Special-shaped holed shell component reinforced by 3D printing connecting piece and manufacturing method of special-shaped holed shell component

Abstract

The invention discloses a special-shaped holed shell component reinforced through a 3D printing connecting piece and a manufacturing method, and belongs to the technical field of building structure engineering and additive manufacturing. The component comprises an upper-layer plate, a lower-layer plate, a middle-hole-shaped 3D printing connecting piece and a filling material of a cavity between the two layers of plates. During manufacturing, the upper-layer plate, the lower-layer plate and the middle-hole-shaped 3D printing connecting piece are assembled firstly, a double-layer structure with a cavity is formed, then filling materials are poured into the cavity, and an integral shell component with the variable thickness and the hole forming state is formed. The 3D printing connecting piece plays a structural reinforcing role, the structural performance such as the strength, rigidity and stability of the shell can be remarkably improved, customized design and 3D printing manufacturing can be achieved according to the thickness and size requirements of the specific position, better adaptability is achieved for a special-shaped shell, meanwhile, the shell is variable in thickness and free in shape, and light-transmitting or light-emitting holes are formed, so that the service life of the shell is prolonged, and the service life of the shell is prolonged. And richer space effect and artistic expressive force are achieved.

Description

Technical Field

[0001] The present invention relates to the field of building structure engineering and additive manufacturing technology, and in particular to a special-shaped hole shell component reinforced by a 3D printed connector and a manufacturing method thereof. Background Art

[0002] The existing shell structures generally have the following technical bottlenecks in engineering applications, which seriously restrict their promotion in complex building forms and functional demand scenarios:

[0003] 1. Limitations of Traditional Shell Mechanical Properties

[0004] Inherent defects of single thickness design: Conventional shells are mostly designed with equal thickness, and local thickness optimization cannot be performed according to the force distribution, resulting in low material utilization. For example, in areas with large bending moments, thin-walled structures are prone to plastic hinges; while in areas with small forces, thick-walled designs result in redundant mass.

[0005] Mechanical defects of sandwich filling structure: Although traditional sandwich shells (such as honeycomb core, foam filling) can partially improve the stiffness, their connection strength with the panel is insufficient and they are prone to debonding or stratification under long-term load.

[0006] The above two traditional shell structures are difficult to adapt to complex mechanical working conditions (such as non-uniform loads and combined bending and torsion stresses).

[0007] 2. Dilemma of adaptability of special-shaped shells

[0008] Geometric constraints of traditional connectors: Conventional connectors such as steel ribs and wooden supports rely on mold processing and have low adaptability to free-form surfaces and variable thickness shells.

[0009] Customized production efficiency is low: Connectors need to be customized piece by piece for complex curved surfaces, which results in a long production cycle and a high mold loss rate.

[0010] 3. The problem of coordination between aesthetics and functionality

[0011] The functionality and safety of light-transmitting holes are in conflict: light-transmitting holes in traditional shells are mostly opened mechanically in the later stage, which destroys the integrity of the panel and is prone to local cracking after being put into use.

[0012] Conflict between decorative needs and structural strength: Traditional shells are difficult to achieve complex curved surface modeling, and in order to meet architects' pursuit of artistic effects such as hollowing and gradient, structural performance often needs to be sacrificed, making it difficult to achieve the unity of mechanical properties and aesthetic design.

[0013] Therefore, traditional shell structures have problems such as insufficient strength under complex working conditions, poor adaptability to special shapes and low construction efficiency. They are difficult to meet the needs of modern buildings for shell structures, and there is an urgent need to break through the existing limitations through innovative structural forms and manufacturing processes. Summary of the invention

[0014] The purpose of the present invention is to provide a special-shaped hole shell component reinforced by 3D printed connectors and a manufacturing method. Through the customized design of the 3D printed connectors and the synergistic effect of the cavity filling material, a special-shaped hole shell component with variable thickness, excellent mechanical properties and rapid assembly is obtained, which solves the problems of insufficient strength of traditional shell structures under complex working conditions, poor adaptability to special shapes and low construction efficiency, and gives the shell artistic expression functions such as light transmission and gradient shape.

[0015] To achieve the above-mentioned purpose, the present invention provides a special-shaped hole shell component reinforced by a 3D printed connector, comprising an upper plate and a lower plate, wherein a 3D printed connector and a cavity filling layer are arranged between the upper plate and the lower plate;

[0016] The upper plate and the lower plate are both provided with holes, and nail holes are evenly provided at the edges of the holes;

[0017] The 3D printed connector is a hollow closed structure with holes formed on the upper and lower end surfaces. The 3D printed connector is fixedly connected to the upper plate and the lower plate by bolts or rivets passing through the nail holes and the holes.

[0018] Preferably, a protrusion is provided on the outer wall of the 3D printed connector to enhance the engagement with the cavity filling layer and effectively prevent it from detaching and slipping.

[0019] Preferably, the protrusion is cylindrical or conical.

[0020] Preferably, the upper plate and the lower plate are aluminum alloy plates or steel plates.

[0021] Preferably, the hole is polygonal, circular or free-curve shaped.

[0022] The present invention also provides a method for manufacturing the above-mentioned special-shaped hole shell component reinforced by a 3D printed connector, comprising the following steps:

[0023] S1. Generate three-dimensional data according to the design model and print 3D printed connectors;

[0024] S2, connecting the upper plate, the lower plate and the 3D printed connector by bolts or rivets to form a cavity structure;

[0025] S3. Pour filling material into the cavity and solidify to form a cavity filling layer.

[0026] Preferably, in S1, the 3D printed connector is made of plastic or metal material by 3D printing, which can enhance the structural performance of the shell.

[0027] Preferably, in S3, the filling material is concrete or resin material.

[0028] Therefore, the special-shaped hole shell component reinforced by a 3D printed connector and the manufacturing method provided by the present invention have the following beneficial effects:

[0029] (1) Improved mechanical properties: The 3D printed connector acts as an internal reinforcement rib, and cooperates with the cavity filling layer to resist shear force. The overall stiffness of the shell is significantly improved, and it can be used as a plane load-bearing component, a vertical load-bearing component, and a spatial load-bearing component.

[0030] (2) Formwork-free construction: The upper and lower plates can also serve as casting formwork, saving traditional formwork materials;

[0031] (3) Integration of art and function: 3D connectors are hollow and light-transmitting (such as transparent resin material + hole array), which can achieve dynamic light and shadow effects and meet the needs of architectural aesthetics;

[0032] (4) Better adaptability to special-shaped shells: 3D printed connectors can be customized and 3D printed according to the thickness and size requirements of the specific position of the shell. They have better adaptability to special-shaped shells and stronger spatial adaptability.

[0033] (5) Rapid customized production: 3D printed connectors can fit any special-shaped openings, and the upper and lower layers of panels and 3D printed connectors can be connected by bolts or rivets. The assembly is quick and easy, shortening the design to installation cycle.

[0034] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a cross-sectional view of a variable thickness shell of the present invention;

[0036] Figure 2 is an exploded view of a shell member of the present invention;

[0037] Description of reference numerals:

[0038] 1. Upper plate; 2. Lower plate; 3. 3D printed connector; 4. Cavity filling layer; 5. Hole; 6. Nail hole; 7. Hole; 8. Rivet; 9. Protrusion. DETAILED DESCRIPTION

[0039] The technical solution of the present invention is further described below by means of the accompanying drawings and embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not used to limit the scope of the present invention. Any other changes, modifications, substitutions, combinations, simplifications made without violating the spirit and principle of the present invention should be equivalent replacement methods and are included in the protection scope of the present invention. In addition, it should be understood that after reading the content of the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms also fall within the scope defined by the claims attached to this application and belong to the scope of protection of the present invention.

[0040] Reference to "embodiment" herein means that the specific features, structures or characteristics described in conjunction with the embodiment may be included in at least one embodiment of the present application. The term "embodiment" appearing in various places in the specification does not necessarily refer to the same embodiment, nor does it particularly limit its independence or association with other embodiments. In principle, in the present application, as long as there is no technical contradiction or conflict, the various technical features mentioned in the embodiments can be combined in any way to form a corresponding implementable technical solution.

[0041] Unless otherwise defined, the technical terms used in this document have the same meanings as those generally understood by those skilled in the art to which this application belongs; the use of relevant terms in this document is only for describing specific embodiments and is not intended to limit this application.

[0042] Unless otherwise specified in the present invention, the reagents, instruments, and equipment used are those commonly used by technicians in this field.

[0043] Material selection for the following examples:

[0044] Upper plate and lower plate: 1.5mm thick aluminum alloy plate, tensile strength ≥300MPa;

[0045] 3D printed connector: transparent PC plastic (light transmittance ≥ 85%), height gradient change (50mm~120mm), outer wall conical protrusion height 8mm;

[0046] Filling material: C40 lightweight concrete (density 1800kg / m 3 ).

[0047] Example 1

[0048] This embodiment provides a curved roof shell component reinforced with a 3D printed connector, such as Figure 1 As shown, it is a cross-sectional view of the variable thickness shell of this embodiment, which illustrates the relationship between the upper and lower layers of plate materials and the 3D printed connector and the filling layer, as well as the thickness change of the shell; Figure 2: This is an exploded view of the shell component of this embodiment, illustrating the assembly relationship between the upper and lower layers of plate materials and the 3D printed connector. Specifically, the curved roof shell component includes an upper plate material 1 and a lower plate material 2, and a 3D printed connector 3 and a cavity filling layer 4 are arranged between the upper plate material 1 and the lower plate material 2.

[0049] The upper plate 1 and the lower plate 2 are both provided with circular openings 5, and nail holes 6 are evenly provided at the edges of the openings 5. The 3D printed connector 3 is a hollow ring wall closed structure, and holes 7 are provided on the upper and lower end faces. The 3D printed connector 3 is fixedly connected to the upper plate 1 and the lower plate 2 by bolts or rivets 8 passing through the nail holes 6 and the holes 7. A cylindrical protrusion 9 is provided on the outer wall of the 3D printed connector 3 to enhance the engagement with the cavity filling layer 4 and effectively prevent it from detaching and slipping.

[0050] Example 2

[0051] This embodiment provides a method for manufacturing a curved roof shell component reinforced with a 3D printed connector, specifically comprising the following steps:

[0052] Step 1: Generate 3D data of connectors based on the roof surface model, ensure that their outer contours match the opening edges of the upper and lower panels, and optimize the distribution density of connectors through finite element analysis;

[0053] Step 2: Use FDM process to print 3D printed connectors with a layer thickness of 0.2mm and a filling rate of 80%;

[0054] Step 3: Connect the 3D printed connector to the pre-perforated upper and lower plates with stainless steel rivets. The maximum thickness of the cavity is 120 mm (central load-bearing area) and the minimum thickness is 50 mm (edge ​​area).

[0055] Step 4: Pump concrete into the cavity from the bottom grouting hole. The pouring thickness of each layer should be ≤30mm. Use an inserted vibrator to compact the concrete. Allow to solidify naturally for 7 days to form a cavity filling layer.

[0056] Effect verification:

[0057] Ultimate bearing capacity test: uniformly distributed load up to 15kN / m 2 No buckling failure occurred (45% improvement compared to the structure without connectors).

[0058] Light transmission effect: During the day, natural light passes through the holes in the connectors to form scattered light spots, and at night, the built-in LED light strips achieve perforated lighting.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that they can still modify or replace the technical solution of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solution to deviate from the spirit and scope of the technical solution of the present invention.

Claims

1. A special-shaped hole shell component reinforced by a 3D printed connector, characterized in that: It comprises an upper plate and a lower plate, wherein a 3D printed connector and a cavity filling layer are arranged between the upper plate and the lower plate; The upper plate and the lower plate are both provided with holes, and nail holes are evenly provided at the edges of the holes; The 3D printed connector is a hollow closed structure with holes formed on the upper and lower end surfaces. The 3D printed connector is fixedly connected to the upper plate and the lower plate by bolts or rivets passing through the nail holes and the holes.

2. The special-shaped hole shell component reinforced by a 3D printed connector according to claim 1, characterized in that: A protrusion is arranged on the outer wall of the 3D printed connecting piece.

3. The special-shaped hole shell member reinforced by a 3D printed connector according to claim 2, characterized in that: The protrusion is cylindrical or conical.

4. The special-shaped hole shell component reinforced by a 3D printed connector according to claim 1, characterized in that: The upper plate and the lower plate are aluminum alloy plates or steel plates.

5. The special-shaped hole shell member reinforced by a 3D printed connector according to claim 1, characterized in that: The hole is in the shape of a polygon, a circle or a free curve.

6. A method for manufacturing a special-shaped hole shell component reinforced by a 3D printed connector as described in any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Generate three-dimensional data according to the design model and print 3D printed connectors; S2, connecting the upper plate, the lower plate and the 3D printed connector by bolts or rivets to form a cavity structure; S3. Pour filling material into the cavity and solidify to form a cavity filling layer.

7. The method for manufacturing a special-shaped hole shell member reinforced by a 3D printed connector according to claim 6, characterized in that: In S1, the 3D printed connector is formed by 3D printing of plastic or metal material.

8. The method for manufacturing a special-shaped hole shell member reinforced by a 3D printed connector according to claim 6, characterized in that: In S3, the filling material is concrete or resin material.

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