Additive manufacturing of concrete construction elements

Patent metadata

Field	Value
Publication number	US-12385264-B2
Application number	US-202017767495-A
Country	US
Kind code	B2
Filing date	Oct 8, 2020
Priority date	Oct 9, 2019
Publication date	Aug 12, 2025
Grant date	Aug 12, 2025

Abstract

A method for obtaining a concrete construction element by additive manufacturing, in which superposed mortar layers are successively deposited so as to form two wall surfaces, opposite one another, so as to form a cavity, as well as a plurality of reinforcement elements each extending from one of the wall surfaces toward the cavity, each reinforcement element being in contact with neither the wall surface opposite to that from which it extends, nor with a reinforcement element extending from the opposite wall surface to that from which it extends.

First claim

The invention claimed is:

1. A method for obtaining a concrete wall of a building by additive manufacturing, the method comprising:
successively depositing superposed mortar layers so as to form (a) two wall surfaces of said concrete wall of the building, opposite one another, so as to form a cavity, and (b) a plurality of reinforcement elements each extending from one of the two wall surfaces toward the cavity, each reinforcement element being in contact with neither the wall surface opposite to that from which it extends, nor with a reinforcement element extending from the opposite wall surface to that from which it extends, and
filling the cavity with an insulating material.

2. The method according to claim 1 , wherein at least one of the plurality of reinforcement elements comprises a first part extending linearly from one of the wall surfaces and transversely to said wall surfaces.

3. The method according to claim 2 , wherein at least one of the plurality of reinforcement elements further comprises a second linear part extending from the first part and transversely thereto.

4. The method according to claim 3 , wherein at least one of the plurality of reinforcement elements has a T-shaped or L-shaped profile.

5. The method according to claim 1 , wherein two consecutive reinforcement elements extend from two different wall surfaces.

6. The method according to claim 5 , wherein, in a plane of a wall surface, a ratio of the distance between two consecutive reinforcement elements extending from said wall surface to a distance between the wall surfaces is between 0.5 and 10.

7. The method according to claim 5 , wherein a number of said reinforcement elements per linear meter of said wall is between 1 and 5.

8. The method according to claim 1 , wherein the insulating material is selected from mineral foams, organic foams, mineral wools, mortars comprising a mineral binder and lightweight aggregates and insulators including one or more of plant and animal fibers.

9. The method according to claim 1 , wherein each reinforcement element is only in contact with the wall surface from which it extends, and with the insulating material which fills the cavity.

10. The method according to claim 1 , wherein the wall only comprises a single cavity.

11. The method according to claim 1 , wherein the wall comprises two reinforcement elements each arranged along one of the two wall surfaces and forming a regular pattern, thereby delimiting a plurality of cells.

12. The method according to claim 6 , wherein the ratio is between 2 and 8.

13. The method according to claim 7 , wherein the number of said reinforcement elements per linear meter of said wall is between 1 and 4.

14. The method according to claim 11 , wherein the regular pattern is sinusoidal or broken lines.

15. The method according to claim 1 , wherein at least one of the reinforcement elements of one of the two wall surfaces extends from said one of the two wall surfaces so as to be positioned between two adjacent reinforcement elements that extend from the other one of the two wall surfaces that is opposite said one of the two wall surfaces.

16. The method according to claim 1 , wherein a thickness of each of the two wall surfaces is between 10 and 200 mm.

17. The method according to claim 1 , wherein a thickness of the concrete wall is between 20 and 100 cm.

18. The method according to claim 1 , wherein a thickness of the superposed mortar layers is between 5 and 40 mm.

19. The method according to claim 1 , wherein at least one of the plurality of reinforcement elements extends from a first wall surface of the two wall surfaces and at least another one of the plurality of reinforcement elements extends from a second wall surface of the two wall surfaces.

20. A concrete wall of a building obtained by additive manufacturing with a method comprising successively depositing superposed mortar layers so as to form (a) two wall surfaces of said concrete wall of the building, opposite one another, so as to form a cavity, and (b) a plurality of reinforcement elements each extending from one of the two wall surfaces toward the cavity, each reinforcement element being in contact with neither the wall surface opposite to that from which it extends, nor with a reinforcement element extending from the opposite wall surface to that from which it extends, wherein the cavity is filled with an insulating material.

21. The concrete wall according to claim 20 , wherein at least one of the plurality of reinforcement elements extends from a first wall surface of the two wall surfaces and at least another one of the plurality of reinforcement elements extends from a second wall surface of the two wall surfaces.

22. A method for obtaining a concrete wall of a building by additive manufacturing, the method comprising successively depositing superposed mortar layers so as to form (a) two wall surfaces of said concrete wall of the building, opposite one another, so as to form a cavity, and (b) a plurality of reinforcement elements each extending from one of the two wall surfaces toward the cavity, each reinforcement element being in contact with neither the wall surface opposite to that from which it extends, nor with a reinforcement element extending from the opposite wall surface to that from which it extends, wherein each reinforcement element forms a closed curve, delimiting at least one cell.

23. The method according to claim 22 , wherein the curve is closed on itself at one of the two wall surfaces.

24. A method for obtaining a concrete construction element of a building by additive manufacturing, the method comprising:
successively depositing superposed mortar layers so as to form (a) two wall surfaces of said concrete construction element of the building, opposite one another, so as to form a cavity, said two wall surfaces being connected to each other by mortar at an end of the concrete construction element during said depositing, and (b) a plurality of reinforcement elements each extending from one of the two wall surfaces toward the cavity, each reinforcement element being in contact with neither the wall surface opposite to that from which it extends, nor with a reinforcement element extending from the opposite wall surface to that from which it extends, and
filling the cavity with an insulating material.

Assignees

• Saint Gobain Weber
• Saint Gobain Isover

Inventors

• Beaumont Julien
• Dunaeva Elena
• Gilles Jérôme

Classifications

• E04B2/8635

  with ties attached to the inner faces of the forms (E04B2/8611 and E04B2/8623 take precedence) · CPC title

• E04B1/74

  Heat, sound or noise insulation, absorption, or reflection (forms of, or arrangements in, rooms for influencing or directing sound E04B1/99); Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls (fire protection E04B1/94; elements chiefly adapted for structural purposes E04C1/00 - E04C3/00; chiefly adapted for surface coverings E04F13/00; as underlayers for floor coverings E04F15/18; closures for wall or like openings E06B) · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• C04B2111/28

  Fire resistance, i.e. materials resistant to accidental fires or high temperatures · CPC title