3d-printed integrated wall panel assembly

Abstract

A 3D-printed integrated panel, assembly, or other building element configured to form part of an overall building can include 3D-printed panels, connectors, and load transfer components. 3D-printed panels can be integrally formed by 3D printing technology using a photocurable composite material. A 3D-printed panel can include an outer frame shell defining a geometric shape having interior and exterior outer surfaces, side edges therebetween, and an infill structure therewithin, the infill structure forming internal cavities within the outer frame shell. Connectors can couple 3D-printed panels to each other and/or to separate building components of the overall building. Load transfer components can be coupled to and transfer loads across 3D-printed panels. Waterproofing elements can be coupled to 3D-printed panels, and thermal insulation material can be disposed within the internal cavities. The panel, assembly, or other building element can comply with building construction standards. Panels or assemblies can include wall panels.

What is claimed is: 
     
         1 . A building element configured to form a portion of an overall building, the building element comprising:
 a plurality of 3D-printed panels formed by 3D printing technology using a photocurable composite material, wherein each of at least a portion of the plurality of 3D-printed panels is integrally formed and includes an outer frame shell defining a geometric shape having an interior outer surface, an exterior outer surface, and side edges between the interior and exterior outer surfaces, and an infill structure within the outer frame shell, the infill structure forming internal cavities within the outer frame shell;   a plurality of connectors coupled to at least a portion of the plurality of 3D-printed panels and configured to couple one or more of the 3D-printed panels to each other, to one or more separate building components of the overall building, or to any combination thereof; and   one or more load transfer components coupled to at least a portion of the plurality of 3D-printed panels and configured to transfer loads across one or more of the 3D-printed panels.   
     
     
         2 . The building element of  claim 1 , wherein the building element meets construction industry requirements regarding structural performance, thermal efficiency, fire performance, and waterproofing. 
     
     
         3 . The building element of  claim 1 , wherein the building element is a 3D-printed integrated wall panel assembly and the overall building is a residential or commercial building. 
     
     
         4 . The building element of  claim 1 , wherein at least one interior outer surface, at least one exterior outer surface, or both are covered by one or more finishing coatings. 
     
     
         5 . The building element of  claim 1 , further comprising:
 one or more waterproofing components coupled to at least a portion of the plurality of 3D-printed panels.   
     
     
         6 . The building element of  claim 5 , wherein the one or more waterproofing components are installed along one or more horizontal or vertical edges of the coupled 3D-printed panels. 
     
     
         7 . The building element of  claim 1 , wherein the shape and the size of a given infill structure determines the stiffness and the ultimate load bearing capacity of its respective 3D-printed panel. 
     
     
         8 . The building element of  claim 1 , wherein the shape and the size of a given infill structure determines the thermal efficiency of its respective 3D-printed panel by extending one or more thermal bridging paths within its respective 3D-printed panel. 
     
     
         9 . The building element of  claim 1 , further comprising:
 a thermal insulation material disposed within at least some of the internal cavities of at least a portion of the plurality of 3D-printed panels.   
     
     
         10 . The building element of  claim 1 , wherein at least some of the side edges include extrusions that form vertical decorative ledges configured to bridge juncture regions between adjacent 3D-printed panels. 
     
     
         11 . The building element of  claim 1 , wherein the one or more separate building components of the overall building include one or more window frames, door frames, traditional wall segments, foundations, or any combination thereof. 
     
     
         12 . The building element of  claim 1 , wherein the plurality of connectors includes one or more mechanical connectors, one or more chemical adhesives, or any combination thereof. 
     
     
         13 . The building element of  claim 1 , wherein at least a portion of the plurality of connectors are coupled directly to at least a portion of the one or more load transfer components. 
     
     
         14 . The building element of  claim 1 , wherein the plurality of connectors includes a rim track with slots formed therein configured to couple to a separate floor component or a separate roof component of the overall building. 
     
     
         15 . The building element of  claim 1 , wherein at least a portion of the plurality of 3D-printed panels include an opening therethrough configured for a window or a door. 
     
     
         16 . The building element of  claim 1 , wherein the one or more load transfer components include one or more sets of tension transmitting members. 
     
     
         17 . The building element of  claim 1 , wherein the one or more load transfer components include a structural frame coupled to a first panel of the plurality of 3D-printed panels to form an integrated panel assembly, the structural frame including a top frame member, a bottom frame member spaced apart from the top frame member, and columnar members extending between the top and bottom members. 
     
     
         18 . The building element of  claim 17 , wherein the first panel includes a plurality of vertically oriented slots formed into top and bottom surfaces thereof, and further comprising:
 one or more insertion plates inserted into one or more of the plurality of vertically oriented slots, wherein the one or more insertion plates are attached to the structural frame to couple the first panel to the structural frame.   
     
     
         19 . The building element of  claim 18 , further comprising:
 one or more base plates coupled to one or more of the columnar members and to one or more of the insertion plates inserted into one or more vertically oriented slots along the bottom of the first panel, wherein the one or more base plates are configured to couple the integrated panel assembly to a separate building component of the overall building.   
     
     
         20 . The building element of  claim 19 , wherein the integrated panel assembly is an integrated wall panel assembly and the separate building component is a foundation of the overall building. 
     
     
         21 . A building panel configured to form a portion of an overall building, the building panel comprising:
 a 3D-printed structure formed by 3D printing technology using a photocurable composite material, wherein the 3D-printed structure is integrally formed and includes:
 an outer frame shell defining a geometric shape having an interior outer surface, an exterior outer surface, and side edges between the interior outer surface and exterior outer surface, and 
 an infill structure within the outer frame shell, the infill structure forming internal cavities within the outer frame shell; and 
   one or more coupling features formed in the 3D-printed structure, wherein the one or more coupling features are configured to facilitate coupling the 3D-printed structure to one or more separate building components of the overall building.   
     
     
         22 . The building panel of  claim 21 , further comprising:
 a load transfer system formed from non-3D-printed material and coupled to the 3D-printed structure, the load transfer system configured to transfer loads across the 3D-printed structure, wherein the 3D-printed structure and the load transfer system combine to form a 3D-printed integrated panel.   
     
     
         23 . The building panel of  claim 22 , wherein the load transfer system includes a structural frame including a top frame member, a bottom frame member spaced apart from the top frame member, and columnar members extending between the top and bottom members. 
     
     
         24 . The building panel of  claim 23 , wherein the one or more coupling features formed in the 3D-printed structure include a plurality of vertically oriented slots formed into top and bottom surfaces thereof, and further comprising:
 one or more insertion plates inserted into one or more vertically oriented slots, wherein the one or more insertion plates are attached to the structural frame to couple the 3D-printed structure to the structural frame.   
     
     
         25 . The building panel of  claim 24 , further comprising:
 one or more base plates coupled to one or more of the columnar members and to one or more of the insertion plates inserted into one or more vertically oriented slots along the bottom of the 3D-printed structure, wherein the one or more base plates are configured to couple the 3D-printed integrated panel to a separate building component of the overall building.   
     
     
         26 . The building panel of  claim 21 , wherein the interior outer surface, the exterior outer surface, or both are covered by one or more finishing coatings. 
     
     
         27 . The building panel of  claim 21 , further comprising:
 a thermal insulation material disposed within at least some of the internal cavities.   
     
     
         28 . The building panel of  claim 21 , wherein the 3D-printed structure has a width of about 1 to 12 feet, a height of about 8 to 12 feet, and a thickness of about 1 to 12 inches. 
     
     
         29 . The building panel of  claim 21 , wherein the outer frame shell of the 3D-printed structure defines a geometric shape that is straight between the side edges to form a straight panel. 
     
     
         30 . The building panel of  claim 21 , wherein the outer frame shell of the 3D-printed structure defines a geometric shape that is complex between the side edges to form a complex panel. 
     
     
         31 . The building panel of  claim 30 , wherein the complex panel defines a complex geometric shape that is curved, wavy, round-cornered, or square-cornered.