Opening unit, building, and construction method of building

Abstract

To provide a useful member to form an opening in a wall of a building to be constructed in a multi-layer construction method.SOLUTION: A member is an opening unit 1 provided with: a pipe member 2 having a through hole; an outer frame member 3 surrounding an outer face of the pipe member 2 in which no through holes are opened; and a heat insulation member 4 placed between the tube member 2 and the outer frame member 3 with smaller thermal conductivity than each of those of the tube member 2 and the outer frame member 3.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to an opening unit, a building using the opening unit, and a method for constructing a building using the opening unit. [Background technology]

[0002] Conventionally, a multi-layer construction method has been known as a method for constructing buildings using cement-based materials. For example, see Patent Documents 1 and 2. The multi-layer construction method is a construction method in which wall materials are injected from a nozzle and layered to form walls. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2015-502870 [Patent Document 2] Japanese Patent Publication No. 2020-26686 Summary of the Invention [Problem to be solved by the invention]

[0004] In order to install electrical wiring, air conditioning refrigerant pipes, or ventilation components in walls constructed using the multi-layer construction method, it is necessary to open up parts of the wall. Cement is generally used as the wall material for multi-layer construction, and in multi-layer construction, holes are drilled using tools such as drills after the layered cement has hardened. However, special tools are required to drill holes in hardened cement-based materials.

[0005] An object of the present disclosure is to provide a member useful for forming an opening in the wall of a building constructed using a multi-layer construction method. [Means for solving the problem]

[0006] The opening unit according to the present disclosure comprises a pipe member having a through hole, an outer frame member surrounding the outer surface of the pipe member without the through hole, and an insulating member provided between the pipe member and the outer frame member and having a lower thermal conductivity than both the pipe member and the outer frame member. [Effects of the Invention]

[0007] The opening unit according to the present disclosure is an effective component for a multi-layer construction method in which layers of wall material are stacked. Specifically, the opening unit is placed on a stack of wall material layers stacked to a certain height, and then additional layers of wall material are stacked to form an opening in the wall without using special tools. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a front view showing an opening unit 1 according to a first embodiment; [Figure 2] FIG. 1 is a perspective view showing an opening unit 1 according to a first embodiment. [Figure 3] Schematic diagram of a system 10 for operating a robotic arm 11 to deposit layers of wall material. [Figure 4] 1 is a perspective view showing a lower part 20a of a laminated wall formed by stacking cement layers in a first step of a method for constructing a building. [Figure 5] 1 is a perspective view showing a lower portion 20a of a laminated wall on which an opening unit 1 is placed in a second step of a method for constructing a building. [Figure 6] A front view showing the process of laying cement layers in the third step of the method for constructing a building. [Figure 7] FIG. 10 is a perspective view showing a laminated wall 20 formed by stacking cement layers in a third step. [Figure 8] FIG. 10 is a front view showing the opening unit 1a according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the drawings. In the drawings and the following description, identical or substantially identical components are designated by the same reference numerals, and descriptions of components designated by the same reference numerals will not be repeated.

[0010] Embodiment 1 Fig. 1 is a front view showing an opening unit 1 according to embodiment 1, and Fig. 2 is a perspective view showing the opening unit 1. The opening unit 1 is a member having a through hole, and specifically includes a pipe member 2 and an outer frame member 3. The pipe member 2 has a through hole, and the outer frame member 3 surrounds the outer surface of the pipe member 2 that does not have a through hole.

[0011] Specifically, the outer frame member 3 is composed of a single member in which six plates are connected in a ring shape. The outer surfaces of the outer frame member 3 have a first surface 3a, a second surface 3b, a third surface 3c, a fourth surface 3d, a fifth surface 3e, and a sixth surface 3f. The outer edges of each of the surfaces 3a to 3f are rectangular. The first surface 3a is flat. The second surface 3b is a flat, inclined surface that faces obliquely upward when the first surface 3a is facing downward. The third surface 3c faces in a different direction from the second surface 3b, and is a flat, inclined surface that faces obliquely upward when the first surface 3a is facing downward. The fourth surface 3d is a surface connected between the second surface 3b and the third surface 3c, and is a flat surface that faces in the opposite direction from the first surface 3a. The fifth surface 3e is a surface connected between the first surface 3a and the second surface 3b, and forms a flat surface that faces in one horizontal direction when the first surface 3a is facing downward. The sixth surface 3f is a surface connected between the first surface 3a and the third surface 3c, and forms a flat surface that faces in the horizontal direction opposite the one horizontal direction when the first surface 3a is facing downward. The surface behind the outer surface of the outer frame member 3 is the inner surface of the outer frame member 3. Although the outer frame member 3 is a single member, it may also be made up of six separate plates joined together.

[0012] The pipe member 2 is cylindrical, and the opening is circular. The opening shape does not have to be circular as long as the pipe structure is perforated on the inside. Here, the direction in which the through hole of the pipe member 2 extends is referred to as the "X direction," and the direction toward the back of the paper in FIG. 1 is referred to as the positive direction. The direction in which the first surface 3a and the fourth surface 3d face is referred to as the "Y direction," and the direction toward the right of the paper in FIG. 1 (the direction in which the fourth surface 3d faces) is referred to as the positive direction. The direction perpendicular to the X direction and the Y direction is referred to as the "Z direction," and the direction toward the right of the paper in FIG. 1 (the direction in which the fifth surface 3e faces) is referred to as the positive direction.

[0013] Each of the surfaces 3a to 3f of the outer frame member 3 extends in the X direction, and the outer edge of the outer frame member 3 viewed in the X direction is approximately trapezoidal. Therefore, the outer frame member 3 can also be viewed as a member extending in the X direction and having a through-hole with an approximately trapezoidal opening. The angle between the first surface 3a and the second surface 3b and the angle between the first surface 3a and the third surface 3c are the same, but may be different. The tubular member 2 is disposed in the through-hole of the outer frame member 3 and is connected to the outer frame member 3. Specifically, the outer surface of the tubular member 2 is connected to the back surfaces of the second surface 3b, the third surface 3c, and the fourth surface 3d, respectively, and is separated from the back surfaces of the first surface 3a, the fifth surface 3e, and the sixth surface 3f, respectively.

[0014] The opening unit 1 includes a heat insulating member 4 provided between a pipe member 2 and an outer frame member 3. The heat insulating member 4 fills three gaps that occur between the outer surface of the pipe member 2 and the inner surface of the outer frame member 3. The heat insulating member 4 has a lower thermal conductivity than both the pipe member 2 and the outer frame member 3, and an example of a material for the heat insulating member 4 is expanded polystyrene. The pipe member 2, the outer frame member 3, and the heat insulating member 4 have a uniform width along the X direction. Note that the pipe member 2 and the entire outer frame member 3 may be separated, with the heat insulating member 4 filling the gap between them.

[0015] The first surface 3a of the outer frame member 3 is provided with multiple spikes 5 that protrude outward in the same direction (negative Y direction). The multiple spikes 5 are spaced apart and arranged in a matrix within the first surface 3a. Therefore, flat surfaces of the first surface 3a are exposed between the spikes 5. Each spike 5 has a shape of pyramid, cone, truncated pyramid, or truncated cone, but any protruding shape is acceptable. It is preferable that the multiple spikes 5 have the same shape; here, each spike 5 is a truncated cone. The first surface 3a is a surface consisting of the outer surface of each spike 5 and the flat surface between the spikes 5. However, from another perspective, the entire first surface 3a can be considered a flat surface, and the outer surface of each spike 5 can be considered a surface separate from the first surface 3a.

[0016] The tubular member 2, outer frame member 3, and multiple spike portions 5 are made of the same material. The material is synthetic resin or metal; if it is synthetic resin, it is polypropylene, and if it is metal, it is stainless steel. If it is synthetic resin, the tubular member 2, outer frame member 3, and multiple spike portions 5 are manufactured as a single member by resin molding using a mold. In addition to resin molding, they can also be manufactured using a 3D printer. If the tubular member 2, outer frame member 3, and multiple spike portions 5 are metal, they are manufactured separately and then bonded by welding or the like. A single member is one example, and the tubular member 2, outer frame member 3, and multiple spike portions 5 may be made of different materials.

[0017] As described above, the opening unit 1 is a component having through holes opened on two surfaces facing outward in the X direction. The opening unit 1 is arranged so that the outer surface of the outer frame member 3 is embedded in the wall. The width of the opening unit 1 along the X direction is uniform and is the same as the thickness of the wall on which the opening unit 1 is arranged. On the other hand, the width of the opening unit 1 along the Z direction is greatest on the first surface 3a and smallest on the fourth surface 3d. The two surfaces of the opening unit 1 opened by the through holes in the pipe member 2 (hereinafter referred to as "opening surfaces") are exposed to the wall surface. Electrical wiring, various pipes, etc. are passed through the through holes. The heat insulating member 4 is used to suppress heat transfer between the walls and maintain the temperature inside the room.

[0018] This opening unit 1 is useful for a multi-layer construction method in which a wall is formed by stacking wall materials in multiple layers. Figure 3 is a configuration diagram showing a construction device for constructing a building using the multi-layer construction method, and in particular a system 10 for operating a robot arm 11 that supplies layers of wall material. An example of the wall material is a cement-based material.

[0019] The system 10 includes a robot arm 11, a nozzle unit 12, a material supply tube 13, a material supply unit 14, a horizontal drive unit 15, a vertical drive unit 16, and a control device 17. The material supply unit 14 stores unhardened, fluid cementitious material. The robot arm 11 receives a supply of cementitious material from the material supply unit 14 via the material supply tube 13. A nozzle unit 12 is attached to the tip of the robot arm 11, and the robot arm 11 injects a cylindrical cementitious material from the nozzle unit 12. The robot arm 11 is attached to a horizontal drive unit 15. The horizontal drive unit 15 moves the robot arm 11 horizontally. The horizontal drive unit 15 is attached to a vertical drive unit 16. The vertical drive unit 16 moves the horizontal drive unit 15 vertically. The horizontal drive unit 15 and the vertical drive unit 16 operate in coordination with signals from the control device 17 to move the robot arm 11 vertically and horizontally. This allows the robot arm 11 to move to any position within its range of motion.

[0020] According to a program installed in the control device 17, the robot arm 11 sequentially layers cementitious materials from bottom to top at a set position. The cementitious materials are layered to form the walls of a building. Hereinafter, each layer of cementitious material will be referred to as a "cement layer," and a wall formed by layering multiple cement layers will be referred to as a "layered wall."

[0021] A method for constructing a building using the multi-layer construction method will be described below. The method includes a first step, a second step, and a third step, and a laminated wall 20 is formed through the third step. The laminated wall 20 is a wall that separates the outdoors from the indoors, but it may also be a wall that separates the indoors.

[0022] In the first step, the robot arm 11 moves and stacks cement layers up to a certain height. The stack of cement layers formed in the first step is referred to as the "lower part of the laminated wall 20a." The lower part of the laminated wall 20a is a portion that will become part of the lower side of the laminated wall 20. Figure 4 is a perspective view showing the lower part of the laminated wall 20a. The illustration shows a laminated wall 20 in which six cement layers are stacked. Here, the thickness direction of the laminated wall 20 is referred to as the "U direction," the direction in which multiple cement layers are stacked is referred to as the "V direction," and the direction parallel to the laminated wall 20 is referred to as the "W direction." The U direction, V direction, and W direction are perpendicular to each other.

[0023] The lower part of the laminated wall 20a is double-layered and has a first wall and a second wall that are parallel to each other. The first wall is referred to as the exterior wall portion 21, which is the wall facing the outdoors, and the second wall is referred to as the interior wall portion 22, which is the wall facing the indoors. The lower part of the laminated wall 20a has a bridge 23. The bridge 23, which is made of six layers of cement-based material, reinforces the exterior wall portion 21 and the interior wall portion 22 and connects each layer of the exterior wall portion 21 and the interior wall portion 22 to make the building self-sustaining. Specifically, the bridge 23 is formed to extend in the W direction while traveling back and forth between the exterior wall portion 21 and the interior wall portion 22.

[0024] A placement slot 24 is provided on the upper surface of the lower laminate wall portion 20a. The placement slot 24 is a recess that is recessed downward. For example, as shown in the figure, the placement slot 24 is formed by providing a portion in the sixth, uppermost layer where no cement layer is stacked. The width of the placement slot 24 in the W direction matches the maximum width of the opening unit 1 in the Z direction. The sixth cement layer has an outer wall portion 21, an inner wall portion 22, and a bridge 23, as well as a portion that connects the outer wall portion 21 and the inner wall portion 22 along the U direction at the boundary with the placement slot 24. Once the sixth cement layer is stacked in this manner, the stacking operation is temporarily stopped and the first step is completed.

[0025] In the second step, a construction worker places the opening unit 1 in the positioning slot 24 with the first surface 3a of the opening unit 1 facing downward. The first surface 3a is a self-supporting portion that allows the opening unit 1 to stand on the upper surface of the lower laminated wall portion 20a. Figure 5 is a perspective view showing the state of the lower laminated wall portion 20a on which the opening unit 1 is placed. The fifth surface 3e and the sixth surface 3f of the opening unit 1 are fitted into the positioning slot 24. The positioning slot 24 is provided to determine the positioning position of the opening unit 1, and the positioning slot 24 allows the construction worker to easily position the opening unit 1. Because the cement layer is fluid, some of the multiple spikes 5 are inserted into the cement layer. The widths of the fifth surface 3e and the sixth surface 3f in the Y direction are configured to be approximately the same as the height of one layer of cement (the width in the V direction).

[0026] In the third step, the cement layer stacking operation is resumed. Fig. 6 is a front view showing the process of stacking cement layers from the state shown in Fig. 5. Since the second surface 3b and the third surface 3c are inclined with respect to the horizontal, the robot arm 11 and the nozzle part 12 can stack the cement layers without interfering with the opening unit 1.

[0027] The cement layer is further laminated beyond the fourth surface 3d of the outer frame member 3. FIG. 7 is a perspective view showing the laminated wall 20 formed by laminating the cement layers in the third step. The portion of the laminated wall 20 formed higher than the fourth surface 3d of the opening unit 1 is referred to as the "upper laminated wall," and the portion of the laminated wall 20 between the lower laminated wall 20a and the upper laminated wall is referred to as the "middle laminated wall." The second surface 3b and the third surface 3c are cement retaining portions that support the cement layer in the middle laminated wall. In each layer of the middle laminated wall, a cement layer is laminated on the outer wall portion 21, the inner wall portion 22, and the portion of the lower laminated wall 20a where the bridge 23 is formed, except for the portion where the opening unit 1 is located. In each layer of the middle laminated wall, a cement layer is further laminated in the U direction at the adjacent portions of the second surface 3b and the third surface 3c of the opening unit 1, connecting the outer wall portion 21 and the inner wall portion 22. The fourth surface 3d is a cement retaining portion that supports the cement layer in the upper laminated wall. In each upper layer of the laminated wall, a cement layer is laminated above the outer wall portion 21, the inner wall portion 22 and the portion where the bridge 23 is formed in the lower part of the laminated wall 20a.

[0028] The opening unit 1 is embedded in the laminated wall 20 with the opening surface exposed on the wall surface. Immediately after each cement layer is injected, gaps may occur between the cement layer and the outer frame member 3 of the opening unit 1, but the cement layer remains fluid for a while after injection, and the gaps are filled over time. After further time has passed, the cement layer hardens. After the third step, the laminated wall 20 is completed, with a double wall formed by the outer wall portion 21 and the inner wall portion 22. After that, electrical wiring, various pipes, etc. are passed through the through holes in the opening unit 1.

[0029] The outer frame member 3 of the opening unit 1 may be configured so that the fifth surface 3e and the sixth surface 3f are not provided, and the second surface 3b and the third surface 3c are continuous with the first surface 3a. Also, as long as the location where the opening unit 1 is to be placed can be accurately determined, it does not matter if the placement slot 24 is not provided in the lower part 20a of the laminated wall in the first step.

[0030] As described above, the opening unit 1, which includes the pipe member 2, outer frame member 3, and insulating member 4, is useful when constructing a building using a multi-layer construction method. The construction worker prepares the opening unit 1 in advance, places the opening unit 1 on the lower part 20a of a laminated wall where layers of wall material are stacked, and then stacks additional layers of wall material to obtain a laminated wall 20 with a through-hole. This allows the construction worker to open the laminated wall 20 without using special tools. Furthermore, the work of opening the laminated wall 20 is simply to place the opening unit 1, which reduces the construction worker's work time.

[0031] The outer frame member 3 has a second surface 3b and a third surface 3c, which are flat inclined surfaces that each face diagonally upward when the opening unit 1 is placed on the lower part 20a of the laminated wall. The robot arm 11 remains perpendicular to the ground during the lamination process, avoiding interference with the opening unit 1. Therefore, an opening can be formed in the laminated wall 20 with an inexpensive system and simple control. If the opening unit were to consist of, for example, only a pipe member 2, the robot arm 11 and nozzle portion 12 would need to be angled to avoid interference with the opening unit. In other words, an expensive robot arm 11 with many moving axes would be required.

[0032] Additionally, the first surface 3a of the outer frame member 3 is provided with a plurality of spikes 5 that protrude in the same direction. When the opening unit 1 is placed on the lower laminated wall portion 20a, some of the spikes 5 are inserted into the lower laminated wall portion 20a, allowing the opening unit 1 to be placed stably. Although the spikes 5 are arranged in a matrix, they may be arranged only along the outer wall portion 21, inner wall portion 22, and bridge 23 shown in FIG. 4, with all of the spikes 5 inserted into the lower laminated wall portion 20a. The spikes 5 are accessory components and are not necessarily required.

[0033] Embodiment 2 FIG. 8 is a front view showing an aperture unit 1a according to a second embodiment. The aperture unit 1a has the same configuration as the aperture unit 1 except that it includes an outer frame member 6 instead of the outer frame member 3. The outer frame member 6 has a different shape from the outer frame member 3. Specifically, the outer frame member 6 has a second surface 3g instead of the second surface 3b and the fifth surface 3e, and a third surface 3h instead of the third surface 3c and the sixth surface 3f. The second surface 3g is connected between the first surface 3a and the fourth surface 3d and is a stepped surface in which surfaces facing positive in the Z direction and surfaces facing positive in the Y direction alternate continuously. The third surface 3h is connected between the first surface 3a and the fourth surface 3d and is a stepped surface in which surfaces facing negative in the Z direction and surfaces facing positive in the Y direction alternate continuously. The outer frame member 6 is made of the same material as the outer frame member 3 of the aperture unit 1 and is composed of a single member.

[0034] The width of the second surface 3g along the X direction is uniform. The length of each second surface 3g facing in the positive Z direction along the Y direction is the same, which corresponds to the thickness of one cement layer along the V direction. The second surface 3g has seven steps, with one cement layer disposed on each step. The width of the third surface 3h along the X direction is uniform. The length of each third surface 3h facing in the negative Z direction along the Y direction is the same, which corresponds to the thickness of one cement layer along the V direction. The third surface 3h has seven steps, with one cement layer disposed on each step.

[0035] When constructing a building using the multi-layer construction method, the opening unit 1a is also embedded in the laminated wall 20 of the building with its opening surface exposed on the wall surface. In a second step, the lowermost positive Z-direction surface of the second surface 3g and the lowermost negative Z-direction surface of the third surface 3h are fitted into the arrangement slot 24. In a third step, when the middle portion of the laminated wall 20 is laminated, each cement layer is laminated on the positive Y-direction surface while abutting the positive Z-direction surface and the negative Z-direction surface of the second surface 3g and the third surface 3h of the opening unit 1a, respectively. The second surface 3g and the third surface 3h are cement holding portions that support the cement layers in the middle of the laminated portion.

[0036] When the opening unit 1a is used to form an opening in the laminated wall 20, the robot arm 11 can complete the lamination process while remaining perpendicular to the ground and avoiding interference with the opening unit 1a, just like the opening unit 1. In addition, compared to the case of the opening unit 1 having the inclined second and third surfaces 3b and 3c, it is possible to reduce the gap between the center of the laminated wall and the second and third surfaces 3g and 3h after the cement layer is injected.

[0037] The embodiments disclosed herein are merely illustrative, and modifications, omissions, or additions of components are possible within the scope of the claims. [Explanation of symbols]

[0038] 1, 1a Opening unit, 2 Pipe member, 3, 6 Outer frame member, 3a First surface, 3b, 3g Second surface, 3c, 3h Third surface, 3d Fourth surface, 3e Fifth surface, 3f Sixth surface, 4 Insulation material, 5 Spike portion, 10 Robot system, 11 Robot arm, 12 Nozzle portion, 13 Material supply tube, 14 Material supply portion, 15 Horizontal drive portion, 16 Vertical drive portion, 17 Control device, 20 Laminated wall, 21 Outer wall portion, 22 Inner wall portion, 23 Bridge, 24 Arrangement slot.

Claims

1. a tubular member having a through hole; an outer frame member surrounding an outer surface of the pipe member where the through hole is not formed; and a heat insulating member provided between the pipe member and the outer frame member, the heat insulating member having a lower thermal conductivity than both the pipe member and the outer frame member; An opening unit equipped with

2. The outer surface of the outer frame member is A first surface; a second surface that forms a flat inclined surface that faces obliquely upward when the first surface is directed downward; a third surface that faces in a direction different from the second surface and forms a flat inclined surface that faces obliquely upward when the first surface is directed downward; The opening unit according to claim 1 , comprising:

3. The outer surface of the outer frame member is A first surface; a stepped third surface in which one lateral surface and one upward surface are alternately continuous when the first surface is facing downward; a fourth surface in a stepped shape in which, when the first surface is facing downward, a horizontal surface facing in the opposite direction to the one horizontal surface and an upward surface are alternately successively arranged; The opening unit according to claim 1 , comprising:

4. the outer surface of the outer frame member has a first surface; The opening unit according to claim 1 , wherein the first surface is provided with a plurality of spikes that protrude in the same direction.

5. 5. The opening unit according to claim 1, wherein the pipe member and the outer frame member are made of the same material, and the material is resin or metal.

6. A wall formed by stacking multiple wall materials; and The opening unit according to claim 1 , wherein the outer surface of the outer frame member is disposed so as to be embedded in the wall. A building equipped with:

7. A wall formed by stacking multiple wall materials; and The opening unit according to any one of claims 2 to 4, wherein the first surface faces downward and the outer surface of the outer frame member is disposed so as to be embedded in the wall. A building equipped with:

8. a first step of stacking layers of wall material from below; a second step of placing the opening unit according to claim 1 on the stack formed in the first step; and A method for constructing a building, comprising a third step of laminating a layer of wall material, which is the same material as the wall material used in the first step, on the laminate and the opening unit to form a wall.

9. a first step of stacking layers of wall material from below; a second step of placing the opening unit according to claim 2 on the stack formed in the first step with the first surface facing downward; and A method for constructing a building, comprising a third step of laminating a layer of wall material, which is the same material as the wall material used in the first step, on the laminate and the opening unit to form a wall.

10. a first step of stacking layers of wall material from below; a second step of placing the opening unit according to claim 3 on the stack formed in the first step with the first surface facing downward; and A method for constructing a building, comprising a third step of laminating a layer of wall material, which is the same material as the wall material used in the first step, on the laminate and the opening unit to form a wall.

11. a first step of stacking layers of wall material from below; a second step of placing the aperture unit according to claim 4 on the laminate formed in the first step so that the plurality of spike portions are embedded in the laminate; and A method for constructing a building, comprising a third step of laminating a layer of wall material, which is the same material as the wall material used in the first step, on the laminate and the opening unit to form a wall.

12. The method for constructing a building according to any one of claims 8 to 11, wherein the wall material is a cement-based material.

13. The method for constructing a building according to any one of claims 8 to 11, wherein each of the first step and the third step includes a step of moving a robot arm horizontally and vertically to extrude and inject the wall material from a nozzle portion of the robot arm.

14. the wall includes a first wall and a second wall parallel to each other, and a bridge connecting the first wall and the second wall; The method for constructing a building according to any one of claims 8 to 11, wherein each of the first wall, the second wall and the bridge is formed by stacking layers of the wall material in the first step and the third step.

15. In the first step, a recess is provided on the top surface of the laminate, The method for constructing a building according to any one of claims 8 to 11, wherein in the second step, the opening unit is placed on the laminate so as to be inserted into the recess.

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