure 31. Subsequently, the production of the contours 15 continues up to another, higher partial height of the paving stone 2. The interior 16 is then once again filled or provided with the internal structure 31. The alternating production of the contours 15 and the filling or the internal structure 31 is continued until the required overall height of the paving element 2 (optionally less the thickness of a cover layer 17) is reached. The surface of the thusly produced paving stone 2 preferably is printed with the cover layer 17. This cover layer, as well as the filling, may be produced from a different material than the contour 15. The diameter of the extrusion die 10 can be reduced when the cover layer 17 is printed in order to achieve a higher resolution. This embodiment makes it easier to ensure the stability of the contours 15 during the production of the paving elements.
[0079] FIG. 3C shows an alternative embodiment, in which the contours 15 and the internal structure 31 are produced layer-by-layer, preferably after the production of one or more horizontal layers. The cover layer 17 is subsequently printed onto the surface of the paving stone 2. The cover layer 17, as well as the filling, may be produced from a different material than the contour 15. The diameter of the extrusion die 10 can be reduced when the cover layer 17 is printed in order to achieve a higher resolution.
[0080] FIGS. 4a-4i show a preferred sequence for the production of the paving area 1, wherein the following steps are carried out successively:
[0081] FIG. 4a): optionally excavating the recess 3,
[0082] FIG. 4b): optionally setting edging stones 18 in concrete,
[0083] FIG. 4c): introducing an unbound or bound upper bearing layer 19,
[0084] FIG. 4d): optionally compacting the (unbound) upper bearing layer 19,
[0085] FIG. 4e): optionally introducing a bedding layer 20, e.g. a sand bedding or mortar bedding, on top of the compacted unbound or bound upper bearing layer 19,
[0086] FIG. 4f): producing the paving stones 2 on the bedding layer 20 or directly on the upper bearing layer 19 in situ in a 3D printing process,
[0087] FIG. 4g): introducing a filling into gaps 13 between the paving stones 2,
[0088] FIG. 4h): optionally compacting the pavement surface,
[0089] FIG. 4i): optionally washing in.
[0090] The steps according to FIGS. 4c, 4e, 4f and 4g can be respectively carried out with the 3D printing device 5. This means that essentially the entire layer structure of the paving area 1 is produced with the 3D printing device 5.
[0091] FIGS. 5A-5e show different embodiments of the mobile 3D printing device 5. FIG. 5a shows a flying drone 21 for transporting the 3D printing device 5. FIG. 5b shows a substructure with a track drive 22, FIG. 5c shows a substructure with air cushion propulsion 23, FIG. 5d shows a wheeled substructure 24 and FIG. 5e shows a substructure that comprises containers 25 with the dry, liquid or viscous printable materials 6. The appropriate substructure is chosen in dependence on the respective application, wherein the printing process is respectively carried out in a fully automated manner by means of control software.
[0092] FIGS. 7 and 8 show flow charts for two variations of the printing method. In the variation according to FIG. 7, the starting materials are mixed in advance, transported to the extruder 9, e.g. via supply lines 7, and blended with additives. The paving stones 2 are subsequently printed. According to FIG. 8, the starting materials are mixed in the extruder 9 itself, wherein the individual starting materials are separately transported to the extruder 9. Printing of the paving stones 2 takes place after the addition of additives.
[0093] FIGS. 9 and 10 show highly simplified representations of the extruder 9 of the 3D printing device 5. The extruder 9 has an extrusion die 10 with an outlet opening 26 that can be closed. In addition, the diameter of the outlet opening 26 of the extrusion die 10 can be varied. In this way, different paving stones 2 and patterns can be printed as needed (see FIG. 6).
[0094] The extruder 9 has a mixing chamber 27, wherein supply lines 7a, 7b, 7c for different dry or liquid starting materials, which are mixed into the printable material 6, lead into said mixing chamber. In the embodiment shown, the extruder 9 furthermore comprises a deceleration chamber 28, from which the printable material 6 is conveyed into the extrusion die 10. The extrusion die 10 applies the printable material 6 onto the surface to be printed in accordance with the specifications of the control software.
[0095] In the embodiment according to FIG. 10, a supply line 7c for additives is directly connected to the extrusion die 10. In this way, the additives, e.g. dye pigments, can be supplied separately from the printable base material.
[0096] FIG. 11 shows different design variations of paving stones 2 with an internal structure 31 within the outer contours 32. The internal structure 31 comprises internal walls 33 that separate hollow spaces 34 from one another.
[0097] FIG. 12 shows an embodiment of a paving stone 2 with an internal hollow space 35 that was calculated by means of topology optimization.
