US010399247B1

(12) United States Patent ( 10) Patent No.: US 10 ,399,247 B1

Al Jassmi et al. (45) Date of Patent: Sep . 3, 2019
(54 ) COMPOUND NOZZLE FOR CEMENT 3D (56 ) References Cited
PRINTER TO PRODUCE THERMALLY
INSULATED COMPOSITE CEMENT U .S . PATENT DOCUMENTS
(71) Applicant: UNITED ARAB EMIRATES 1,124 ,579 A * 1/1915 Ambursen ......... .... B28C
D2 5 /026
239/ 403
UNIVERSITY , Al Ain (AE ) 1,459 ,657 A * 6 /1923 Dempsey ................. B28C3665//4038
(72 ) Inventors: Hamad Al Jassmi, Al Ain (AE ); Fady 1,648 ,216 A * 11/ 1927 Cassiere ................. B28C 5 /026
S . Alnajjar, Al Ain (AE ); Waleed K . 239 /428
Ahmed , Al Ain (AE) (Continued )
(73 ) Assignee : Qatar University , Doha (QA ) FOREIGN PATENT DOCUMENTS
CN 204818064 U 12 /2015
( * ) Notice: Subject to any disclaimer, the term of this CN 106965428 A 7 /2017
patent is extended or adjusted under 35 (Continued )
U .S .C . 154 (b ) by 0 days.
OTHER PUBLICATIONS
(21) Appl. No.: 16 /234,357 Anne Van Der Meij , Co -extrusion 3D printing improves solar cells
and battery,Mar. 14 , 2013, https://www .3ders.org/articles/20130314
(22 ) Filed : Dec. 27, 2018 co -extrusion - 3d -printing -improves -solar- cells-and -battery.html.
(51 ) Int. Ci. Primary Examiner — Benjamin R Shaw
B28B 1/ 00 ( 2006 . 01) (74 ) Attorney , Agent, or Firm — Richard C . Litman
B28B 3 / 26 (2006 .01) (57) ABSTRACT
E04B 1/ 16 ( 2006 .01) The compound nozzle for a cement 3D printer to produce
B33Y 30 /00 ( 2015 .01) thermally insulated composite cement is useful for produc
(52 ) U .S . CI. ing composite thermally insulated cement sections using a
CPC ............ B28B 1/001 ( 2013 .01); B28B 3 /2636 3D printer. The nozzle includes an insulation nozzle con
(2013. 01 ); B33Y 30 / 00 ( 2014 . 12 ); E04B 1/ 16 centrically disposed in the central discharge orifice of the
(2013.01); E04B 2103/02 (2013 .01) compound nozzle to produce a stream of insulation media
(58 ) Field of Classification Search axially surrounded by a stream of cement mixture extruded
CPC ....... B28B 1 /001; B28B 3 /2636 ; B33Y 30 /00 ; from the nozzle to form a wall with a cement exterior and an
E04B 1 / 16 ; E04B 2103/02; B28C 5 / 00 ; insulation interior. A motor-driven auger is controlled by a
B28C 5 /026 ; B28C 5 /04; B28C 5 /38 ; controller, and the cement is supplied from the top either
B28C 5 /408; B28C 7 /126 ; B28C 7 / 128 manually or by a concrete pump. The insulating material is
See application file for complete search history . (Continued )
100
9 L 122102
226
222 216
118
1146118 - KINH
238
T? THI 1126
5228
- 230
212 232
118 M

240 2

108

200

--- 202
250

116
252
118
- 204
206
r 104
110 x244 HA120
BY BL106
.
54
 US 10 ,399 , 247 B1
Page 2

supplied to the insulation nozzle by a separate line that uses 5 ,389,167 A * 2 /1995 Sperber ................. B05B 7/0025
another pump. The system includes a cleaning mechanism to 156 /291
clean the internal components of the compound nozzle using 5 ,529 ,471 A * 6 / 1996 Khoshevis ................ B28B 3 / 20
water jets and a drying system to dry the internal compo 425 /112
3 ,681, 194 A * 10 / 1997 Baker ..................... B29B 17/00
nents without disassembling the system . 428 /903. 3
5 ,718, 508 A * 2 /1998 Williams ............ B01F 7 /00433
5 Claims, 3 Drawing Sheets 366 / 138
6 ,004 ,626 A * 12/ 1999 Noone .................. B05B 7/1481
427 /427
6 ,095 ,082 A * 8/ 2000 Belt B05C 19/ 04
118 / 308
(56 ) References Cited 6 , 481,883 B1 * 11/2002 Ellen ....... B28C 5 /04
U . S . PATENT DOCUMENTS 366 / 18
9 , 156 ,205 B2 * 10 /2015 Mark ............... . . . .. B29C 70 /20
2009/ 0039104 A1* 2 /2009 Genewick A23G 9 / 282
1,770 ,011 A * 7/ 1930 Poston .................... B28C 5 /026 222 /1
239 /336 2013/0037628 A1* 2/2013 Wurz .................... B05B 770012
2,597,916 A * 5/ 1952 Anderson ......... B28C 3665 /026
.......
/ 10
239 /418
2014 /0252668 A1 * 9 /2014 Austin . ................ B28B 3/ 20
3,035,940 A * 5/ 1962 Hobson .............. E04F 21 /12 264 /40 .7
106 /650 2014 /0271961 A1* 9/2014 Khoshnevis ......... C04B 35 /622
3 , 185 ,396 A * 5 / 1965 Black .................. E04F 21/ 12 425/ 78
239 / 336 2016 /0375451 A1 * 12/2016 Hoiland . .. . BOSB 7 / 1486
3,669,418 A * 6 /1972 Cornwell ............ B28C 5 /003 239 / 398
366 / 5 2017 /0365365 A1 * 12 /2017 White .................. G21F 1/042
4 ,042 , 175 A * 8 / 1977 Johnson ................ B05B 7 / 1495 2018 /0071949 A1 * 3 /2018 Giles .. . .. . . . . .. ........ .... B33Y 10 / 00
239 /420 2018 /0154437 A1 * 6 /2018 Mark .................... B22F 3 / 1025
4 ,095 ,748 A * 6 / 1978 Ohtake ................ B01F 5 /0256 2018 /0169956 A1 * 6 /2018 Singov .................... B29C 64/40
239/419 .3
4 ,263,346 A * 4/ 1981 Sandell ..... BO5B 7 / 1495 FOREIGN PATENT DOCUMENTS
118 / 308
4 ,411,389 A * 10/ 1983 Harrison ........ ........ B05B 7 /149 CN 206416289 U 8 / 2017
222 / 145 . 1 CN 107327045 A 11/ 2017
4,530,468 A * 7/1985 Sperber B05B 7 /0025 CN 206967983 U 2 /2018
239 /419 . 3 KR 20180012432 A 2 / 2018
4 ,796 ,814 A * 1/ 1989 Klemm ................ BO5B 7/ 1481
239/ 430 * cited by examiner
U . S . Patent Sep . 3 , 2019 Sheet 1 of 3 US 10 , 399, 247 B1

122

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114 112
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1140 118 _ 0

102 ure

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116

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FIG . 1
U .S . Patent Sep . 3 , 2019 Sheet 2 of 3 US 10 ,399,247 B1

100 INC
S7 L122
102
22 Ww 226
216
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1 146 112b
Plot 2224228
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U . S . Patent Sep . 3 , 2019 Sheet 3 of 3 US 10 , 399 ,247 B1

102 - 232
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228
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500 244
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FIG . 5 FIG . 6
 US 10 ,399 ,247 B1
COMPOUND NOZZLE FOR CEMENT 3D FIG . 4 is a section view taken through lines 4 -4 of FIG .
PRINTER TO PRODUCE THERMALLY
INSULATED COMPOSITE CEMENT FIG . 5 is a section view taken through lines 5 -5 of FIG .
BACKGROUND 5 FIG . 6 is a section view taken through lines 6 -6 of FIG .
2.
1 . Field Similar reference characters denote corresponding fea
tures consistently throughout the attached drawings.
The disclosure of the present patent application relates to DETAILED DESCRIPTION OF THE
building construction tools and methods, and particularly to 10
a compound nozzle for a cement 3D printer to produce PREFERRED EMBODIMENTS
thermally insulated composite cement. FIG . 1 is a perspective view of a compound nozzle for a
2 . Description of the Related Art cement 3D printer to produce thermally insulated composite
15 cement, the nozzle being designated generally as 100 in the
A relatively new method of building construction drawings. Nozzle 100 includes a substantially cylindrical
involves the use of three -dimensional (3D ) printers for body 102 having a substantially conical discharge nozzle
printing cement. Walls are formed by printing the cement 104 at its lower end . The bottom of the discharge nozzle 104
one layer at a time until a wall of the desired height is includes a nozzle flange 106 for connecting the compound
formed . The 3D printer includes a nozzle that is attached to 20 nozzle 100 to the printer head of a 3D printer using , for
a scanning mechanism that is controlled by a programmable example , countersunk hex screws 120 . The discharge nozzle
controller, such as a computer. The scanning mechanism 104 also includes an upper cylindrical portion 116 for
moves the nozzle in the X , Y and Z directions to form the attaching the discharge nozzle 104 to the cylindrical body
wall. While the existing 3D printers provide flexibility in 102 using three countersunk hex screws 118 ( one shown in
terms of the shape of the wall , when insulation is desired it 25 FIG . 1 ). A cement supply line 108 is attached obliquely to
must be added manually to the inside surface of the wall , the the body 102 for supplying cement to the interior of the body
outside surface of the wall, or both after the cement wall is 102 . An insulation supply line 110 supplies insulation media
constructed . The current technique of insulating the cement to the discharge nozzle 104 . A water supply line 112 supplies
wall is both time- consuming and expensive , requiring addi- water near the top of the body 102 for washing the internal
tional equipment and personnel. Thus, a compound nozzle 30 components of the compound nozzle 100 between fabricat
for a cement 3D printer to produce thermally insulated ing jobs, or intermittently, as needed . The water supply line
composite cement solving the aforementioned problems is 112 splits into two water supply arms 112a and 112b for
desired . supplying two water nozzles, as described below with
respect to FIG . 2 . Likewise , an air supply line 114 supplies
SUMMARY 35 pressurized air near the top of the body 102 for drying the
internal components of the compound nozzle 100 after
The compound nozzle for a cement 3D printer to produce washing the internal components of the compound nozzle
thermally insulated composite cement is useful for produc - 100. The air supply line 114 splits into two air supply
ing composite thermally insulated cement sections using a branches 114a and 114b for supplying two air drying
3D printer. The nozzle is capable of printing self -insulated 40 nozzles , as described below with respect to FIG . 2 . The top
walls through the nozzle , thereby eliminating the extra work of the cylindrical body 102 may be closed with an appro
required to add insulation to an existing wall while increas - priate cover 122 to protect internal components.
ing the insulation efficiency of the wall . The nozzle includes FIG . 2 is a cross sectional view of the compound nozzle
an insulation nozzle centered at the discharge opening of the 100 , showing the internal components thereof. An auger 200
cement nozzle . A motor- driven auger is controlled by a 45 with a central driveshaft 202 is housed in the lower part of
controller, and the cement is supplied from the top , either body 102. The auger 200 may have any suitable number of
manually or by a concrete pump . The insulatingmaterial is blades for preparing the cement mixture for discharge and
supplied to the insulation nozzle by a separate line that uses extruding the cement mixture through the discharge orifice ,
another pump. The system also includes a cleaning mecha - as described below . The driveshaft 202 is rotatably sup
nism to clean the internal parts of the compound nozzle 50 ported on its lower end by a lower auger ball bearing 204
through water jets that are provided at the top of the system that is mounted in a lower auger ball bearing housing 206 .
and supplied water by a pump. A drying system is included The lower auger ball bearing housing 206 is held in place by
to dry out the internal components without the need to three countersunk hex screws 118 that extend through
disassemble the system when a job is completed . through -holes in the upper cylindrical portion 116 of the
These and other features of the present disclosure will 55 discharge nozzle 104 , through through -holes in the wall of
become readily apparent upon further review of the follow the body 102 and into threaded holes in the lower auger ball
ing specification and drawings. bearing housing 206 . A lower auger ball bearing housing
reinforcing plate 250 is attached to the top of the lower auger
BRIEF DESCRIPTION OF THE DRAWINGS ball bearing housing 206 using three countersunk hex screws
60 252 .
FIG . 1 is a perspective view of a compound nozzle for a The driveshaft 202 is rotatably supported at its upper end
cement 3D printer to produce thermally insulated composite by an upper auger ball bearing 210 that is mounted in an
cement . upper auger ball bearing housing 212 . The upper auger ball
FIG . 2 is a section view taken through lines 2 -2 of FIG . bearing housing 212 is held in place by four countersunk
65 screws 118 ( two shown in FIG . 2 and one shown in FIG . 1 )
FIG . 3 is a section view taken through lines 3 - 3 of FIG . that extend through through -holes in the wall of the body
102 and into threaded holes in the upper auger ball bearing
 US 10 ,399 , 247 B1
housing 212 . A motor support plate 216 is mounted above discharge orifice 254 . The cement is discharged in area 502
the upper auger ball bearing housing 212 using four coun around the insulation discharge nozzle 244 to thereby pro
tersunk screws 118 (two shown in FIG . 2 and one shown in duce a composite output including the insulation stream
FIG . 1 ) that extend through holes in the wall of the body 102 completely surrounded by a stream of cement. It should be
and into threaded holes in themotor supportplate 216 .ADC 5 noted that while only a single insulation discharge nozzle
motor 220 is supported on the motor support plate 216 and 244 is shown, multiple insulation discharge nozzlesmay be
is held in place by four countersunk hex screws 222 (two provided to produce multi- core insulation composite out
shown ) that extend through holes in the motor support plate puts.
216 and into threaded holes in the lower housing of the FIG . 6 is a section view of the composite output 600 of the
motor 220 . A flexible coupling 224 connects the drive shaft 10 compound nozzle 100 . As can be seen , the insulation I is
226 of the motor 220 with the central driveshaft 202 of the completely surrounded by the cement C . As the output 600
auger 200 . is discharged from the compound 3D printer cement/insu
The upper auger ball bearing housing 212 also secures the
washing and drying components. The water supply line 112b lation nozzle 100 , both the cement C and the insulation I
connects to a water elbow 228 that is held aligned with a 15 settle to produce the structure shown having an increase in
bore 234 by an elbow retaining plate 230 that is attached to width and a decrease in height. To produce a wall , the
the upper auger ball bearing housing 212 using four coun compound nozzle 100 is used to deposit (print) multiple
tersunk hex screws 232 (two shown in FIG . 2 ). A water layers of the output section 600 on top of one another until
cleaning nozzle 236 is mounted in the upper auger ball the desired height of the wall is reached . This results in a
bearing housing 212 and is aligned with the bore 234 on the 20 composite cement/insulation wall that is substantially more
bottom of the upper auger ball bearing housing 212 for insulated than a conventional all- cement wall, thereby elimi
directing water at the auger 200 and the other internal nating the need for external insulation structures .
components of the compound nozzle 100 . The air supply It is to be understood that the compound nozzle for a
line 114b connects to an air elbow 238 that is also held cement 3D printer to produce thermally insulated composite
aligned with a bore 240 by the elbow retaining plate 230 . An 25 cement is not limited to the specific embodiments described
air drying nozzle 242 is mounted in the upper auger ball above, but encompasses any and all embodiments within the
bearing housing 212 and is aligned with the bore 240 on the scope of the generic language of the following claims
bottom of the upper auger ball bearing housing 212 for enabled by the embodiments described herein , or otherwise
directing air at the auger 200 and the other internal compo - shown in the drawings or described above in terms sufficient
nents of the compound nozzle 100 . 30 to enable one of ordinary skill in the art to make and use the
The bottom of the discharge nozzle 104 includes a cen - claimed subject matter .
trally located final discharge orifice 254 for discharging
cement and insulation . The insulation supply line 110 ter - We claim :
minates in an insulation discharge nozzle 244 positioned in 1 . A compound nozzle for a cement 3D printer to produce
the center of the final discharge orifice 254 for discharge of 35 thermally insulated composite cement, the nozzle compris
a separate stream of insulation media in the center of the ing :
stream of cement being discharged , as is further described a substantially cylindrical body having a top portion and
below with respect to FIG . 5 . a bottom portion ;
FIG . 3 is a section view of the compound nozzle 100 taken a cement supply line attached obliquely to the bottom
through lines 3 -3 of FIG . 1 and shows the top of the upper 40 portion of the cylindricalbody for introducing a cement
auger ball bearing housing 212 surrounded by the body 102 mixture into the cylindrical body ;
and hidden by the elbow retaining plate 230 . Both water a substantially conical discharge nozzle having a conical
supply lines 112a and 112b , as well as both air supply lines peripheral outer surface , a top portion and a bottom
114a and 114b , can be seen and are arranged radially at 90° portion , the top portion of the discharge nozzle being
to one another. The four countersunk screws 232 for holding 45 attached to the bottom portion of the substantially
the elbow retaining plate 230 on the upper auger ballbearing cylindrical body and adapted to receive the cement
housing 212 are also shown and are also arranged radially at mixture, the bottom portion of the discharge nozzle
90° to one another. defining a central discharge orifice for discharging a
FIG . 4 is a section view of the compound nozzle 100 taken stream of cement from the cylindrical body ; and
through lines 4 -4 of FIG . 1 and shows the top of the lower 50 at least one insulation supply line entering the conical
auger ball bearing housing 212 . The lower auger ball bearing discharge nozzle through the conical peripheral outer
housing 212 includes a central boss 400 , the lower auger ball surface thereof, an insulation discharge nozzle disposed
bearing race 204 being mounted in the central boss 400 . at the end of the insulation supply line , wherein the
Three supporting ribs 402 connect the central boss 400 to the insulation discharge nozzle is concentrically disposed
body 102 using three countersunk hex screws 118 ( one 55 solely in the discharge orifice for discharging a stream
shown in FIG . 1 and one shown in FIG . 2 ). The lower auger of insulation media axially centered in the stream of
ball bearing housing reinforcing plate 250 and the three cement, thereby producing a thermally insulated com
countersunk hex screws 252 can also be seen in FIG . 4 . posite cement.
FIG . 5 shows the details of the final discharge orifice 254. 2 . The compound nozzle as recited in claim 1 , further
The final discharge orifice 254 includes the insulation dis - 60 comprising an auger mounted inside the substantially cylin
charge nozzle 244 with a central opening 500 for discharg - drical body for preparing the cement mixture for discharge
ing insulation media supplied via the insulation supply line and extruding the cement mixture through the central dis
110 . The insulation supply line 110 is connected to a pump, charge orifice .
which pumps the insulation media through the supply line 3 . The compound nozzle as recited in claim 1 , further
110 and impels the insulation media through the insulation 65 comprising:
discharge nozzle 244 in a stream of insulation concentrically at least one water supply line entering the top portion of
flowing within the stream of cement extruded through the said cylindrical body; and
 US 10 , 399,247 B1
at least one water cleaning nozzle attached to the at least
one water supply line , the least one water cleaning
nozzle being mounted in the top portion of said cylin
drical housing .
4 . The compound nozzle as recited in claim 1, further 5
comprising :
at least one air supply line entering the top portion of said
cylindrical body ; and
at least one air drying nozzle attached to the at least one
air supply line, the least one air drying nozzle being 10
mounted in the top portion of said cylindrical housing .
5 . The compound nozzle as recited in claim 1, further
comprising a mounting flange extending from said discharge
nozzle adapted for mounting the compound nozzle to a
cement 3D printer. 15