One-step formation of an integrated composite structure comprising cured mortar layers and a polyurethane layer by 3d printing

Patent metadata

Field	Value
Publication number	US-2022305717-A1
Application number	US-202017619153-A
Country	US
Kind code	A1
Filing date	Jun 10, 2020
Priority date	Jun 14, 2019
Publication date	Sep 29, 2022
Grant date	—

Abstract

The present invention relates to a process of fabricating a multi-layer composite structure by 3D printing, said composite structure comprises at least one cured mortar layer formed by curing of a mortar composition, and at least one polyurethane layer formed by polymerization of a first polyurethane forming composition, wherein said mortar composition and said first polyurethane forming composition are dispensed individually and simultaneously via adjacent printing nozzles. The mortar composition is optionally modified by a second polyurethane forming composition.

First claim

1 . A process of fabricating a multi-layer composite structure by 3D printing, said composite structure comprising at least one cured mortar layer formed by curing of a mortar composition, and at least one polyurethane layer formed by polymerization of a first polyurethane forming composition, wherein said mortar composition and said first polyurethane forming composition are dispensed individually and simultaneously via adjacent printing nozzles.

2 . The process according to claim 1 , wherein each of the at least one polyurethane layer is sandwiched between two cured mortar layers.

3 . The process according to claim 1 , wherein the slump of the mortar composition is 10 to 100 mm.

4 . The process according to claim 1 , wherein the gel time t 1 of the first polyurethane forming composition is 0.5 to 10 minutes.

5 . The process according to claim 1 , wherein the initial setting time t 2 of the mortar composition is 0.5 to 4 hours.

6 . The process according to claim 1 , wherein t 1 and t 2 should satisfy the relationship of t 2 −t 1 <2 hours.

7 . The process according to claim 1 , wherein the mortar composition is modified and the pot life t 3 of the modified mortar composition is 0.05 to 2 hours.

8 . The process according to claim 7 , wherein the mortar composition is modified by a second polyurethane forming composition.

9 . The process according to claim 8 , wherein the content of the second polyurethane forming composition is 0.1% to 50% by weight based on the total weight of the modified mortar composition.

10 . The process according to claim 7 , wherein t 1 and t 3 should satisfy the relationship of t 3 −t 1 <0.5 hours.

11 . The process according to claim 8 , wherein the mortar composition is modified by the second polyurethane forming composition by mixing with the second polyurethane forming composition before being introduced into the printing nozzles.

12 . The process according to claim 1 , wherein the first polyurethane forming composition comprises:
(1) Component A comprising polyol; and (2) Component B comprising isocyanate, wherein Component A and Component B are mixed after being introduced into the printing nozzles.

13 . A multi-layer composite structure prepared by the process according to claim 1 .

14 . A multi-layer composite structure according to claim 13 , wherein the polyurethane layer and the cured mortar layer are combined without using additional adhesives.

15 . The process according to claim 3 , wherein the slump of the mortar composition is 30 to 90 mm.

16 . The process according to claim 3 , wherein the slump of the mortar composition is 50 to 70 mm.

17 . The process according to claim 4 , wherein the gel time t 1 of the first polyurethane forming composition is 1 to 5 minutes.

18 . The process according to claim 5 , wherein the initial setting time t 2 of the mortar composition is 1 to 2 hours.

19 . The process according to claim 6 , wherein t 1 and t 2 should satisfy the relationship of t 2 −t 1 <1.5 hours.

20 . The process according to claim 6 , wherein t 1 and t 2 should satisfy the relationship of t 2 −t 1 <1 hours.

21 . The process according to claim 7 , wherein the mortar composition is modified and the pot life t 3 of the modified mortar composition is 0.1 to 1 hours.

22 . The process according to claim 7 , wherein the mortar composition is modified and the pot life t 3 of the modified mortar composition is 0.2 to 0.5 hours.

23 . The process according to claim 9 wherein the content of the second polyurethane forming composition is 5% to 30% by weight based on the total weight of the modified mortar composition.

24 . The process according to claim 9 wherein the content of the second polyurethane forming composition is 10% to 20% by weight based on the total weight of the modified mortar composition.

25 . The process according to claim 10 , wherein t 1 and t 3 should satisfy the relationship of t 3 −t 1 <0.4 hours.

26 . The process according to claim 10 , wherein t 1 and t 3 should satisfy the relationship of t 3 −t 1 <0.25 hours.

Assignees

• Construction Research & Technology Gmbh

Inventors

• Xu Hang
• Zhou Shengzhong
• Xi Bang Wei
• Liu xi tao
• Wang li xia
• Zhao he meng
• Feichtenschlager Bernhard
• Hirsemann Stefan

Classifications

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• C04B28/02

  containing hydraulic cements other than calcium sulfates · CPC title

• B28B19/0046

  to plastics · CPC title

• B28B3/20

  wherein the material is extruded {(extrusion moulding of plastics B29C48/00)} · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title