Decorative member and method for forming decorative member

Abstract

To provide a decorative member in which a plurality of holes communicating with the inside and the outside are formed by using a 3D printer, and a method for forming the decorative member.SOLUTION: A decorative member 1 is formed by laminating a hydraulic composition discharged from a nozzle of a 3D printer, in which a first laminate 11 in which a protrusion 21 and a recess 22 are continuously formed by meandering the nozzle and a second laminate 12 in which a recess 22 and a protrusion 21 are continuously formed by meandering the nozzle are alternately stacked in a plurality of stages, and a recess 5 is formed between the protrusions 21 of the first laminate 11 and between the protrusions 21 of the second laminate 12 in a front view. The depression 5 is surrounded by the first laminate 11 and the second laminate 12 in a plan view, and the depressions 5 adjacent to each other in the vertical direction communicate with each other.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a decorative member formed using a 3D printer and a method for forming a decorative member. [Background technology]

[0002] When forming a concrete member, it is common to pour concrete into a formwork, let it cure for a predetermined period, and then remove the formwork. However, the conventional construction method requires time and effort for assembling and removing the formwork, and for placing the necessary reinforcing bars, and it also takes time for the concrete to cure.

[0003] Therefore, by using a 3D printer (additive manufacturing device) to form parts, it is possible to eliminate the labor required for assembling and demolding molds. Also, with 3D printing, the desired shape can be created by moving the nozzle, which increases the degree of freedom in design. As shown in Patent Document 1, the present applicant has disclosed a method for forming a hollow member by laminating hydraulic compositions discharged from the nozzle of a 3D printer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 2023-167467 Summary of the Invention [Problem to be solved by the invention]

[0005] 2. Description of the Related Art In buildings and the like, a plurality of irregularities or openings may be formed on the surfaces of structural members such as pillars and walls in order to ensure aesthetic appearance and desired functionality. 3D printing involves layering hydraulic compositions ejected from a nozzle, so although it is possible to form holes that open in the vertical direction, it has been difficult to form holes that communicate with the inside and outside of the laminate.

[0006] From this perspective, the present invention aims to propose a decorative member having a plurality of holes formed therein that connect the inside and outside of a laminate using a 3D printer, and a method for forming this decorative member. [Means for solving the problem]

[0007] In order to solve the above problems, the decorative member of the present invention is formed by laminating hydraulic compositions ejected from the nozzle of a 3D printer, and a first laminate in which convex portions and concave portions are formed successively by snaking the nozzle, and a second laminate in which concave portions and convex portions are formed successively by snaking the nozzle are alternately stacked in multiple layers, the convex portions forming a back surface space that opens to the back surface side, and the concave portions forming a surface space that opens to the front surface side, and the back surface space and the surface space are connected in the vertical direction, thereby forming holes that communicate with the inside and outside.

[0008] Such decorative members have a staggered pattern of protrusions and recesses when viewed from the front, allowing the interior and exterior of the decorative member to communicate with each other. That is, even when a 3D printer (additive manufacturing device) is used, such decorative members have multiple holes that communicate with the interior and exterior.

[0009] In addition, this method for forming a decorative member includes repeating a first laminate formation step of forming a first laminate having successively formed convex portions and concave portions by discharging a hydraulic composition from a nozzle while moving the nozzle in a serpentine motion, and a second laminate formation step of forming a second laminate having successively formed concave portions and convex portions by discharging a hydraulic composition from the nozzle above the first laminate while moving the nozzle in a serpentine motion. In the second laminate formation step, the nozzle is moved so that the concave portions of the second laminate are located between the convex portions of the first laminate arranged above and below each other in a front view.

[0010] According to this method of forming a decorative member, a 3D printer (additive manufacturing device) is used to stack a first laminate and a second laminate so that the concave and convex patterns are arranged in a staggered pattern, thereby forming multiple depressions on the surface and allowing communication between the inside and outside of the decorative member through the depressions.

[0011] If the decorative member has multiple holes that connect the inside and outside of the laminate, the effects of lighting and air conditioning installed inside the decorative member (the space surrounded by the recessed and protruding portions) or on the backside of the decorative member can be dispersed. This prevents the lighting source from directly entering the line of sight and prevents the air conditioning vents from concentrating at one point. The hydraulic composition that constitutes the decorative member is preferably mortar with a vane shear strength in the range of 0.4 kPa to 1.0 kPa.

[0012] Furthermore, it is desirable that the first laminate and the second laminate are assemblies in which hydraulic compositions are laminated in multiple layers. Such a decorative member may be manufactured by forming the first laminate by laminating the hydraulic compositions multiple times by moving the nozzle so as to follow the same locus in a plan view in the first laminate-forming step, and by forming the second laminate by laminating the hydraulic compositions multiple times by moving the nozzle so as to follow the same locus in a plan view in the second laminate-forming step. [Effects of the Invention]

[0013] According to the decorative member and the method for forming the decorative member of the present invention, it is possible to use a 3D printer to provide a decorative member having a plurality of holes formed on the top, bottom, left and right sides. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a perspective view showing a decorative member according to an embodiment of the present invention. [Figure 2] FIG. [Figure 3] FIG. 10 is a front view showing the manufacturing process of the decorative member. [Figure 4] FIG. 2 is a perspective view showing a part of a hydraulic composition (filament). [Figure 5] FIG. 2 is a perspective view showing a part of the decorative member. DETAILED DESCRIPTION OF THE INVENTION

[0015] In an embodiment of the present invention, a decorative member 1 is described which is formed by stacking filaments 2 formed from a hydraulic composition discharged from the nozzle of a 3D printer, and which has holes 3 that communicate with the inside and outside of the laminate (see Fig. 1). Figs. 1 and 2 show the decorative member 1. As shown in Figs. 1 and 2, the decorative member 1 is a member attached to the periphery of a column P which is rectangular in plan view so as to surround the column P. The decorative member 1 has a plurality of holes 3, 3, ... that communicate with the inside and outside formed in a staggered pattern.

[0016] Fig. 3 shows the manufacturing process of the decorative member 1. As shown in Fig. 3, the decorative member 1 is formed by laminating filaments 2 formed from a hydraulic composition discharged from a nozzle 41 of a 3D printer 4. In this embodiment, the nozzle 41 is supported by a robot arm 42 so as to be movable up and down, front and back, and left and right.

[0017] In this embodiment, the hydraulic composition used is mortar having a vane shear strength in the range of 0.4 kPa to 1.0 kPa, measured in a hopper (not shown) immediately before printing. Fig. 4 shows a part of the filament 2. As shown in Fig. 4, the filament 2 is discharged from the nozzle 41 and has a rectangular (or oval) cross-sectional shape. The width of the filament 2 is at least twice the height, and preferably in the range of 2 to 3 times.

[0018] FIG. 5 shows a portion of the decorative member 1. As shown in FIG. 5, the decorative member 1 is formed by alternately stacking first laminates 11 and second laminates 12 in multiple layers. The first laminates 11 and the second laminates 12 are assemblies of filaments 2 stacked one above the other in three layers. The filaments 2 constituting the first laminate 11 are formed by discharging a hydraulic composition while meandering a nozzle 41 of a 3D printer. Convex portions 21 and concave portions 22 are formed continuously on the filaments 2. The filaments 2 constituting the second laminate 12 are formed by discharging a hydraulic composition while meandering a nozzle 41 so that the filaments 2 are in the opposite phase to the filaments 2 constituting the first laminate 11. The convex portions 21 are U-shaped in plan view (curved and convex toward the surface) that protrude toward the surface side of the decorative member 1, forming a back space that opens toward the back side (toward the column P in this embodiment). On the other hand, recess 22 has a U-shape in plan view (a curved shape convex toward the back side) that protrudes toward the back side of decorative member 1, and forms a surface space (depression 5) that opens toward the front side.

[0019] In the decorative member 1, recesses 5 are formed between the protrusions 21 of the first laminate 11 and between the protrusions 21 of the second laminate 12 in a front view. That is, the recesses 5 are spaces (holes) surrounded by the protrusions 21, 21 on the top, bottom, left, and right. The recesses 5 are surrounded by the first laminate 11 and the second laminate 12 in a plan view. Furthermore, the recesses 5, 5 adjacent to each other above and below across the protrusion 21 in a front view are connected to each other. That is, the upper and lower recesses 5, 5 are connected to the space on the back side (rear space) of the protrusions 21 between the recesses 5, 5, forming holes 3 that connect the inside and outside of the decorative member 1.

[0020] Next, we will explain the method for forming the decorative member 1. The decorative member 1 is formed into a predetermined shape by repeating the first laminate formation step and the second laminate formation step. In the first laminate forming step, the hydraulic composition is discharged from the nozzle 41 while the nozzle 41 is made to snake, thereby forming the first laminate 11 having continuous convex portions 21 and concave portions 22. It is preferable to confirm that the vane shear strength of the hydraulic composition in the hopper is in the range of 0.4 kPa to 1.0 kPa immediately before printing.

[0021] In the first laminate formation step, first, the hydraulic composition is discharged while the nozzle 41 is moved in a serpentine motion to form a lower filament 2 in which convex portions 21 and concave portions 22 are alternately connected. Next, directly above this filament 2, the hydraulic composition is discharged while the nozzle 41 is moved so as to follow the same trajectory in plan view as the trajectory of the nozzle 41 when forming the filament 2, thereby laminating a new filament 2 on the existing filament 2. In this embodiment, the first laminate 11 is formed by laminating the filaments 2 in three layers.

[0022] In the second laminate formation step, a second laminate 12 is formed above the first laminate 11. When forming the second laminate 12, a hydraulic composition is discharged from the nozzle 41 while the nozzle 41 is moved in a zigzag motion, thereby forming a filament 2 in which recesses 22 and protrusions 21 are continuous. In the second laminate formation step, the nozzle 41 is moved so that the recesses 22 of the second laminate 12 are positioned above the protrusions 21 of the existing first laminate 11 in a front view. In the second laminate formation step, first, a hydraulic composition is discharged while the nozzle 41 is moved in a zigzag motion, thereby forming a filament 2 in which protrusions 21 and recesses 22 are alternately connected. Next, the hydraulic composition is discharged directly above the filament 2 while the nozzle 41 is moved so as to follow the same trajectory in a plan view as the trajectory of the nozzle 41 when forming the filament 2, thereby stacking the filaments 2. In this embodiment, the second laminate 12 is formed by stacking three layers.

[0023] After the second laminate 12 is formed, the first laminate 11 is formed above the second laminate 12 (first lamination step). Similarly, the second laminate formation step and the first laminate formation step are repeated to form a decorative member 1 of a predetermined height.

[0024] According to the decorative member 1 and the method for forming the decorative member 1 of this embodiment, the recesses 5 are arranged in a staggered pattern when viewed from the front, and the interior and exterior of the decorative member 1 are in communication with each other through the recesses 5. In other words, the decorative member 1 is provided with a plurality of holes 3 that communicate with the interior and exterior of the decorative member 1, even when a 3D printer (additive manufacturing device) is used.

[0025] If decorative member 1 has multiple holes 3 that communicate with the inside and outside, it is possible to disperse the effects of lighting and air conditioning provided inside the decorative member (the space surrounded by recessed portions 22 and protruding portions 21) and on the back surface of decorative member 1. This prevents lighting sources from directly entering the line of sight and prevents air conditioning vents from concentrating at one point.

[0026] The following are experimental results of an experiment conducted to verify whether the shape of the hole 3 (depression 5) is maintained when decorative members are formed by changing the shape of the irregularities (bridge width W1 and amplitude W2) of the filament 2 and the number of layers. Table 1 shows the conditions and results. In this experiment, a single layer of filament 2 (case 1), three layers of filament 2 (cases 2 and 3), and five layers of filament 2 (cases 4 and 5) were compared. Tables 1 to 3 show the results. In cases 1 to 3, the cross-sectional shape of the filament 2 was set to a width W = 12 mm and a height H = 5 mm, while in cases 4 and 5, the cross-sectional shape of the filament 2 was set to a width W = 25 mm and a height H = 10 mm. The "bridge width W1" is the width of the depression 5 at the transition point between the protrusions 21 and depressions 22 (the midpoint of the amplitude), as shown in Figure 5, and is given by the inner and outer dimensions of the filament 2. Further, the "total amplitude W2" is the width between the tip of the convex portion 21 and the tip of the concave portion 22, and is given by the outer and outer dimensions of the filament 2.

[0027] [Table 1]

[0028] [Table 2]

[0029] [Table 3]

[0030] In Tables 1 to 3, "◯" indicates that holes were formed, and "×" indicates that holes were not formed. As shown in Table 1, in Case 1, where the number of layers of filament 2 was one, the filament 2 sagged, and no holes were formed, regardless of the size of the bridge width. On the other hand, in Case 2, where the number of layers of filament 2 was three, as shown in Table 2, when the bridge width was 1.0 to 5.7 mm (Case 2-1 to Case 2-5), the filament 2 sagged, and no holes were formed. However, in Cases 2-6 to 2-10, where the bridge width was 6.8 mm to 11.2 mm, holes were formed. Furthermore, in Cases 4 and 5, where the number of layers of filament 2 was five, the shape of hole 3 (depression portion 5) was maintained, as shown in Table 1. Therefore, it was confirmed that the shape of hole 3 (depression portion 5) can be maintained by stacking filament 2 in multiple layers.

[0031] Next, based on the results of Table 2, further investigation was carried out into the relationship between the crosslink width of the filament 2 and the sagging of the filament 2. Table 3 shows the investigation results (Case 3) when the crosslink width was 6.0 mm or more. As shown in Table 3, when the crosslink width was within the range of 6.0 to 12.0 mm (Cases 3-1 to 3-3), it was confirmed that the shape of the depression 5 (hole 3) was maintained. On the other hand, when the crosslink width was 15 mm or more (Cases 3-4 to 3-5), the shape of the hole could not be maintained. Based on the above results, the crosslink width is preferably 0.50 to 1.25 times the width of the filament 2, and more preferably 0.5 to 1.0 times.

[0032] The present invention is not limited to the above-described embodiment, and each of the above-described components can be appropriately modified without departing from the spirit of the present invention. For example, in the above embodiment, the decorative member 1 is described as being installed on the surface of a pillar P, but the use of the decorative member 1 is not limited thereto, and it may be installed on the surface of a wall, beam, etc. Furthermore, a plurality of decorative members 1 may be connected to cover the surface of a structural member, or a single decorative member 1 may be installed on the surface of a structural member. Furthermore, the decorative member 1 is not limited to being installed on the surface of a structural member, and may be installed alone.

[0033] In the above embodiment, the nozzle 41 is described as being supported by the robot arm 42, but the support means (moving means) for the nozzle 41 is not limited thereto, and for example, the nozzle 41 may be supported by a moving support means that moves a rail provided on a frame. In the above embodiment, each laminate (first laminate 11, second laminate 12) is configured to have three layers of filaments 2 laminated together, but the number of layers of filaments 2 is not limited as long as it is two or more, and is preferably three to five layers. The vane shear strength of the filaments 2 is not limited to the range of 0.4 kPa to 1.0 kPa, as long as the filaments 2 have a strength that will not cause them to be crushed or sagged due to lamination. [Explanation of symbols]

[0034] 1 Decorative materials 11 First laminate 12 Second laminate 2 filaments 21 Convex part 22 recess 3 holes 4. 3D printer 41 nozzle 42 Robot Arm 5. Recess

Claims

1. A decorative member formed by laminating hydraulic compositions ejected from a nozzle of a 3D printer, a first laminate in which convex portions and concave portions are continuously formed by making the nozzle meander; a second laminate in which recesses and protrusions are continuously formed by meandering the nozzle, and a rear space that opens to a rear surface side is formed by the convex portion, and a front space that opens to a front surface side is formed by the concave portion, A decorative member characterized in that the rear surface space and the front surface space are connected in the vertical direction, thereby forming a hole that communicates between the inside and outside.

2. 2. The decorative member according to claim 1, wherein the first laminate and the second laminate are assemblies in which hydraulic compositions are laminated in multiple layers.

3. 3. The decorative member according to claim 1, wherein the hydraulic composition is a mortar having a vane shear strength in the range of 0.4 kPa to 1.0 kPa.

4. a first laminate forming step of forming a first laminate having convex portions and concave portions formed continuously by discharging a hydraulic composition from a nozzle while moving the nozzle in a serpentine motion; a second laminate forming step of forming a second laminate having a continuous pattern of recesses and protrusions by discharging a hydraulic composition from a nozzle while moving the nozzle in a serpentine motion above the first laminate, A method for forming a decorative member, characterized in that in the second laminate formation process, the nozzle is moved so that the concave portions of the second laminate are positioned between the convex portions of the first laminate arranged above and below when viewed from the front.

5. In the first laminate forming step, the nozzle is moved so as to follow the same trajectory in a plan view, thereby laminating the hydraulic composition a plurality of times to form a first laminate; 5. The method for forming a decorative member according to claim 4, wherein in the second laminate forming step, the second laminate is formed by laminating the hydraulic composition multiple times by moving the nozzle so as to follow the same trajectory in a plan view.

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