Mixing and feeding system for 3d printing of buildings

Abstract

The present invention is a mixing and feeding system for 3D printing of buildings, designed for extruding highly viscous construction material with a high setting speed. The invention ensures consistent quality of material mixture and does not depend on external and unpredictable factors. The system utilizes a piston water dispenser, a single horizontal brushless motor, water metering nozzles, a pneumatic clutch, separation of wet and dry areas, an optional high pressure washer, and an automatic release of flushing balls for additional and autonomous cleaning. Any extruder should be installed as close as possible to the dispenser supply line of the present invention, such that the system sensors may detect the proper dose of mixed material.

What is claimed is: 
     
         1 . A mixing and feeding system for 3-dimensional (3D) printing of buildings, comprising:
 a mixing system,   a flushing ball release mechanism, and   a mixture dispenser,   said mixing system comprising:
 a hopper for inputting dry material, said hopper being coupled to a dry material auger, 
 a horizontal mixing chamber, said horizontal mixing chamber receiving said dry material from said dry material auger, said horizontal mixing chamber also receiving water via one or more horizontal chamber water metering nozzles, said water being injected via a piston water dispenser connected to a water dispenser drive shaft, 
 a vertical mixing chamber located after said horizontal mixing chamber, said vertical mixing chamber receiving an output of said horizontal mixing chamber and water via one or more vertical chamber water metering nozzles, said water being injected via said piston water dispenser, 
 a main progressive cavity pump located after said vertical mixing chamber, 
 a first brushless DC (BLDC) motor powering a horizontal kneading shaft of said horizontal mixing chamber, said piston water dispenser, and said dry material auger, 
 a second BLDC motor powering a vertical kneading shaft of said vertical mixing chamber, 
 a pneumatic clutch for separating said dry material auger from said first BLDC motor, 
 a pneumatic cylinder for pinching a soft hose, said soft hose located between said dry material auger and said horizontal mixing chamber, and 
 a supply line from the mixing system to said mixture dispenser, 
   said flushing ball release mechanism being located after said main progressive cavity pump and prior to said supply line from the mixing system to the mixture dispenser, said flushing ball release mechanism comprising:
 a turret, said turret holding mounted flushing balls, 
 a rotating pneumatic cylinder rotating the turret, 
 a clamping pneumatic cylinder, 
 a main progressive cavity pump, and 
 two pushers, 
   said mixture dispenser being located after said supply line from the mixing system to the mixture dispenser, said mixture dispenser comprising:
 a main dispensing chamber, 
 a dosage progressive cavity pump powered by a third BLDC motor, 
 a force sensor, said force sensor recording and controlling pressure within said mixing system and within said mixture dispenser, and 
 a line-switching system. 
   
     
     
         2 . The system of  claim 1 , wherein said line-switching system comprises:
 two hollow rod hydraulic cylinders,   an ultrasonic sensor,   a pneumatic ram cylinder,   a pressure supply plunger supplying pressure to said two hollow rod hydraulic cylinders,   a rotary cylinder for switching channels,   a mixture supply line from said mixing system to said mixture dispenser,   a feed line of the mixture from said mixture dispenser to an extruder, and   a slider for moving said mixture supply line and said feed line to bypass said dosage progressive cavity pump via a bypass pipe.   
     
     
         3 . The system of  claim 1 , wherein said mixing system further comprises a high pressure pump. 
     
     
         4 . The system of  claim 1 , wherein said mixing system further comprises one or more air compressors. 
     
     
         5 . The system of  claim 1 , further comprising a lubrication system. 
     
     
         6 . The system of  claim 1 , further comprising tracks or wheels. 
     
     
         7 . The system of  claim 1 , further comprising a rotary unit supplying high pressure water, said high pressure water further cleaning said vertical mixing chamber. 
     
     
         8 . The system of  claim 1 , wherein water is injected via said horizontal and vertical water metering nozzles at a pressure of 500-1200 psi. 
     
     
         9 . The system of  claim 2 , wherein said flushing ball release mechanism comprises a release of a first flushing ball and a release of a second flushing ball. 
     
     
         10 . The system of  claim 9 , wherein said first flushing ball travels from said supply line to said ultrasonic sensor. 
     
     
         11 . The system of  claim 10 , wherein said second flushing ball bypasses said dosage progressive cavity pump and travels through said extruder. 
     
     
         12 . The system of  claim 11 , wherein said second flushing ball is pushed through with clean water. 
     
     
         13 . The system of  claim 1 , wherein said dry material auger is mechanically disconnected from said horizontal chamber BLDC motor via a pneumatic clutch during a cleaning mode. 
     
     
         14 . The system of  claim 5 , said lubrication system comprising a release of liquid lubricating silicone.