A template for a complex curved concrete truss beam member

Abstract

This utility model relates to the field of concrete component manufacturing technology, and in particular to a template for a complex curved concrete truss beam component. The template comprises a glass fiber reinforced ABS 3D template and a UHPC reinforcing layer. The glass fiber reinforced ABS 3D template is formed by stacking several layers of glass fiber reinforced ABS 3D printed layers in the height direction. The glass fiber reinforced ABS 3D template encloses the concrete pouring space. The UHPC reinforcing layer is uniformly sprayed on the outer surface of the glass fiber reinforced ABS 3D template, and the two constitute an integral structure. The advantages of this utility model are: the main raw material for 3D printing is glass fiber reinforced ABS, which has high strength; the template thickness can be controlled within 10mm, effectively reducing the template weight and facilitating on-site installation and disassembly; spraying UHPC on the outer side of the printed template further enhances the overall toughness of the template and increases its reusability; the production cycle is short and efficient, greatly improving construction efficiency; it eliminates the need for cumbersome mold making, reducing template manufacturing costs to a certain extent.

Description

Technical Field

[0001] This utility model relates to the field of concrete component manufacturing technology, and in particular to a template for a complex curved concrete truss beam component. Background Technology

[0002] When making concrete components with ordinary shapes, most of them use wooden formwork, steel formwork, aluminum formwork or plastic formwork. Simple straight or curved surfaces can be customized using steel formwork.

[0003] For concrete components requiring surface texture, silicone or polyurethane formwork can be used. When using silicone or polyurethane formwork, a seed mold needs to be made first, and then silicone or polyurethane is poured onto the seed mold to create the final product.

[0004] When the component has a complex curved shape, such as Figure 4 As shown, the 40.8m long concrete truss beam has a double-curved lower section, with all web members having double-curved surfaces that gradually taper from the middle to both ends. Using steel formwork to create the curved surface cannot achieve the desired double-curved effect, and the dimensional accuracy (±3mm) cannot be met. CNC milling would be too costly. Using silicone or polyurethane formwork requires full-size precast molds, which not only lengthens the production cycle but also significantly increases costs. Furthermore, because silicone or polyurethane is a flexible material, to prevent deformation, the finished formwork needs to be fixed to rigid wooden or steel plates for support. This further increases the weight of the formwork, making installation and disassembly during pouring difficult and complicating the component production process.

[0005] For the fabrication of formwork for concrete truss beams with complex roof shapes, conventional methods mainly have the following problems: (1) Steel formwork cannot achieve a hyperboloid effect; (2) The steel formwork cannot meet the dimensional accuracy requirements; (3) The cost of using CNC machine tools to mill and form steel templates is too high; (4) If silicone or polyurethane templates are used, seed molds need to be made, which has a long production cycle and high cost; (5) Using silicone or polyurethane templates requires external mold reinforcement and shaping, which greatly increases the weight of the templates and makes on-site installation and disassembly difficult. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of the prior art by providing a template for complex curved concrete truss beam components. This template is made by combining 3D-printed glass fiber reinforced ABC structures and UHPC reinforcement layers to achieve rapid fabrication of complex curved templates.

[0007] The objective of this utility model is achieved through the following technical solutions: A template for a complex curved concrete truss beam component is characterized in that: the template includes a glass fiber reinforced ABS 3D template and a UHPC reinforcement layer, wherein the glass fiber reinforced ABS 3D template is formed by stacking several layers of glass fiber reinforced ABS 3D printed layers in the height direction, the glass fiber reinforced ABS 3D template encloses the concrete pouring space, and the UHPC reinforcement layer is uniformly sprayed on the outer surface of the glass fiber reinforced ABS 3D template, the two forming an integral structure.

[0008] The templates include straight-edge templates and curved templates.

[0009] The formwork located on both sides of the pouring space is reinforced by a U-shaped clamp at the upper end.

[0010] The template also includes a base plate, and the template is fixed to the base plate by fasteners.

[0011] The template is provided with reinforcing ribs at the positions corresponding to the fasteners, and the reinforcing ribs protrude outward from the outer surface of the template.

[0012] The bottom of the template is provided with an outwardly extending connecting wing plate, which is connected and fixed to the base plate by a connector.

[0013] The fastener is a right-angle fastener, with its vertical part fixedly connected to the template and its horizontal part fixedly connected to the base plate.

[0014] An interface adhesive is applied between the glass fiber reinforced ABS 3D template and the UHPC reinforcement layer.

[0015] The advantages of this utility model are: 1) The template is modeled in 3D using software, and 3D printing is performed based on the template's 3D data, which can achieve accurate printing of complex curved surfaces.

[0016] 2) Using 3D printing templates, the manufacturing precision is high and can be controlled within ±1mm.

[0017] 3) The main raw material for 3D printing is glass fiber reinforced ABS, which has high strength and the template thickness can be controlled within 10mm, which can effectively reduce the weight of the template and facilitate on-site installation and disassembly.

[0018] 4) Spraying UHPC on the outside of the printed template can further enhance the overall toughness of the template and increase the number of times the template can be used.

[0019] 5) 3D printed templates have a short production cycle and high efficiency, which greatly improves construction efficiency.

[0020] 6) 3D printed templates can eliminate the need for tedious mold making, which reduces the cost of template production to some extent. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a schematic diagram of the 3D printed structure in this utility model; Figure 3 This is a schematic diagram of the cross-sectional structure of this utility model; Figure 4 This is a structural schematic diagram of the complex curved concrete truss beam component that this utility model addresses. Detailed Implementation

[0022] The features and other related features of this utility model will be further described in detail below with reference to the accompanying drawings and embodiments, so as to facilitate the understanding of those skilled in the art: like Figure 1-4 As shown in the figure, the markings represent: straight edge template 1, outer frame arc template 2, wooden board 3, right angle fastener 4, upper port U-shaped clamp 5, connecting wing plate 6, reinforcing rib 7, inner frame arc template 8, glass fiber reinforced ABS layer 9, 3D printing head 10, 3D printing layer 11, UHPC reinforcing layer 12.

[0023] Example: Figures 1 to 3 As shown, in this embodiment, the concrete pouring space formed by the template of the complex curved concrete truss beam component is appropriately matched with the outer contour shape and size of the complex curved concrete truss beam component to be poured. For example... Figure 4 The truss beam component is shown. In this embodiment, the template includes a straight-edge template 1, an outer frame arc template 2, and an inner tube arc template 8. The straight-edge template 1 cooperates with each other to form a casting space corresponding to the straight segment of the truss beam component, while the outer frame arc template 2 and the inner frame arc template 8 cooperate to form a casting space corresponding to the curved segment of the truss beam component.

[0024] In summary, this embodiment is based on Figure 4 Taking the complex curved surface of the concrete truss beam as an example, the template mainly includes straight-edge templates and curved templates. When the structural form of the truss beam changes, the template can also include a corresponding structure, such as a folded template.

[0025] Combination Figure 2 and Figure 3 As shown, the template in this embodiment includes a 3D printed layer 11 formed by stacking several glass fiber reinforced ABS layers 9 in the forward direction through a 3D printing head 10, and a UHPC reinforcing layer 12 sprayed on the outer surface of the 3D printed layer 11.

[0026] In this embodiment, a glass fiber reinforced ABS layer is 3D printed. Glass fiber reinforced ABS has higher strength, toughness and rigidity, which can greatly improve the template. It also has higher heat resistance and corrosion resistance, ensuring that the template does not deform during use. Even with steam curing, it does not affect the template's service life. At the same time, its printing temperature is lower, and it is lightweight, with lower printing costs compared to metal powder 3D printing materials.

[0027] In this embodiment, the 3D printing layer 11 is fabricated using a layer-by-layer printing method. Therefore, the adhesion between the vertical glass fiber reinforced ABS layers is much lower than the horizontal tensile strength (anisotropy). Consequently, during use, especially when demolding with external force, the glass fiber reinforced ABS layers are prone to detachment, leading to template damage. To address this, this embodiment sprays a UHPC reinforcement layer 12 onto the outer surface of the 3D printing layer 11. Utilizing the high tensile strength and excellent adhesion between UHPC and ABS, the adhesion between the glass fiber reinforced ABS layers is significantly improved. This allows the 3D printing layer 11 and the UHPC reinforcement layer 12 to form a unified whole, working together to withstand stress, effectively solving the problem of easy damage caused by the anisotropy of layered 3D printing.

[0028] In this embodiment, to further improve the bonding performance between the 3D printed layer 11 and the UHPC reinforcement layer 12 and ensure a strong bond between them, an interface adhesive (e.g., acrylic emulsion) is coated on the outer surface of the printed 3D printed layer 11, and UHPC is sprayed on after the interface adhesive dries.

[0029] like Figure 1 As shown, in this embodiment, in order to ensure the stability of the templates, each template is installed on a wooden board 3, which serves as the base plate, and the wooden board 3 should have a high surface precision to ensure that the height of each template is consistent.

[0030] like Figure 1 As shown, each template has an outwardly extending connecting wing plate 6 at its bottom. Bolt holes are provided on the connecting wing plate 6, and screws are screwed into these holes to connect and fix the connecting wing plate 6 to the wooden board 3, thus securing the template to the template 3. To ensure the uprightness and structural stability of each template, reinforcing ribs 7 are provided on the outer side of the template. Right-angle fasteners 4 are provided on the outer side of the reinforcing ribs 7. The vertical part of the right-angle fastener 4 is fixed to the reinforcing rib 7 with bolts, and the horizontal part is fixed to the wooden board 3 with bolts. In this embodiment, several reinforcing ribs 7 are arranged at certain intervals along the extension direction of the template, ensuring its performance.

[0031] like Figure 1 As shown, an upper-port U-shaped clamp 5 is engaged between the tops of the formwork on both sides of the pouring space constituting the truss beam member, connecting the formwork on both sides to form an integral structure, thereby ensuring resistance to the outward force generated during concrete pouring; for example, between the straight-edge formwork 1 on both sides. In this embodiment, to facilitate the installation of the upper-port U-shaped clamp 5, a flange adapted to the upper-port U-shaped clamp 5 can be provided on the top surface of the formwork, so that the upper-port U-shaped clamp 5 can be easily engaged with the formwork, facilitating installation and disassembly.

[0032] When applied, this embodiment includes the following manufacturing method: 1) Based on the CAD drawings of the complex curved concrete truss beam components, a three-dimensional model of the components was created using Rhino3D NURBS software, and a three-dimensional model of the overall template was created based on the three-dimensional model of the components.

[0033] 2) The overall template model is segmented. The segmentation principle is: easy to disassemble and suitable for the printing parameters of 3D printing equipment (such as length, width, height, etc.).

[0034] 3) Convert the 3D data of the split template into data path code for the 3D printing equipment.

[0035] 4) Using the SZSKY1 particle 3D printing equipment, glass fiber reinforced ABS is used as the raw material, and template 3D printing is performed according to the data path code.

[0036] 5) Six hours after the template printing is completed, spray UHPC material to reinforce the outer surface (or apply an interface adhesive first and then spray UHPC material). The spray thickness is 10mm. The material used for spraying is UHPC material with a compressive strength of 100MPa and a fiber (PVA, diameter 0.2mm, length 6mm) volume content of 1.5~2%.

[0037] 6) After 24 hours of moisturizing and curing following the spraying process, the template can be put into use.

[0038] In the specific implementation of this embodiment: Figure 1 The image shown is only a sample of the actual product. Figure 4 For a portion of the complex curved concrete truss beam component, the formwork for the remaining parts can be designed and manufactured according to the formwork structure in this embodiment. Since the formwork in this embodiment adopts a segmented assembly structure, the segments can be simply connected by bolts or other connectors. At the same time, the sealing of the segment connections should also be considered.

[0039] In this embodiment, the thickness of the UHPC reinforcement layer 12 is 10mm, and the performance requirements are: expansion ≥ 650MPa, compressive strength ≥ 100MPa, and tensile strength ≥ 5MPa.

[0040] Although the above embodiments have described the concept and embodiments of the present invention in detail with reference to the accompanying drawings, those skilled in the art will recognize that various improvements and modifications can still be made to the present invention without departing from the scope of the claims, and therefore will not be elaborated here.

Claims

1. A formwork for a complex curved concrete truss beam member, characterized in that: The template includes a glass fiber reinforced ABS 3D template and a UHPC reinforcement layer. The glass fiber reinforced ABS 3D template is formed by stacking several layers of glass fiber reinforced ABS 3D printed layers in the height direction. The glass fiber reinforced ABS 3D template encloses the concrete pouring space. The UHPC reinforcement layer is uniformly sprayed on the outer surface of the glass fiber reinforced ABS 3D template. The two form an integral structure.

2. The template for a complex curved concrete truss beam member according to claim 1, characterized in that: The templates include straight-edge templates and curved templates.

3. The template for a complex curved concrete truss beam member according to claim 1, characterized in that: The formwork located on both sides of the pouring space is reinforced by a U-shaped clamp at the upper end.

4. The formwork for a complex curved concrete truss beam member according to claim 1, characterized in that: The template also includes a base plate, and the template is fixed to the base plate by fasteners.

5. The template for a complex curved concrete truss beam member according to claim 4, characterized in that: The template is provided with reinforcing ribs at the positions corresponding to the fasteners, and the reinforcing ribs protrude outward from the outer surface of the template.

6. The template for a complex curved concrete truss beam member according to claim 4, characterized in that: The bottom of the template is provided with an outwardly extending connecting wing plate, which is connected and fixed to the base plate by a connector.

7. The template for a complex curved concrete truss beam member according to claim 4, characterized in that: The fastener is a right-angle fastener, with its vertical part fixedly connected to the template and its horizontal part fixedly connected to the base plate.

8. The template for a complex curved concrete truss beam member according to claim 1, characterized in that: An interface adhesive is applied between the glass fiber reinforced ABS 3D template and the UHPC reinforcement layer.

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