A special-shaped open-hole shell member reinforced with a 3D printing connector and a manufacturing method thereof

Abstract

The application discloses a special-shaped open-hole shell component reinforced by a 3D printing connecting piece and a manufacturing method, and belongs to the fields of building structure engineering and additive manufacturing technology. The component comprises upper and lower plate materials, a middle open-hole 3D printing connecting piece and filling materials of cavities between the two layers of plate materials. During manufacturing, the upper and lower plate materials and the middle open-hole 3D printing connecting piece are assembled first to form a double-layer structure with cavities, and then the cavities are poured with the filling materials to form an overall shell component with variable thickness and open-hole state. The 3D printing connecting piece plays a role in structural reinforcement, can significantly improve the structural performance of the shell, such as the strength, rigidity and stability, and can be customized and designed and 3D printed according to the thickness and size requirements of specific positions, has better adaptability to special-shaped shells, and is variable in thickness, free in form, has light-transmitting or light-emitting holes and has richer space effects and artistic expressiveness.

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] Existing shell structures generally have the following technical bottlenecks in engineering applications, which seriously restrict their promotion in scenarios with complex building forms and functional requirements:

[0003] 1. Limitations of Traditional Shell Mechanical Properties

[0004] Inherent drawbacks of single-thickness design: Conventional shells often use a constant thickness design, making it impossible to optimize local thickness based on stress distribution, resulting in low material utilization. For example, thin-walled structures are prone to plastic hinges in areas subject to large bending moments, while thick-walled designs create redundant mass in areas subject to less stress.

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

[0006] The structures of the above two traditional shells 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 synergy 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 later, 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 shapes, and in order to meet architects' pursuit of artistic effects such as hollowing and gradients, structural performance often needs to be sacrificed, making it difficult to achieve the unity of mechanical performance 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 with 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 produced. It solves the problems of insufficient strength, poor adaptability to special shapes and low construction efficiency of traditional shell structures under complex working conditions, and gives the shell artistic expression functions such as light transmission and gradient shape.

[0015] To achieve the above-mentioned object, the present invention provides a special-shaped hole shell component reinforced with a 3D printed connector, comprising an upper plate and a lower plate, wherein a 3D printed connector and a cavity filling layer are provided 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 based on the design model and print 3D printed connectors;

[0024] S2. Connect 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 present invention provides a special-shaped hole shell component reinforced with a 3D printed connector and a manufacturing method thereof, which has the following beneficial effects:

[0029] (1) Improved mechanical properties: 3D printed connectors act as internal reinforcement ribs, working together with the cavity filling layer to resist shear forces. The overall rigidity 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 serve as pouring formwork, saving traditional formwork materials;

[0031] (3) Fusion of art and function: 3D connectors are hollow and light-transmitting (e.g., transparent resin material + hole array), which can achieve dynamic light and shadow effects and meet architectural aesthetic requirements;

[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 be adapted to any special-shaped openings, and the upper and lower layers of panels and 3D printed connectors can be connected by bolts or rivets. 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 the shell component 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 examples. It should be understood that these examples are only used to illustrate the present invention and are not intended to limit the scope of the present invention. Any other changes, modifications, substitutions, combinations, and simplifications made without violating the spirit and principles of the present invention should be considered as equivalent replacement methods and are included in the protection scope of the present invention. In addition, it should be understood that after reading the contents 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] References to "embodiments" herein mean that the specific features, structures, or characteristics described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the word "embodiment" in various places in the specification does not necessarily refer to the same embodiment, nor does it particularly limit its independence or relevance to other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the various technical features mentioned in the embodiments can be combined in any manner to form a corresponding implementable technical solution.

[0041] Unless otherwise defined, the technical terms used herein have the same meanings as those generally understood by those skilled in the art to which this application belongs; the use of relevant terms herein 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 those skilled in the art.

[0043] Material selection for the following examples:

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

[0045] 3D printed connector: transparent PC plastic (light transmittance ≥ 85%), height gradient (50mm to 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 3D printed connectors, such as Figure 1 As shown in FIG, it is a cross-sectional view of the variable thickness shell of this embodiment, illustrating the relationship between the upper and lower layers of plate materials and the 3D printed connector and filling layer, as well as the thickness change of the shell; Figure 2This is an exploded view of the shell structure of this embodiment, illustrating the assembly relationship between the upper and lower panels and the 3D-printed connectors. Specifically, the curved roof shell structure includes an upper panel 1 and a lower panel 2, with a 3D-printed connector 3 and a cavity-filling layer 4 positioned between them.

[0049] Both the upper and lower plates 1 and 2 have circular openings 5, with nail holes 6 evenly spaced around their edges. The 3D-printed connector 3 is a closed, hollow ring-wall structure with holes 7 defined on its upper and lower end faces. Bolts or rivets 8 penetrate these holes and securely connect the 3D-printed connector 3 to the upper and lower plates 1 and 2, respectively. Cylindrical protrusions 9 are provided on the outer wall of the 3D-printed connector 3 to enhance engagement with the cavity-filling layer 4 and prevent disengagement and slippage.

[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 for connectors based on the roof surface model, ensuring their outer contours match the opening edges of the upper and lower panels. Optimize connector distribution density through finite element analysis.

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

[0054] Step 3: Connect the 3D printed connector to the pre-perforated upper and lower panels 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 is ≤30mm. Use an inserted vibrator to compact it. 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 solutions of the present invention rather than to limit the same. 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 solutions of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A special-shaped hole shell component reinforced with a 3D printed connector, characterized in that: The shell member is a variable thickness shell member, comprising an upper plate and a lower plate, wherein a 3D printed connector and a cavity filling layer are provided 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. The 3D printed connector is designed to be hollow and light-transmitting; The outer wall of the 3D printed connector is provided with protrusions for enhancing the engagement with the cavity filling layer and preventing separation and slippage.

2. The special-shaped hole shell component reinforced with a 3D printed connector according to claim 1, characterized in that: The protrusion is cylindrical or conical.

3. The special-shaped hole shell component reinforced with 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.

4. The special-shaped shell member reinforced with 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.

5. A method for manufacturing a special-shaped hole shell component reinforced with a 3D printed connector according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1. Generate three-dimensional data based on the design model and print 3D printed connectors; S2. Connect 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.

6. The method for manufacturing a special-shaped shell member reinforced with a 3D printed connector according to claim 5, characterized in that: In S1, the 3D printed connector is made of plastic or metal material by 3D printing.

7. The method for manufacturing a special-shaped shell member reinforced with a 3D printed connector according to claim 5, characterized in that: In the above-mentioned S3, the filling material is concrete or resin material.

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