CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a Completion Application which claims the priority benefit of co-pending U.S. Provisional Patent Application Serial No. 63/350,088, filed on June 8, 2022, for “In Situ Concrete Building Construction Using Additive Manufacturing,” the disclosure of which is hereby incorporated by reference, in its entirety, including the drawing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention concerns building construction. More particularly, the present invention concerns in situ concrete building construction using additive manufacturing. Even more particularly, the present invention concerns in situ concrete housing construction using additive manufacturing.

2. Prior Art.

[0003] As is known to those skilled in the art to which the present invention pertains pre-fabricated buildings and, especially, concrete housing has advantages over conventional wood, asbestos, cement block and other materials used for housing or other building construction. Unlike other housing materials, houses fabricated from cement or concrete have extended lifetimes and are not susceptible to extraordinary weather conditions such as hurricanes, tornadoes and the like. [0004] Furthermore, the manufacturing process itself, is less susceptible to defects and the like.

[0005] However, one drawback in concrete housing construction is the technique or process ordinarily used for such manufacturing. Today forms are necessary to create the shell of the house and defines the volume into which the concrete is poured. To accomplish this requires pairs of spaced apart, interlocked forms which need to be erected to create the space therebetween into which the concrete is poured. The concrete must then set and the forms, then, removed to leave the shell of the structure in place. Thereafter, the balance of the house, i.e., the roof, interior framing must be constructed. This is a time-consuming process since the concrete must be set before the construction can be resumed thereby diminishing the efficacy of the use of the material in construction.

[0006] Moreover, if the structure is manufactured off site, it must then be transported to the site. Usually, gantries are connected to the structure which then carries it to the site which, in turn, potentially creates problems including accidental falling, etc.

[0007] As is known to those skilled in the art to which the present invention pertains additive manufacturing is a technique in which various materials are used to create three-dimensional objects. Additive manufacturing, in general, uses data- controlled computer aided design (CAD) software for 3D object scanner direct hardware to deposit material, layer upon layer, in precise geometric shapes.

[0008] The merging of additive manufacturing and concrete, as subsequently detailed, enables the in situ construction of a concrete or element house with substantially all the disadvantages previously attendant therewith eliminated.

SUMMARY OF THE INVENTION

[0009] The present invention provides means and methods for on-site construction of a concrete or cement structure and, preferably, a house which utilizes a pair of spaced apart frames, having a guide rail extending therebetween to which is mounted an extruder which terminates in a nozzle for depositing concrete in a predetermined path along the X-Y-Z axes. The frames are mounted on transport wheels to facilitate the positioning thereof. Auto levehng jacks are incorporated into the frames to maintain the extruder in a horizontal plane.

[0010] A counterbalance secured to the guide rail is incorporated into the structure in order to maintain the proper positioning.

[0011] The rail is rotatable for ease of transport to the site.

[0012] In use, each frame is mounted onto a rig, having a cab and a bed or chassis rearward of the cab and delivered and positioned at the site.

[0013] The wheels are used to deliver the rig on site and are then disengaged therefrom and maintained in position for moving the frame itself. [0014] For a more complete understanding of the present invention, reference is made to the following detailed description and accompanying drawings in which:

BRIEF DESCRIPTION OF THE DRAWING

[0015] FIG. 1 is an environmental view showing the transport of the additive manufacturing equipment used in the practice of the present invention;

[0016] FIG. 2 is a first environmental view of the construction of a concrete structure using additive manufacturing layering;

[0017] FIG. 3 is a depiction showing the on-site positioning of additive manufacturing equipment including the extruder for use in the manufacturing process hereof; and

[0018] FIG. 4 is a view of a rack and pinion assembly for translating the extruder in the X, Y and Z planes.

DESCRIPTION OF THE INVENTION

[0019] At the outset, it should be noted that the terms “concrete” and “cement” are used interchangeably herein, although it is understood that cement is a component of concrete.

[0020] Turning to the drawing there is depicted therein an embodiment for the in situ construction of a building, such as a house, or the like in accordance herewith and, generally, denoted at 8.

[0021] Initially, in practicing the present invention it is essential that a level or otherwise graded ground surface be provided. Therefore, preliminarily, the construction of a building requires proper grading, a substantially horizontal flat surface having its subsurface foundation, drain tile, sewer lines or septic field lines, water or well pipes installed beforehand.

[0022] The building construction hereof requires an initial concrete base or foundation or floor 10 positioned over any subterranean or subsurface installations. [0023] In order to dehver the requisite equipment to the site and as shown in FIG. 1 at least one rig 18 for transporting the necessary construction equipment to the site, has one support frame 20 removably mounted onto the rig. The rig 18 has an over-the-road having a cab 19 and a transport bed or chassis 21.

[0024] The support frame 20 is mounted onto the bed with conventional tie downs (not shown). The support frame is equipped with ground engaging transport wheels 21, 21' onto which the frame is mounted.

[0025] The wheels 21, 21' are dual purpose in that they are road engaging during transport as well as facilitating proper positioning of the frame.

[0026] A plurality of adjustable ground engaging auto levehng jacks 12’, 14’, etc., are secured to the frame, as shown.

[0027] The jacks enable an associated positioning of an extruder 22 in relation to the foundation 10. The jacks maintain the proper geometry for the proper disposition of cement of the structure. The plurality of jacks are spaced apart on their respective frames. [0028] A boom or girder or guide rail 24 is rotatably mounted to the associated frame 20 and is removably positioned on the rig 18 for transport.

[0029] As shown, the extruder 22 is suspended from and positioned on an end of the girder 24.

[0030] For purposes of clarity, the description of a single girder 24 on a rig will be described. However, it is to be understood, that the ensuing description applies to multiple girders, if used.

[0031] As shown, a turntable 26 is disposed and mounted onto the frame 20.

The boom or girder 24 is rotatably secured to the turntable 26 to enable a 90° rotation thereof in a horizontal plane.

[0032] As shown in FIG. 4 a rack and pinion assembly 25 traverses the girder to move the extruder 22 along the length of the boom and is operatively connected to the turntable to control the movement of the extruder along the X-axis. A motor 27 powers the movement.

[0033] As shown in FIG. 4, the rack and pinion of the assembly 25 traverses the length of the boom along a linear guideway or track 29 provided in the girder. [0034] The pinion is operatively connected to the motor 27 which urges the extruder along the guideway 29.

[0035] The assembly 25 includes a conventional rack 30 mounted onto the rail guideway 29 and is engaged by a pinion 32 associated with the extruder 22 such that the extruder travels the length of the boom along the X-axis on a path defined by the guideway via the rack and pinion assembly, in a conventional manner.

[0036] Similarly, a ring and pinion assembly (not shown) is operatively connected to the turntable to control the rotation of the boom into and out of operative position.

[0037] Second linear guideways 34, 36 secured to the top of the associated frames 20 enable the boom to move or translate along the Y-axis in the horizontal plane.

[0038] Suitable means, such as a computer (not shown) connected to the motor controls the path of travel. At least one counterbalance 40 is operatively connected to the boom to maintain the consistency of the path of travel in the X and Z axes.

[0039] Linear guideways or guiderails are well known and commercially available and generally comprise ball bearing assemblies which facilitate the linear movement of equipment mounted thereto. Here, the guiderails have respective first and second ends 42’, 44’, each end operatively connected to the top of the frame 20 for controlhng linear movement in the horizontal plane along the Y-axis.

[0040] A counterbalance 40 assists in maintaining the boom guiderail in its proper place.

[0041] The extruder 22, itself, is a substantially hollow structure which terminates in a nozzle 38. A source of concrete (not shown) communicates with the extruder 22 and enables a continuous flow of concrete thereinto, which issues through the nozzle.

[0042] A computer, as noted, is pre-programmed with suitable CAD software, is in electrical communication with the extruder 22, the turntable 26 and the motor 32 and controls the movement of the guide rails and the turntable, and the extruder 22.

[0043] The controlled movement of the extruder enables the deposition of layers of concrete according to the computer -controlled pattern.

[0044] The boom moves or translates upwardly via a motor control (not shown), when necessary, to enable the layers or beads of concrete to be deposited along both the X and Y axes as the extruder is vertically moved upwardly along the Z-axis.

[0045] In manufacturing a structure in accordance herewith, a suitable site is selected and the underpinnings including the drain tile, sewage connectors, etc. is then placed on the construction site. Thereafter, the foundation 10 is constructed which may be either via the extruder or otherwise. At least a pair of similar rigs deliver an associated frame to the site such that the guiderail opens therebetween. Depending on the size of the structure to be built, multiple pairs of spaced apart frames may be used. [0046] The leveling jacks are positioned and engage the ground to provide stabilization of the extruder. The extruder then moves in its tri-axial movement between the frames.

[0047] In transporting the boom between its operative position and transport position one end of the boom or girder is disconnected from its frame to enable it to swing 90° and be positioned on its associated rig.

[0048] Thus, the structure, be it a house or other structure, is created in situ thereby eliminating the need for gantries, concrete forms, etc.

[0049] Having, thus, described the invention, what is claimed is: