Dry cementitious material mixture for 3d-printing

Patent metadata

Field	Value
Publication number	US-2024383811-A1
Application number	US-202218693847-A
Country	US
Kind code	A1
Filing date	Sep 21, 2022
Priority date	Sep 21, 2021
Publication date	Nov 21, 2024
Grant date	—

Abstract

A dry cementitious material mixture for 3D-printing, includes a hydraulic cement, at least one viscosity enhancing admixture, and clay and optionally aggregates, wherein the at least one viscosity enhancing admixture is present in an amount of 0.05-1.5% by weight based on the hydraulic cement and the clay is present in an amount of 0.01-5.0% by weight based on the hydraulic cement.

First claim

1 . A dry cementitious material mixture for 3D-printing, comprising a hydraulic cement, at least one viscosity enhancing admixture, and clay and optionally aggregates, wherein the at least one viscosity enhancing admixture is present in an amount of 0.01-1.5% by weight based on the hydraulic cement and the clay is present in an amount of 0.01-5.0% by weight based on the hydraulic cement.

2 . The dry cementitious material mixture according to claim 1 , wherein the hydraulic cement consists of Portland cement.

3 . The dry cementitious material mixture according to claim 1 , wherein the hydraulic cement comprises Portland cement and an aluminate cement, wherein said Portland cement is present in an amount of >90% by weight based on the total amount of hydraulic cement and said aluminate cement is present in an amount of <5% by weight based on the total amount of hydraulic cement.

4 . The dry cementitious material mixture according to claim 1 , wherein the dry cementitious mixture is free from an accelerator.

5 . The dry cementitious material mixture according to claim 1 , wherein the at least one viscosity enhancing admixture comprises or consist of,
unmodified polysaccharides, or modified polysaccharides, or acrylic polymers, or copolymers of acrylic acid.

6 . The dry cementitious material mixture according to claim 1 , wherein the clay is selected from sepiolite, attapulgite, bentonite, montmorillonite, hectorite, saponite, smectite, kaolinite, laponite and wollastonite.

7 . The dry cementitious material mixture according to claim 1 , wherein the dry cementitious material mixture further comprises fibers.

8 . The dry cementitious material mixture according to claim 1 , wherein the dry cementitious material mixture further comprises a superplasticizer.

9 . The dry cementitious material mixture according to claim 1 , wherein the dry cementitious material mixture further comprises a fine mineral component having a particle size distribution characterized by a D50 of <9 μm.

10 . The dry cementitious material mixture according to claim 9 , wherein the fine component comprises, or consists of, calcium carbonate, silica fume, or mixtures thereof.

11 . The dry cementitious material mixture according to claim 1 , containing aggregates that consist of particles having a maximum particle size of 30 mm.

12 . The dry cementitious material mixture according to claim 11 , wherein the aggregates comprise fine aggregates having a maximum particle size of 4 mm, and/or microsand, having a maximum particle size of 1 mm.

13 . The dry cementitious material mixture according to claim 1 , wherein the hydraulic cement is present in an amount of 30-45% by weight based on the dry cementitious material mixture.

14 . A fresh mortar or concrete composition for 3D-printing, obtainable by mixing the dry cementitious material mixture according to claim 1 and water.

15 . A method of building structural components layer-by-layer, said method comprising:
providing or preparing a fresh mortar or concrete composition according to claim 14 , and placing the fresh mortar or concrete composition through an extrusion nozzle of a deposition head in order to form a layer of construction material.

16 . The method according to claim 15 , wherein the step of preparing the fresh mortar composition comprises:
providing a dry cementitious material mixture, mixing the dry cementitious material mixture with water and optionally with aggregates to obtain the fresh mortar or concrete composition, conveying the fresh mortar or concrete composition to the deposition head.

17 . The method according to claim 15 , wherein the step of preparing the fresh mortar composition comprises:
providing a dry cementitious material mixture that does not contain the viscosity enhancing admixture and the clay, mixing the dry cementitious material mixture with water and optionally with aggregates to obtain the fresh mortar or concrete composition, conveying the fresh mortar or concrete composition to the deposition head, and adding the viscosity enhancing admixture and the clay to the deposition head and mixing the same with the fresh mortar or concrete composition.

18 . The method according to claim 16 , wherein the amount of water mixed with the dry cementitious material mixture is selected to obtain a water/hydraulic cement weight ratio of 0.25-0.90.

19 . The method according to claim 15 , wherein the fresh mortar or concrete composition has a yield strength of 0.25-4 kPa when being placed.

20 . The dry cementitious material mixture according to claim 1 , wherein the at least one viscosity enhancing admixture is present in an amount of 0.1-0.5% by weight based on the hydraulic cement and the clay is present in an amount of 0.5-1% by weight based on the hydraulic cement.

Assignees

• Holcim Technology Ltd

Inventors

• Carrion Benito
• Blachier Christian
• Lombois-Burger Hélène
• Duchand Sylvain

Classifications

• C04B2111/00181

  Mixtures specially adapted for three-dimensional printing (3DP), stereo-lithography or prototyping · CPC title

• C04B2103/32

  Superplasticisers · CPC title

• C04B24/383

  Cellulose or derivatives thereof · CPC title

• C04B14/106

  Kaolin · CPC title

• C04B14/104

  Bentonite, e.g. montmorillonite · CPC title