The present disclosure relates generally to systems and methods for manufacturing concrete structures. More particularly, the present disclosure relates to systems and methods for dispensing concrete mixtures.
The embodiments disclosed herein relate to construction systems, assemblies, and methods. For example, in various embodiments, the disclosed systems and methods can be used for manufacturing concrete structures. In some embodiments, the disclosed systems and methods comprise a concrete dispensing assembly. The concrete dispensing assembly can be configured to dispense a plurality of discrete units. In other embodiments, the concrete dispensing assembly is configured to simultaneously dispense two or more different concrete mixtures.
The concrete dispensing assemblies can comprise various components. In some embodiments, the concrete dispensing assembly comprises a dispensing head. For example, the dispensing head can be an extrusion head, a pour head, a spray head, or a rotary head. Other types of dispensing heads can also be used.
In some embodiments, the dispensing head is configured to shape or form the mixtures that are being dispensed. The concrete dispensing assemblies can further comprise one or more additional shaping devices. The shaping devices may be coupled to the dispensing head. In some embodiments, the shaping device comprises a removable face plate. In some embodiments, the shaping device comprises one or more trowels.
The disclosed concrete dispensing assemblies can be controllable. In some embodiments, for example, the concrete dispensing assemblies can comprise a computer control system. The computer control system can comprise one or more processors. Further, the computer control system can comprise a user interface.
The concrete dispensing assemblies can further comprise an orientation control mechanism. In some embodiments, the orientation control mechanism is coupled to the computer control system. The orientation control mechanism can be configured to control movement of the concrete dispensing assemblies in three dimensions. For example, the orientation control mechanism may control movement along the X, Y, and Z axes.
Additives and/or curing agents may also be used in the embodiments disclosed herein. In some embodiments, the additives and/or curing agents can comprise carbon dioxide. For example, in some embodiments, the additives and/or curing agents comprise dry ice. In other embodiments, the additives and/or curing agents comprise carbon dioxide clathrate. Other additives and/or curing agents can also be used.
The additives and/or curing agents may be added to the concrete forming materials in various ways. For example, in some embodiments, dry ice may be added to the concrete forming materials prior to dispensing the materials from the concrete dispensing assembly. Carbon dioxide and/or carbon dioxide clathrate may also be sprayed onto a surface of the dispensed mixture to accelerate the curing of the mixture.
Further disclosed herein are embodiments wherein a concrete mixture is sprayed from the concrete dispensing assembly in combination with a carbon dioxide clathrate. In doing so, the concrete mixture rapidly cures thereby allowing multiple layers to be readily built up.
These and other aspects of the present disclosure will be discussed in greater detail hereinafter.
The embodiments disclosed herein will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. These drawings depict only typical embodiments, which will be described with additional specificity and detail through use of the accompanying drawings in which:
The embodiments disclosed herein relate to construction systems, assemblies, and methods. For example, in various embodiments, the disclosed systems and methods can be used for manufacturing concrete structures. In some embodiments, the disclosed systems and methods comprise a concrete dispensing assembly. The concrete dispensing assembly can be configured to dispense a plurality of discrete units. In other embodiments, the concrete dispensing assembly is configured to simultaneously dispense two or more different concrete mixtures.
The concrete dispensing assemblies can comprise various components. In some embodiments, the concrete dispensing assembly comprises a dispensing head. For example, the dispensing head can be an extrusion head, a pour head, a spray head, or a rotary head. Other types of dispensing heads can also be used.
In some embodiments, the dispensing head is configured to shape or form the mixtures that are being dispensed. The concrete dispensing assemblies can further comprise one or more additional shaping devices. The shaping devices may be coupled to the dispensing head. In some embodiments, the shaping device comprises a removable face plate. In some embodiments, the shaping device comprises one or more trowels.
The disclosed concrete dispensing assemblies can be controllable. In some embodiments, for example, the concrete dispensing assemblies can comprise a computer control system. The computer control system can comprise one or more processors. Further, the computer control system can comprise a user interface.
The concrete dispensing assemblies can further comprise an orientation control mechanism. In some embodiments, the orientation control mechanism is coupled to the computer control system. The orientation control mechanism can be configured to control movement of the concrete dispensing assemblies in three dimensions. For example, the orientation control mechanism may control movement along the X, Y, and Z axes.
Additives and/or curing agents may also be used in the embodiments disclosed herein. In some embodiments, the additives and/or curing agents can comprise carbon dioxide. For example, in some embodiments, the additives and/or curing agents comprise dry ice. In other embodiments, the additives and/or curing agents comprise carbon dioxide clathrate. Other additives and/or curing agents can also be used. Curing agents may be used to accelerate the curing rate, or can be used to retard the curing rate. In some embodiments, accelerants can include calcium chloride, calcium formate, calcium nitrite, or calcium thiosulfate, singly or in combination. In some embodiments, retardants may be used to reduce the rate of evaporative water loss.
The additives and/or curing agents may be added to the concrete forming materials in various ways. For example, in some embodiments, dry ice may be added to the concrete forming materials prior to dispensing the materials from the concrete dispensing assembly. Carbon dioxide and/or carbon dioxide clathrate may also be sprayed onto a surface of the dispensed mixture to accelerate the curing of the mixture.
Further disclosed herein are embodiments wherein a concrete mixture is sprayed from the concrete dispensing assembly in combination with a carbon dioxide clathrate. In doing so, the concrete mixture rapidly cures thereby allowing multiple layers to be readily built up.
The embodiments of the disclosure will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The components of the disclosed embodiments, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Furthermore, the features, structures, and operations associated with one embodiment may be applicable to or combined with the features, structures, or operations described in conjunction with another embodiment. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of this disclosure.
Thus, the following detailed description of the embodiments of the systems and methods of the disclosure is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments. In addition, the steps of a method do not necessarily need to be executed in any specific order, or even sequentially, nor do the steps need to be executed only once.
As used herein, the phrases “connected to,” “coupled to,” and “in communication with” refer to any form of interaction between two or more entities, including but not limited to mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interaction. Two components may be coupled to each other even though they are not in direct contact with each other. For example, two components may be coupled to each other through an intermediate component.
The system 100 may comprise various components. As shown in
Dispensing digital or discrete units is advantageous in various construction applications. For example, in some embodiments, a user may determine a specified number of discrete units that may be needed to form a particular concrete structure. The user may thereafter dispense the specified number of discrete units. The discrete units can then be arranged or positioned as desired. For example, the user may stack the discrete units to build a wall-type structure. In other embodiments, the plurality of discrete units may be dispensed in a specified sequence or pattern such that the user need not rearrange or reposition them. This pattern may be predetermined. Further, the pattern may be controlled by the user. In some embodiments, the pattern may be programmed into the concrete dispensing assembly 102. For example, the pattern may be programmed into a computer control system 110 that is coupled to or integral with the concrete dispensing assembly 102.
In some embodiments, the number of discrete units that are dispensed is predetermined. For example, the concrete dispensing assembly 102 may be set or otherwise configured to dispense a predetermined number of discrete units. In other embodiments, the number of discrete units that are dispensed is determined and controlled by the user during the dispensing process. For example, one or more concrete forming materials may be fed into the concrete dispensing assembly 102 and the user may continuously dispense discrete units until a desired number has been dispensed.
Further, in some embodiments, the number of discrete units being dispensed from the concrete dispensing assembly 102 is counted. The number can be counted manually by the user, or counted automatically by the concrete dispensing assembly 102. For example, the concrete dispensing assembly 102 may comprise a computer control system 110 that may be configured to automatically count the number of discrete units that are dispensed.
Counting the number of discrete units that have been, or are being, dispensed may be useful for tracking and/or monitoring purposes. For example, counting the number of discrete units that have been dispensed may be useful in determining the volume of material that has been dispensed. Counting the number of discrete units that have been dispensed may also be useful in controlling one or more aspects of the dispensing process. For example, in some embodiments, the concrete dispensing assembly 102 is configured to dispense a first plurality of discrete units and a second plurality of discrete units. The value of one or more parameters of the first plurality of discrete units and the second plurality of discrete units may be different. Such parameters include the composition, size, shape, curing rate, tensile strength, compressive strength, water content, cement content, concrete aggregate content, additive content, etc.
As can be appreciated, it may be desirous to dispense a specified first number of discrete units of the first plurality and a specified second number of discrete units of the second plurality. By separately counting and tracking the number of discrete units of the first and second pluralities that are dispensed, the user may ensure that the proper amounts of discrete units are dispensed. For example, during the dispensing process, the number of discrete units of the first plurality that are dispensed may be counted separately from the number of discrete units of the second plurality that are dispensed. Once the proper amounts of the first and second pluralities of discrete units have been dispensed, the concrete dispensing assembly may be configured to stop the dispensing process.
For illustration purposes, a more specific example may include the following: A particular construction application may require 15 large discrete units and 25 small discrete units. The 15 large discrete units may be representative of a first number of discrete units of a first plurality having a particular parameter (large size). The 25 small discrete units may be representative of a second number of discrete units of a second plurality having a particular parameter (small size). During the dispensing process, the concrete dispensing assembly may separately count the number of large and small discrete units that are dispensed. After the desired number of large and small discrete units have been dispensed, the concrete dispensing assembly may stop the dispensing process. Accordingly, by counting and/or tracking the number of discrete units that are dispensed, the user may ensure that the proper amounts of discrete units are dispensed thereby eliminating and/or reducing the amount of waste that is produced.
The composition of the discrete units may vary as desired. In some embodiments, the discrete units comprise one or more concrete forming materials, including, but not limited to, cement, concrete aggregate, and water. For example, the discrete units may comprise a mixture of cement, concrete aggregate, and water. Such mixtures comprising cement, concrete aggregate, and water may be referred to as “concrete mixtures.” As can be appreciated, the relative amount of cement, concrete aggregate, and/or water may be varied to achieve desired properties and/or characteristics.
In many embodiments, the discrete units that are dispensed comprise un-cured mixtures of one or more concrete forming materials. However, whether the discrete units comprise un-cured mixtures or cured mixtures may vary depending on the particular construction application. As such, in other embodiments, the discrete units can comprise cured mixtures of concrete forming materials. Still further, the discrete units can comprise partially cured mixtures of concrete forming materials.
In further embodiments, the discrete units may comprise mixtures that are dehydrated and/or substantially dry. For example, the discrete units may comprise a substantially dry mixture of cement and/or concrete aggregate. At the discretion of the user, one or more discrete amounts of water may thereafter be dispensed, either from the concrete dispensing assembly or from another water dispensing device (e.g., a hose, water truck, etc.). At the further discretion of the user, the one or more discrete amounts of water may be mixed with the dry discrete units and allowed to dry to form a concrete structure.
The composition of the discrete units may further comprise one or more additives. Various additives may be used, including, but not limited to, one or more of the following: water (or water agents), curing agents, colorants, strengthening agents, and reinforcing agents. Other additives known in the art or hereinafter developed may also be used. As can be appreciated, the additives may be configured to provide the discrete units with one or more desired properties and/or characteristics at the user's discretion.
The composition between different discrete units may also be variable. In other words, the composition of a first discrete unit may vary from the composition of a second discrete unit. For example, the amount of cement, concrete aggregate, and/or water may vary between different discrete units depending on the desired application. Other properties and/or parameters of the discrete units may also be varied. For example, the size, shape, tensile strength, compressive strength, water content, etc. may vary between different discrete units as desired.
Further, in some embodiments, the user may control, adjust, and/or change the composition of the discrete units during the dispensing process. For example, the user may increase or decrease the amount of any particular component of the discrete units. For example, a user may increase or decrease the relative amount of cement, concrete aggregate, and/or water that may be used to form the discrete units. In some embodiments, the composition of the discrete units may be controlled by a computer control system 110.
It is contemplated that the discrete units may be dispensed from the concrete dispensing assembly 102 in various ways. In some embodiments, for example, the discrete units may be extruded from the concrete dispensing assembly 102. In other embodiments, the discrete units may be dumped from the concrete dispensing assembly 102. In yet other embodiments, the discrete units may be spewed or otherwise ejected from the concrete dispensing assembly 102.
In some embodiments, the concrete dispensing assembly 102 is configured to cover each discrete unit, or at least a portion of each discrete unit, with a covering or covering material. For example, the covering may comprise a skin-like material. In some embodiments, the concrete dispensing assembly 102 is configured to cover the discrete unit during the dispensing process (i.e., while the discrete unit is being dispensed). In other embodiments, the concrete dispensing assembly 102 is configured to cover the discrete unit prior to dispensing the discrete unit.
Covering the discrete units may yield various benefits and/or advantages. For example, in some embodiments, the covering may be configured to retain the contents of the discrete unit. In embodiments wherein the discrete unit comprises substantially dry cement and concrete aggregate, for example, the covering may retain or otherwise hold the mixture together. Further, in some embodiments, the covering may be used to retain the discrete unit in a designated shape.
The covering may also be used as an indicator. For example, in some embodiments, the covering comprises a colorant. The color of the covering may also depend on a parameter of the discrete unit. And different colors and/or colorants may represent different characteristics of the discrete units. For example, in an illustrative embodiment, a blue colorant may indicate that the discrete unit comprises a first composition, and a red colorant may indicate that the discrete unit comprises a second composition.
The covering may comprise various types of materials. For example, in some embodiments, the covering comprises a gelling compound. In other embodiments, the covering comprises a layer comprising carbon dioxide. In other embodiments, the covering comprises a film or film-like material. In other embodiments, the covering comprises a woven material. The woven material may comprise polymeric and/or metallic materials. In some embodiments, the woven material comprises a mesh material.
Other properties of the covering may also vary as desired. In some embodiments, for example the covering comprises a substantially water soluble material. The substantially water soluble material may be configured to substantially dissolve when contacted (e.g., sprayed) with water. In other embodiments, the covering comprises a substantially water penetrable or water permeable material. The substantially water penetrable material may allow water to pass. The substantially water penetrable material may or may not be dissolvable. In yet other embodiments, the covering comprises a substantially water insoluble material. In yet other embodiments, the covering comprises a substantially water impenetrable or water impermeable material.
With continued reference to
The concrete dispensing assembly 102 may be controlled in various ways. For example, in some embodiments, the concrete dispensing assembly 102 is manually controlled. In other embodiments, the concrete dispensing assembly 102 is controlled by a computer control system 110. In yet other embodiments, one or more dispensing parameters of the dispensing assembly 102 are controlled manually, and one or more dispensing parameters of the concrete dispensing assembly 102 are controlled by a computer control system 110.
Various types of computer control systems 110 may be used. In some embodiments, the computer control system 110 is integral with the concrete dispensing assembly 102. In other embodiments, the computer control system 110 is coupled to the concrete dispensing assembly 102. Further, the computer control system 110 may be coupled to the concrete dispensing assembly 102 via a wired or a wireless connection network.
The computer control system 110 comprises various components. In some embodiments, the computer control system 110 comprises a control interface. Through the control interface, the user may interact with the computer control system 110 to control one or more aspects of the concrete dispensing assembly 102. The computer control system 110 may further comprise one or more processors. The processors may be used to carry out the various input/output operations of the computer control system 110. Any suitable variety of processors may be used. The computer control system 110 may further comprise additional components known in the art or hereinafter developed for use in computer control systems 110.
As further shown in
The orientation control mechanism 111 may be manually, mechanically, and/or electrically controllable. Further, the orientation control mechanism 111 may be configured to control the orientation of the concrete dispensing assembly 102 in at least three different dimensions. For example, the orientation control mechanism 111 may be configured to control the orientation of the concrete dispensing assembly 102 along an X-axis, Y-axis, and/or Z-axis.
With continued reference to
The concrete dispensing assembly 102 may further comprise one or more openings or orifices 108. The orifice 108 may be disposed on the dispensing head 104. The size and/or shape of the orifice 108 may determine the size and/or shape of the discrete units. In other words, the size and/or shape of the discrete units may be dependent upon the size and/or shape of the orifice 108. For example, the discrete units may be dispensed from the concrete dispensing assembly 102 through the orifice 108. Further, in some embodiments, the discrete units are extruded through the orifice 108. As can be appreciated, as the discrete units are dispensed through the orifice 108, the discrete units may be shaped and/or sized in accordance with the shape and/or size of the orifice 108.
The shape and/or size of the orifice 108 may vary. For example, in some embodiments the orifice 108 is substantially rectangular in shape. In yet other embodiments, the orifice 108 is substantially square in shape. In still other embodiments, the orifice 108 is substantially circular in shape. In still other embodiments, the orifice 108 is substantially oval in shape. Other shapes are also contemplated. Further, in some embodiments, the shape and/or size of the orifice 108 is changeable.
Other types of shaping devices or shaping tools may also be used. For example, in some embodiments a face plate may be coupled to the concrete dispensing assembly 102. The face plate may also be coupled to the dispensing head 104 of the concrete dispensing assembly 102. The face plate may be removable. The orifice 108 may also extend through the face plate. In some embodiments, the face plate may be used to alter or change the shape of the orifice 108 thereby shaping the discrete units that are being dispensed from the concrete dispensing assembly 102. Other shaping devices that may also be used include trowels. Trowels may be coupled to the concrete dispensing assembly 102, or coupled to the dispensing head 104 of the concrete dispensing assembly 102, and may aid in shaping the discrete units.
As further shown in
As shown in the illustrated embodiment, the hopper 112 may be coupled to the concrete dispensing assembly 102. The hopper 112 is also in fluid communication with the dispensing head 104 and the orifice 108 through which the concrete forming materials are dispensed. Accordingly, the one or more concrete forming materials may be transferred or otherwise passed from the hopper 112 to the concrete dispensing assembly 102 and out of the orifice 108 during a typical dispensing process.
One or more intermediate components may also be used with the disclosed system 100. Exemplary intermediate components include pumps, conveyors, extrusion screws, tubes, and/or other devices that may be configured to retain, transfer, mix, and/or move the one or more concrete forming materials throughout the system 100.
As previously stated, in some embodiments, one or more additives may be used. In some embodiments, the additives are mixed with the concrete forming materials that are used in forming the plurality of discrete units. For example, the additives may be mixed with the concrete forming materials prior to dispensing the discrete units from the concrete dispensing assembly. Further, in some embodiments, the additives are mixed with the concrete forming materials in a hopper 112. In other embodiments, the additives are applied to the discrete units during the dispensing process, or after the discrete units have been dispensed.
As shown in the illustrated embodiment of
In some embodiments, the concrete dispensing assembly 102 can be configured to dispense additives. For example, the concrete dispensing assembly 102 can be configured to dispense the additives into the discrete units or onto at least one surface of the discrete units. Further, in some embodiments, the additives are dispensed by the concrete dispensing assembly 102 during the dispensing process.
In certain embodiments, the additives may be sprayed on the discrete units. The additives may be sprayed on the discrete units either while the discrete units are being dispensed, or after the discrete units have been dispensed. Further, the additives may be sprayed on the entirety of the discrete units, or on only a portion of the discrete units. For example, the additives may be sprayed on at least one outer surface of the discrete units. The additives may also be sprayed onto at least a corner of the discrete units.
Various types of additives may be used. In some embodiments, the additive comprises water. Further, in some embodiments, the additive is mixed with water. For example, an additive may be mixed with water to form an aqueous additive mixture. A discrete amount of the aqueous additive mixture may thereafter be dispensed to the discrete unit.
In some embodiments, the additive comprises a curing agent. The curing agent can be configured to accelerate the curing of the concrete forming materials. When applied to a surface of a discrete unit, the curing agent may be configured to accelerate the curing of at least the surface (or portion) of the discrete unit to which it has been applied. Exemplary curing agents may comprise carbon dioxide. For example, in some embodiments, the curing agent may comprise carbon dioxide, carbon dioxide clathrate, and/or dry ice. In other embodiments, the additive may comprise a curing inhibitor that may be configured to delay the curing of the concrete forming materials. Other types of additives may also be used.
When using dry ice as an additive and/or curing agent, the dry ice may be configured to sublime and disperse carbon dioxide throughout a portion of at least one discrete unit. In doing so, the curing rate is accelerated throughout the portion of the discrete unit comprising the dry ice. If desired, the dry ice may comprise a temporary outer barrier (e.g., a shell or coating) that is configured to delay sublimation of the dry ice.
Additionally, in some embodiments, the additives may be configured to control the curing rate of the concrete forming materials. Such additives may be described as rate controlling additives. Exemplary rate controlling additives comprise cement powder. The rate controlling additives may be applied in various ways. For example, in some embodiments, the rate controlling additives are dispensed and mixed with the concrete forming materials prior to dispensing the discrete units. In other embodiments, the rate controlling additives are dispensed during the dispensing process. In yet other embodiments, the rate controlling additives are dispensed onto a surface of the discrete units after they have been dispensed.
The rate control additives comprising cement powder may further be mixed with a fluidizing agent. The fluidizing agent may be configured to aid in the transportation and dispersion of the cement powder. In some embodiments, the fluidizing agent comprises ethylene glycol. Other types of fluidizing agents may also be used.
In further embodiments, the additive comprises one or more reinforcement members. The reinforcement members may be configured to add strength and support to the discrete units. Various types of reinforcement members may be used. For example, in some embodiments, the reinforcement member comprises rebar. In other embodiments, the reinforcement member comprises mesh. The mesh may include a metal material (e.g., steel), and/or a polymeric material. In some embodiments, the reinforcement member comprises a fiber or fiber-like material, such as, for example, fiberglass, metallic fiber (steel fiber), and/or synthetic fiber.
The reinforcement member may be dispensed in various ways. For example, in some embodiments, the reinforcement member is dispensed into at least one of the discrete units while the discrete unit is being dispensed from the concrete dispensing assembly 102. In other embodiments, the reinforcement member may be dispensed into at least one of the discrete units after the discrete unit has been dispensed from the concrete dispensing assembly 102.
In some embodiments, the reinforcement member is dispensed such that it is at least partially disposed in at least one discrete unit. The reinforcement member may also be dispensed such that it is entirely disposed within a discrete unit. Further, in some embodiments, the reinforcement member is dispensed such that it is at least partially disposed within a first discrete unit and at least partially disposed within a second discrete unit. In other embodiments, the reinforcement member is dispensed such that it is adjacent to at least one discrete unit. For example, the reinforcement member may be dispensed such that it is disposed between two discrete units.
As previously stated, the plurality of discrete units may be dispensed in a predetermined pattern. Exemplary patterns are depicted in
In
In
In
In
Rapidly curing the shell 966 around the discrete unit 951 is advantageous in various construction applications. For example, the shell 966 may be relatively rigid. The shell 966 may also enable the discrete unit 951 to retain its shape. The shell 966 may further enable the discrete unit 951 to be capable of supporting the weight of a material that is placed on top of the discrete unit 951. In other words, one or more materials (e.g., additional discrete units 951) may be stacked on top of the discrete unit 951 after the shell 966 has been formed. Other advantages may also be appreciated.
As previously discussed, various curing agents may be used in accordance with the embodiments disclosed herein. Exemplary curing agents that may be used in curing or partially curing the discrete unit to form the outer shell 966 include curing agents that comprise carbon dioxide or carbon dioxide clathrate. Other curing agents may also be used.
The primary difference between the system 1000 of
Simultaneously dispensing a plurality of concrete mixtures is advantageous in many ways. For example, in some instances, the plurality of concrete mixtures may integrate with one another better when they are dispensed simultaneously. The plurality of concrete mixtures may also cure better when they are dispensed simultaneously. Other advantages may also be realized.
Additionally, in some embodiments, at least one parameter of the first and second concrete mixtures may be different. Simultaneously dispensing the different concrete mixtures may thereby enable the user to design and develop numerous different types of concrete structures having varying properties. For example, in one embodiment, the first concrete mixture has a faster curing rate than the second concrete mixture. In another embodiment, the first concrete mixture has a greater tensile strength than the second concrete mixture. In yet another embodiment, the first concrete mixture has a greater compressive strength than the second concrete mixture. In yet another embodiment, the first concrete mixture has a greater water content than the second concrete mixture. In yet another embodiment, the first concrete mixture has a greater cement content than the second concrete mixture. In yet another embodiment, the first concrete mixture has a different cement composition from the second concrete mixture. In yet another embodiment, the first concrete mixture has a different concrete aggregate content from the second concrete mixture. Other properties may also be varied.
With continued reference to
The shape of the first and second orifices 1008, 1009 may be the same as that described above with respect to the orifice 108 of
As further shown in
As can be appreciated, the first and second concrete mixtures may be dispensed by the system 1000 to form a predetermined pattern of concrete layers. For example,
In
In
In
Various curing agents 1684 may be used. In some embodiments, the curing agent comprises carbon dioxide, or comprises a calcium compound. In some embodiments, the curing agent 1684 is mixed with the concrete mixture 1682 prior to being dispensed from the dispensing head 1604. In other embodiments, the curing agent 1684 and the concrete mixture 1682 are mixed as they are being dispensed.
Simultaneously spraying a curing agent 1684 and a concrete mixture 1682 may provide various advantages. For example, in some embodiments, simultaneously spraying a curing agent 1684 and a concrete mixture 1682 may increase or otherwise accelerate the curing of the concrete mixture 1682. In the illustrated embodiment, the curing agent 1684 may cause the concrete mixture 1682 being sprayed to rapidly cure or substantially cure as it contacts a surface to form a first concrete layer almost immediately. As such, additional layers (e.g., a second layer, third layer, etc.) of concrete mixtures 1682 may continuously and/or immediately be sprayed on top of the first concrete layer to build up and form a concrete wall or similar structure.
Various construction methods, e.g., methods of forming concrete structures, are also provided herein. In particular, it is contemplated that any of the components, principles, and/or embodiments discussed above may be utilized by either a system or a method. For example, in an embodiment, a construction method comprises a step of dispensing a first plurality of discrete units from a concrete dispensing assembly, wherein each of the discrete units comprises a mixture of cement, concrete aggregate, and water. The method further comprises a step of controlling one or more dispensing parameters of the concrete dispensing assembly with a computer control system.
In another embodiment, a construction method comprises a step of dispensing a plurality of discrete units from a concrete dispensing assembly, wherein each of the discrete units comprises at least one of cement and concrete aggregate. The method further comprises a step of dispensing a discrete amount of water to each of the discrete units. Still further, the method may comprise a step of mixing each discrete unit with a discrete amount of water to form a plurality of discrete concrete mixtures.
In another embodiment, a construction method comprises a step of dispensing a plurality of discrete units from a concrete dispensing assembly, wherein each of the discrete units comprises cement, concrete aggregate, and water. The method further comprises a step of covering each of the discrete units with a skin-like material.
In another embodiment, a method of manufacturing a concrete structure comprises a step of dispensing a first concrete mixture to form a first concrete layer, and a step of dispensing a second concrete mixture to form a second concrete layer, wherein the first concrete mixture has a different composition from the second concrete mixture, and the first and second concrete mixtures are dispensed simultaneously from a concrete dispensing assembly.
In another embodiment, a method of manufacturing a concrete structure comprises a step of dispensing a concrete mixture and a step of dispensing a curing agent that comprises carbon dioxide, wherein the curing agent is configured to increase the curing rate of the concrete mixture, wherein the concrete mixture and the curing agent are dispensed simultaneously. In some embodiment, the step of dispensing the concrete mixture comprises spraying the concrete mixture to form a first concrete layer. Other methods are also contemplated.
References to approximations are made throughout this specification, such as by use of the terms “substantially.” For each such reference, it is to be understood that, in some embodiments, the value, feature, or characteristic may be specified without approximation. For example, where qualifiers such as “about” and “substantially” are used, these terms include within their scope the qualified words in the absence of their qualifiers. For example, where the term “substantially circular” is recited with respect to a feature, it is understood that in further embodiments the feature can have a precisely circular configuration.
Reference throughout this specification to “an embodiment” or “the embodiment” means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the quoted phrases, or variations thereof, as recited throughout this specification are not necessarily all referring to the same embodiment.
Similarly, it should be appreciated that in the above description of embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure. This method of disclosure, however, is not to be interpreted as reflecting an intention that any claim require more features than those expressly recited in that claim. Rather, as the following claims reflect, inventive aspects lie in a combination of fewer than all features of any single foregoing disclosed embodiment.
The claims following this written disclosure are hereby expressly incorporated into the present written disclosure, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims. Moreover, additional embodiments capable of derivation from the independent and dependent claims that follow are also expressly incorporated into the present written description.
Without further elaboration, it is believed that one skilled in the art can use the preceding description to utilize the invention to its fullest extent. The claims and embodiments disclosed herein are to be construed as merely illustrative and exemplary, and not a limitation of the scope of the present disclosure in any way. It will be apparent to those having ordinary skill in the art, with the aid of the present disclosure, that changes may be made to the details of the above-described embodiments without departing from the underlying principles of the disclosure herein. In other words, various modifications and improvements of the embodiments specifically disclosed in the description above are within the scope of the appended claims. The scope of the invention is therefore defined by the following claims.
If an Application Data Sheet (ADS) has been filed on the filing date of this application, it is incorporated by reference herein. Any applications claimed on the ADS for priority under 35 U.S.C. §§ 119, 120, 121, or 365(c), and any and all parent, grandparent, great-grandparent, etc. applications of such applications, are also incorporated by reference, including any priority claims made in those applications and any material incorporated by reference, to the extent such subject matter is not inconsistent herewith. The present application claims the benefit of the earliest available effective filing date(s) from the following listed application(s) (the “Priority Applications”), if any, listed below (e.g., claims earliest available priority dates for other than provisional patent applications or claims benefits under 35 USC § 119(e) for provisional patent applications, for any and all parent, grandparent, great-grandparent, etc. applications of the Priority Application(s)). In addition, the present application is related to the “Related Applications,” if any, listed below. None U.S. patent application Ser. No. ______, entitled SYSTEMS AND METHODS FOR MANUFACTURING CONCRETE STRUCTURES, naming Jeffrey A. Bowers, Bran Ferren, W. Daniel Hillis, Roderick A. Hyde, Cameron A. Myhrvold, Conor L. Myhrvold, Nathan P. Myhrvold, Clarence T. Tegreene and Lowell L. Wood, Jr. as inventors, filed Sep. 6, 2013, with attorney docket no. 46076/116, is related to the present application. The United States Patent Office (USPTO) has published a notice to the effect that the USPTO's computer programs require that patent applicants reference both a serial number and indicate whether an application is a continuation, continuation-in-part, or divisional of a parent application. Stephen G. Kunin, Benefit of Prior-Filed Application, USPTO Official Gazette Mar. 18, 2003. The USPTO further has provided forms for the Application Data Sheet which allow automatic loading of bibliographic data but which require identification of each application as a continuation, continuation-in-part, or divisional of a parent application. The present Applicant Entity (hereinafter “Applicant”) has provided above a specific reference to the application(s) from which priority is being claimed as recited by statute. Applicant understands that the statute is unambiguous in its specific reference language and does not require either a serial number or any characterization, such as “continuation” or “continuation-in-part,” for claiming priority to U.S. patent applications. Notwithstanding the foregoing, Applicant understands that the USPTO's computer programs have certain data entry requirements, and hence Applicant has provided designation(s) of a relationship between the present application and its parent application(s) as set forth above and in any ADS filed in this application, but expressly points out that such designation(s) are not to be construed in any way as any type of commentary and/or admission as to whether or not the present application contains any new matter in addition to the matter of its parent application(s). If the listings of applications provided above are inconsistent with the listings provided via an ADS, it is the intent of the Applicant to claim priority to each application that appears in the Priority Applications section of the ADS and to each application that appears in the Priority Applications section of this application. All subject matter of the Priority Applications and the Related Applications and of any and all parent, grandparent, great-grandparent, etc. applications of the Priority Applications and the Related Applications, including any priority claims, is incorporated herein by reference to the extent such subject matter is not inconsistent herewith.