Building structures and methods for manufacturing building structures

Abstract

To provide technologies that make building structures less susceptible to the effects of moisture and other factors. [Solution] The 3D-printed house 1 includes one or more molded objects 31 manufactured by additive manufacturing using a predetermined filament. A water-repellent portion 33 having a water-repellent function is formed on at least the exterior surface of the molded object 31. This water-repellent portion 33 is composed of a first water-repellent portion 33a formed by adhering to the exterior surface and a second water-repellent portion 33b formed by penetrating into the molded object 31 through at least the layer lines created by the layering of layered bands due to the movement of the filament.

Description

Technical Field

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[0001] The present invention relates to a building structure and a method for manufacturing a building structure.

Background Art

[0002] In recent years, with the development of 3D printer technology, attempts have been made to manufacture building structures (such as houses) by laminating concrete and mortar using a 3D printer in the construction field (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] For example, if the outer wall is made of exposed concrete, the concrete will be affected by rainwater, moisture, and salt contained in the outside air. At this time, for example, there is a risk that moisture will penetrate into the indoor side. As a measure to prevent moisture intrusion, it is conceivable to apply, for example, a water repellent to the surface of the concrete to impart a water repellent function and use this as a protective film. However, the effect of the water repellent function lasts only about several months when exposed to ultraviolet rays. Therefore, improvement is desired, but in the conventional technology including the technology of Patent Document 1, such a desire cannot be sufficiently met.

[0005] The present invention has been made in view of such a situation, and an object thereof is to provide a technology that is hardly affected by moisture and the like with respect to a building structure.

Means for Solving the Problems

[0006] To achieve the above objective, a building structure according to one aspect of the present invention is: A building structure comprising one or more molded objects manufactured by additive manufacturing using a specified filament, A water-repellent portion having a water-repellent function is formed on at least the exterior surface of the molded object. The water-repellent part is A first water-repellent portion is formed by adhering to the aforementioned exterior surface, A second water-repellent portion is formed by penetration into the fabricated object through at least the layer lines created by the layering of the laminated bands due to the movement of the filament, It is composed of including the following.

[0007] Furthermore, in order to achieve the above objective, a method for manufacturing a building structure according to one aspect of the present invention is: A method for manufacturing a building structure, which includes one or more molded objects produced by additive manufacturing using a predetermined filament, A step of manufacturing the aforementioned molded object, A water-repellent portion forming step, in which a water-repellent portion having a water-repellent function is formed on at least the outer surface of the molded object, It includes, In the water-repellent portion formation step, A first water-repellent portion is formed by adhering to the aforementioned exterior surface, A second water-repellent portion is formed by penetration into the fabricated object through at least the layer lines created by the layering of the laminated bands due to the movement of the filament, The water-repellent portion is formed by including the above. [Effects of the Invention]

[0008] According to the present invention, since the structure includes a molded object that has a water-repellent function even inside, it is possible to provide a building structure that is less susceptible to the effects of moisture and other factors. [Brief explanation of the drawing]

[0009] [Figure 1] This is a cross-sectional view showing an example of the exterior wall of a 3D-printed house according to one embodiment of the building structure of the present invention. [Figure 2] This diagram illustrates an example of manufacturing (printing) an object using a 3D printer. [Figure 3] This is a front view of a 3D-printed house, an example of an architectural structure. [Figure 4] This is a cross-sectional view showing an example of the exterior wall of a 3D-printed house according to another embodiment of the present invention. [Modes for carrying out the invention]

[0010] Embodiments of the present invention will be described below. In this embodiment, a building structure (a residential building structure) manufactured by the 3D printing additive manufacturing method will be referred to as a "3D printed house" and will be denoted by reference numeral 1. The 3D printing additive manufacturing method described above refers to a manufacturing method in which, based on digital data of a building structure (which may simply be called a building), a material such as mortar (filament (material)) output from the header 71 of a 3D printer 7 (see Figure 2), described later, is layered in a predetermined direction to produce at least a part of the building structure (in this case, the fabricated object 11 that will become the exterior wall).

[0011] A "3D printer" is a device that, based on a pre-prepared 3D model (digital data, including data related to the fabricated object 11) for the manufacture of a 3D printed house 1 (see Figure 3), prints material onto a predetermined surface parallel to the XY plane (so-called horizontal plane) to form a single strip-shaped filament layer (filament layering strip), and then moves the header in the Z direction (vertical direction, Q direction described later) to print the next filament layer on top of the previous filament layer (3D printing additive manufacturing method (method related to the additive manufacturing of filaments)).

[0012] First, I will explain the exterior wall of 3D-printed house 1, referring to Figure 1. Figure 1 is a cross-sectional view showing an example of the exterior wall of a 3D-printed house according to one embodiment of the building structure of the present invention.

[0013] In the case of FIG. 1, the 3D printer house 1 is installed on the ground 2. Here, the illustration of the foundation part is omitted. The 3D printer house 1 is configured to include an outer wall 3, a roof 4 (see FIG. 3) described later, and the like.

[0014] The outer wall 3 is composed of a shaped object 31 manufactured by laminated modeling and an RC structure part 32 manufactured by placing fresh concrete in an internal cavity of the shaped object 31 described later. Note that the configuration and structure of the outer wall 3 are the same even if they are, for example, the configuration and structure of columns not shown in the drawings.

[0015] The outer wall 3 is manufactured without using a general wooden formwork. Specifically, the shaped object 31 is used as a formwork (remaining formwork), and the outer wall 3 is completed by manufacturing the RC structure part 32 with the shaped object 31.

[0016] The outer wall 3 is manufactured into a wall having a structure such that the shaped object 31 functions as a protective film for the RC structure part 32. The outer wall 3 is manufactured into a wall having a structure such that the outer wall 31a and the inner wall 31b of the shaped object 31 described later are respectively in contact with the outer surface and the inner surface of the RC structure part 32.

[0017] The RC structure part 32 is a wall made of RC construction and has a structure including a plurality of reinforcing bars not shown in the drawings. Although not particularly limited, here, a heat insulating material (not shown) is also arranged in the internal cavity of the outer wall 31a together with the reinforcing bars, and then fresh concrete is placed and manufactured. Instead of the RC structure part 32, an SRC structure of SRC construction may be adopted for the outer wall 3.

[0018] The shaped object 31 has an outer wall 31a which is the outer (outdoor side) wall of the outer wall 3, an inner wall 31b, ribs 31c (see FIG. 2) described later, and an internal cavity and the like. The object 31 is manufactured by horizontally running a strip of filament (filament layer) formed by printing, for example, mortar (in this case, mortar made by adding water to premixed mortar) from the header 71 of the 3D printer 7 (see Figure 2), which will be described later, and then stacking these strips vertically.

[0019] In the example shown in Figure 1, the outer wall 31a and inner wall 31b are manufactured in which the aforementioned strip-shaped filament layers extend in the direction perpendicular to the plane of the paper (extending from the front to the back of the paper), and these layers are stacked vertically. The lamination of these filament layers results in lamination marks (recessed portion of the uneven shape in cross-sectional view) on the outer wall 31a and the inner wall 31b, respectively.

[0020] The exterior wall 31a has an exterior surface on the outdoor side, as shown in Figure 1, which corresponds to the exterior surface of the exterior wall 3. A water-repellent portion 33, including a first water-repellent portion 33a and a second water-repellent portion 33b, is formed on the exterior surface of the outer wall 31a. The water-repellent portion 33 is formed to provide a water-repellent function to the outdoor side of the outer wall 31a (in this case, the water-repellent portion 33 is formed over the entire outdoor side of the outer wall 31a, but it may be formed only in the necessary parts).

[0021] The first water-repellent portion 33a is formed by applying a water-repellent agent (water-repellent agent) to the outdoor surface of the outer wall 31a. The second water-repellent portion 33b is formed when a water-repellent agent penetrates the interior side of the outer wall 31a (the side facing the RC structure 32) through minute gaps, etc., present in the lamination marks (not shown) created by the lamination of the filament layers (filament lamination strips) described above. Furthermore, the second water-repellent portion 33b is also formed when a water-repellent agent penetrates the outer wall 31a toward the indoor side through minute gaps or the like present on the outdoor surface of the outer wall 31a. In other words, the second water-repellent portion 33b is formed when a water-repellent agent penetrates into the interior through minute gaps or other structures present in the outer wall 31a itself.

[0022] In this embodiment, since the filament layer (filament stack) is formed by mortar, the penetration of the water-repellent agent (water-repellent agent) is better in terms of material surface compared to concrete, for example. As a result, the water-repellent agent that penetrates the interior remains there for a long period (approximately 30 to 40 years), allowing it to exhibit water-repellent properties during that time (long-term water-repellent effect is obtained).

[0023] Furthermore, when comparing hardened mortar and concrete, the penetration depth of the water-repellent agent (water-repellent agent) is 7mm to 12mm in the mortar layer (filament layer) and approximately 2mm to 5mm in concrete. As described above, by allowing the water-repellent agent to penetrate through minute gaps in the lamination marks (symbols omitted), penetration can be achieved more deeply than through surface penetration (not limited to the 7mm to 12mm mentioned above, but can penetrate "nearly 20mm" in some places).

[0024] Penetration through the lamination marks occurs at multiple lamination marks that are formed in the lamination direction (e.g., direction Q in Figure 2) of the mortar lamination zone (filament lamination zone). Therefore, the water-repellent agent that penetrates through the lamination marks not only penetrates in one direction toward the interior side of the outer wall 31a (the side facing the RC structure 32), but also penetrates between the lamination marks, i.e., in the lamination direction, so that the water-repellent agent can penetrate over a wide area and evenly.

[0025] The outer wall 31a, on which the water-repellent portion 33 is formed, allows the water-repellent agent (water-repellent agent) to penetrate over a wider area and evenly compared to concrete, thus enabling it to function as a protective film for the RC structure 32. In this embodiment, by positioning the RC structure 32 inside the molded object 31 (outer wall 31a), the molded object 31 can function as a protective film for the RC structure 32. Furthermore, by forming the water-repellent portion 33, it can function as an even more effective protective film (it can function as a protective film that blocks rainwater and moisture / salt contained in the outside air). The water-repellent portion 33 can contribute to extending the lifespan of the RC structure portion 32.

[0026] The water-repellent agent (water-repellent agent) mentioned above is preferably a silane-based penetrating water-repellent agent. The reason for this is that it becomes possible to form a painted area 34 (see Figure 4) by applying water-based paint to the surface (outside surface) of the outer wall 31a on which the water-repellent portion 33 is formed. For the water-repellent agent (water-repellent agent), Shin-Etsu Chemical Co., Ltd.'s "M Shin-Etsu Bio Water Guard M (registered trademark)" is used here. Silane-based penetrating water-repellent agents have the characteristic of penetrating deeply into porous mortar layers.

[0027] The water-repellent portion 33 is formed by spraying a water-repellent agent (water-repellent agent) onto the surface of the outer wall 31a (the exterior surface) using a sprayer. In this embodiment, the water-repellent agent (water-repellent agent) is sprayed in a predetermined amount (for example, 300 ml / m2) at intervals of several minutes, while the worker confirms that it is penetrating. There are no particular limitations, but 200 ml / m2 may also be used. A commercially available sprayer is sufficient.

[0028] The inner wall 31b is formed in the same way as the outer wall 31a (layering marks are also formed on the inner wall 31b). In this embodiment, the inner wall 31b does not have a water-repellent portion 33, but a water-repellent portion 33 may be formed as needed. As a variation, if the column is installed on the exterior side, the water-repellent portion 33 will be formed not only on one surface but on the entire circumferential surface.

[0029] In the example shown in Figure 1, first, in the "formation of molded object" step S1, an exterior wall 3 having a molded object 31 and an RC structure 32 is manufactured, and then, in the "formation of water-repellent portion" step S2, a water-repellent portion 33 is formed. By going through these steps, the construction of the 3D-printed house 1 (see Figure 3), which will be described later, will proceed.

[0030] Next, the 3D printer 7 and the fabricated object 31 will be described with reference to Figure 2. Figure 2 shows an example of the manufacturing (printing) of an object using a 3D printer.

[0031] In Figure 2, for example, a factory not shown in the diagram is equipped with a 3D printer 7 that performs additive manufacturing by printing. The 3D printer 7 can store concrete, mortar, or ceramic material in a storage section, for example, by passing it through two hoses, and then output (extrude) it as filament from the header 71. In this embodiment, mortar is used as the material.

[0032] The 3D printer 7 forms one filament layer by outputting material onto a predetermined plane parallel to the XY plane based on 3D housing data. Furthermore, it can move the header 71 in the Q direction (Z direction (vertical direction)) to print the next layer on top of the existing filament layer. The 3D printer 7 can print objects such as the exterior wall 3 31 and the roof 4 of the 3D printed house 1 (see Figure 3) by stacking multiple layers in the Q direction (Z direction (vertical direction)).

[0033] The wall-like structure 31 shown in Figure 2 has an outer wall 31a and an inner wall 31b. The structure 31 also has several ribs 31c that are substantially perpendicular to the outer wall 31a and the inner wall 31b. The molded object 31 has an internal cavity formed between the outer wall 31a and the inner wall 31b. Multiple stripes (layering stripes) are formed on the fabricated object 31 due to the layering process.

[0034] In this embodiment, a method is employed to create a double-layered wall structure using an outer wall 31a and an inner wall 31b (hereinafter referred to as the "double-layered structure method"). By employing a double-layer structure method, the outer wall 31a and inner wall 31b can be used as formwork to manufacture the RC structural part 32 in the internal cavity. Furthermore, by employing a double-layer structure, the outer wall 31a and inner wall 31b can function as protective films for the RC structure 32. Furthermore, by adopting a double-layer structure, insulation material can be inserted between the outer wall 31a and the inner wall 31b to enhance both thermal insulation and soundproofing effects.

[0035] The fabricated object 31 shown in Figure 2 has multiple openings 31d. This opening 31d is formed, for example, as a frame-like portion for installing reinforced concrete columns (or as a structural portion into which special mortar, which serves as a substitute for reinforced concrete, is injected (effective as a portion that meets building codes)).

[0036] Next, we will explain the 3D-printed house 1 with reference to Figure 3. Figure 3 is a front view of a 3D-printed house, which is an example of an architectural structure.

[0037] In Figure 3, the 3D-printed house 1 is constructed with an exterior wall 3 and a roof 4 as its frame. In addition to the frame, the 3D-printed house 1 is also equipped with a door 5 and windows 6. The exterior wall 3 has a water-repellent portion 33 formed on it, which includes a first water-repellent portion 33a and a second water-repellent portion 33b as shown in Figure 1. Due to the formation of the water-repellent section 33, no rain streaks are visible after the construction of the 3D-printed house 1 (when the painted section 34, described later, is formed, the gloss of the paint is maintained and there is no dirt. More specifically, in a facility built near the sea, the gloss of the paint is maintained and it remains clean even several months after completion). Furthermore, if the water-repellent portion 33 is not formed (no water-repellent portion), moisture and dirt will accumulate in the lamination marks, causing rainwater to run down (and also causing moss to grow).

[0038] Next, with reference to Figure 4, we will describe the exterior wall of a 3D-printed house according to another embodiment. Figure 4 is a cross-sectional view showing an example of the exterior wall of a 3D-printed house according to another embodiment of the present invention.

[0039] The exterior wall 3 shown in Figure 4 differs from the exterior wall 3 in Figure 1 only in that a painted area 34 is formed thereon. The painted portion 34 is formed on top of the water-repellent portion 33. Specifically, the painted portion 34 is formed on the outer surface of the first water-repellent portion 33a using a water-based paint (for example, organic glass resin paint manufactured by Rock Paint Co., Ltd.) as a coating for the exterior surface.

[0040] Generally, water-based paints do not adhere to water-repellent surfaces. However, water-based paints can be applied to the first water-repellent portion 33a, which is due to the surface structure of the mortar laminate (filament laminate), thereby forming the painted portion 34. As shown in step S3 in Figure 4, the painted area 34 can be formed.

[0041] As explained above with reference to Figures 1 to 4, since the fabricated object 31 has a water-repellent function even inside, it is possible to provide a 3D-printed house 1 that is less susceptible to the effects of moisture and other factors.

[0042] Although one embodiment of the present invention and other embodiments have been described so far, the present invention is not limited to these embodiments, and any modifications, improvements, etc. that can achieve the objectives of the present invention are included in the present invention. In the above-described embodiment, the object to be printed by the 3D printer 7 was the 3D-printed house 1, but it is not limited to this, and any building will suffice. In the above-described embodiment, a water-repellent portion 33 and a painted portion 34 were formed on the exterior wall 3, but they are not limited to these and can also be formed on the roof 4.

[0043] In summary, the building structure to which the present invention applies only needs to have the following configuration, and various embodiments can be taken.

[0044] The building structures to which the present invention applies (for example, the 3D-printed house 1 in Figures 1, 3, and 4) are: A building structure comprising one or more molded objects (e.g., molded objects 31 in Figures 1, 2, and 4) manufactured by additive manufacturing using a predetermined filament (e.g., mortar made by adding water to premixed mortar), A water-repellent portion having a water-repellent function (for example, the water-repellent portion 33 in Figures 1 and 4) is formed on at least the exterior surface of the molded object (for example, the exterior surface of the outer wall 31a in Figures 1, 2 and 4), The water-repellent part is A first water-repellent portion (for example, the first water-repellent portion 33a in Figures 1 and 4, etc.) is formed by adhering to the exterior surface, A second water-repellent portion (for example, the second water-repellent portion 33b in Figures 1 and 4) is formed by penetration into the fabricated object through at least the layering marks (for example, the concave portions of the cross-sectional uneven shape shown on the outer wall 31a and the inner wall 31b) caused by the layering of the laminated band due to the movement of the filament, It is composed of, That will suffice.

[0045] As a result, since the structure includes a molded material with water-repellent properties even inside, it is possible to provide a building structure that is less susceptible to the effects of moisture and other elements. A structure with water-repellent properties extending to the interior provides long-term waterproofing. The formation of a water-repellent layer effectively blocks moisture and salt from the outside air.

[0046] Furthermore, as a coating for the exterior surface, a painted area (for example, painted area 34 in Figure 4) is formed on the outer surface of the first water-repellent part using a water-based paint. It is preferable. This overcomes the conventional limitation that water-based paints cannot adhere to water-repellent surfaces. This is because the second water-repellent layer is formed in a deeply penetrating state, preventing the surface from becoming a complete water-repellent layer, thus allowing water-based paints to adhere. The combination of water-repellent and water-based paints allows for maintaining a glossy finish while keeping surfaces clean.

[0047] Furthermore, an RC structure (for example, the RC structural part 32 in Figures 1 and 4) or a SRC structure is placed on the inner surface of the molded object (for example, the internal cavity of the molded object 31 in Figures 1 and 4). It is preferable. This creates a double protective layer between the molded object itself and the water-repellent coating, which can extend the lifespan of the concrete (RC structure).

[0048] Furthermore, the aforementioned molded object is manufactured using a construction 3D printer (for example, 3D printer 7 in Figure 2). It is preferable. This eliminates the need for compaction or low-pressure treatment like with conventional concrete, and allows for the formation of a gap structure that allows the water-repellent agent to penetrate deeply.

[0049] Furthermore, the method for manufacturing a building structure to which the present invention applies is: A method for manufacturing a building structure, which includes one or more molded objects produced by additive manufacturing using a predetermined filament, The process for manufacturing the aforementioned molded object (for example, the "formation of molded object" step S1 in Figures 1 and 4), The steps include forming a water-repellent portion having a water-repellent function on at least the outer surface of the molded object (for example, step S2 of "formation of water-repellent portion" in Figures 1 and 4), It includes, In the water-repellent portion formation step, A first water-repellent portion is formed by adhering to the aforementioned exterior surface, A second water-repellent portion is formed by penetration into the fabricated object through at least the layer lines created by the layering of the laminated bands due to the movement of the filament, The water-repellent portion is formed by including the following: That will suffice.

[0050] This allows for the creation of a building structure that is less susceptible to the effects of moisture and other elements, as it includes a molded object with water-repellent properties throughout.

[0051] Furthermore, the process includes a step of forming a painted area (for example, step S3 of "Formation of Water-Repellent Area" in Figure 4) in which a painted area is formed on the outer surface of the first water-repellent area using a water-based paint, as part of the painting of the exterior surface. It is preferable. This provides a method to overcome the conventional limitation that water-based paints cannot adhere to water-repellent surfaces.

[0052] Furthermore, the process includes a step of arranging the molded object, in which an RC structure or a SRC structure is placed on the inner surface of the molded object (for example, a step (not shown) in which a RC structure 32 is manufactured by pouring ready-mix concrete into the internal cavity of the molded object 31). It is preferable. This provides a method that extends the lifespan of concrete (RC structures) by creating a double protective layer consisting of the molded object itself and the water-repellent portion.

[0053] Furthermore, in the step of forming the water-repellent portion, a silane-based penetrating water-repellent agent is used to form the water-repellent portion. It is preferable. This allows for the use of silane-based penetrating water-repellent agents, which have the characteristic of deeply penetrating the interior of molded structures, to extend the lifespan of concrete (RC structures).

[0054] Furthermore, in the step of forming the water-repellent portion, the water-repellent portion is formed by spraying a predetermined amount (for example, 300 ml / m2, etc.) of the silane-based penetrating water-repellent agent per predetermined area toward the exterior surface using a sprayer. It is preferable. This allows for the adhesion of water-based paints by avoiding excessive spraying and preventing excessive water-repellent residue from remaining on the surface. [Explanation of Symbols]

[0055] 1. 3D Printed Houses 2...ground 3. Exterior walls 31...modeled object 31a...Outside wall 31b...Inner wall 31c... Rib 31d...Opening 32...RC structure part 33...Water-repellent section 33a...First water-repellent section 33b...Second water repellent part 34. Painting Department 4. Roof 5 doors 6... windows 7. 3D printer

Claims

1. A building structure comprising one or more molded objects manufactured by additive manufacturing using a specified filament, A water-repellent portion having a water-repellent function is formed on at least the exterior surface of the molded object. The water-repellent part is A first water-repellent portion is formed by adhering to the aforementioned exterior surface, A second water-repellent portion is formed by penetration into the fabricated object through at least the layer lines created by the layering of the laminated bands due to the movement of the filament, A building structure that includes [this element].

2. As for the coating on the exterior surface, a water-based paint coating is formed on the outer surface of the first water-repellent portion. The building structure according to claim 1.

3. A reinforced concrete (RC) structure or a steel-reinforced concrete (SRC) structure is arranged on the inner surface side of the aforementioned molded object. The building structure according to claim 1.

4. The aforementioned object is manufactured using a construction 3D printer. The building structure according to claim 1.

5. A method for manufacturing a building structure, which includes one or more molded objects produced by additive manufacturing using a predetermined filament, A step of manufacturing the aforementioned molded object, A water-repellent portion forming step, in which a water-repellent portion having a water-repellent function is formed on at least the outer surface of the molded object, It includes, In the water-repellent portion formation step, A first water-repellent portion is formed by adhering to the aforementioned exterior surface, A second water-repellent portion is formed by penetration into the fabricated object through at least the layer lines created by the layering of the laminated bands due to the movement of the filament, The water-repellent portion is formed by including the following: A method for manufacturing building structures.

6. Painted area forming step: Forming a painted area on the outer surface of the first water-repellent portion using a water-based paint as the painting of the exterior surface. A method for manufacturing a building structure according to claim 5, further comprising:

7. A step of arranging the molded object: Arranging an RC structure or a SRC structure on the inner surface of the molded object. A method for manufacturing a building structure according to claim 5, further comprising:

8. In the step of forming the water-repellent portion, a silane-based penetrating water-repellent agent is used to form the water-repellent portion. A method for manufacturing a building structure according to claim 5.

9. In the step of forming the water-repellent portion, the water-repellent portion is formed by spraying a predetermined amount of the silane-based penetrating water-repellent agent per predetermined area toward the exterior surface using a sprayer. A method for manufacturing a building structure according to claim 8.

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