Structural member and method for manufacturing a structural member

Abstract

This provides a structural member that can be made highly durable and offers a high degree of design flexibility, as well as a method for manufacturing the structural member. [Solution] The laminate 2 is made up of multiple layers 22 made of a hydraulic mixture 21, and reinforcing wires 3 are installed between adjacent layers 23 along the lamination direction. Reinforcing wires that intersect when viewed from the lamination direction are installed between different layers, and the reinforcing wires are installed along the upper surface of the laminated layers.

Description

Technical Field

[0001] The present invention relates to a structural member and a method for manufacturing the structural member.

Background Art

[0002] Recently, additive manufacturing apparatuses such as 3D printers for manufacturing structural members by laminating materials such as cement and resin-based materials have been developed (see, for example, Patent Document 1). By automatically printing structural members with an additive manufacturing apparatus at a site, it is possible to shorten the construction period and reduce costs. Further, by using an additive manufacturing apparatus, since a mold is not used, it is possible to reduce CO2 emissions. Furthermore, since the additive manufacturing apparatus can print a free-form-form, it is possible to enhance the designability.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, current materials are mostly cement and resin-based materials, and the bending strength and tensile strength of the materials themselves are small. For this reason, additive manufacturing apparatuses mostly manufacture wall bodies by laminating and stacking materials, and it is difficult to manufacture structural members with a high strength and long span, and the degree of freedom in design is low.

[0005] Therefore, an object of the present invention is to provide a structural member that can have high strength and a high degree of freedom in design, and a method for manufacturing the structural member.

Means for Solving the Problems

[0006] To achieve the above objective, the structural member according to the present invention comprises a laminate in which a plurality of layers made of a hydraulic mixture are stacked, and reinforcing wires installed between adjacent layers along the stacking direction.

[0007] The method for manufacturing a structural member according to the present invention comprises a hydraulic mixture discharge step of dischargeing a hydraulic mixture from an additive manufacturing apparatus to laminate layers of the hydraulic mixture, and a reinforcing wire installation step of installing reinforcing wires on the layers of the hydraulic mixture, wherein in the hydraulic mixture discharge step, the reinforcing wires installed in the reinforcing wire installation step are covered with a newly laminated layer of hydraulic mixture.

[0008] In this invention, reinforcing wires are installed along the interlayers of the hydraulic mixture, allowing for high load-bearing capacity in the structural members. Furthermore, since formwork is unnecessary and there is flexibility in the shape of the layers of hydraulic mixture to be stacked and the reinforcing wires installed between the layers, there is a high degree of design freedom for the structural members.

[0009] Furthermore, in the structural member according to the present invention, the reinforcing wire is embedded in either of the adjacent layers.

[0010] Furthermore, the method for manufacturing a structural member according to the present invention includes a reinforcing wire embedding step in which the reinforcing wire is pressed into and embedded in the layer of hydraulic mixture after the reinforcing wire installation step, and in the hydraulic mixture discharge step, a layer of hydraulic mixture is laminated on top of the layer of hydraulic mixture in which the reinforcing wire was embedded in the reinforcing wire embedding step.

[0011] This configuration allows the reinforcing wires, installed along the layers of hydraulic mixture, to be embedded within the layers, thereby enabling high load-bearing capacity in the structural members. Furthermore, since formwork is unnecessary and there is flexibility in the shape of the layers of hydraulic mixture to be stacked and the reinforcing wires embedded within the layers, there is a high degree of design freedom for the structural members.

[0012] Furthermore, in the structural member according to the present invention, the reinforcing wires that intersect when viewed from the stacking direction are installed between different layers.

[0013] Moreover, in the method for manufacturing a structural member according to the present invention, in the reinforcing wire installation step, the intersecting reinforcing wires viewed from the lamination direction may be installed on different layers from each other.

[0014] With such a configuration, since the intersecting reinforcing wires do not interfere with each other when viewed from the lamination direction, the arrangement of the reinforcing wires and the embedding of the reinforcing wires by the layer of the hydraulic mixture are easy.

[0015] Moreover, in the method for manufacturing a structural member according to the present invention, in the reinforcing wire installation step, a part of the length direction of the reinforcing wire is inserted into the layer of the hydraulic mixture.

[0016] With such a configuration, the degree of freedom in arranging the reinforcing wire with respect to the layer of the hydraulic mixture can be increased.

Advantages of the Invention

[0017] According to the present invention, it is possible to increase the high strength of the structural member and increase the degree of freedom in the design of the structural member.

Brief Description of the Drawings

[0018] [Figure 1] It is a side view of a structural member according to the first embodiment of the present invention. [Figure 2] It is a cross-sectional view taken along line A-A of FIG. 1. [Figure 3] It is a cross-sectional view taken along line B-B of FIG. 1. [Figure 4] It is a side view of a structural member in which the second reinforcing bar is omitted. [Figure 5] It is a side view of a structural member in which the first reinforcing bar is omitted. [Figure 6] It is a perspective view showing the hydraulic mixture discharging step. [Figure 7] It is a perspective view showing the reinforcing wire installation step. [Figure 8] It is a perspective view showing the hydraulic mixture discharging step following FIG. 7. [Figure 9] It is a perspective view showing the reinforcing wire installation step following FIG. 8. [Figure 10]Cross-sectional view of the structural member according to the second embodiment of the present invention. [Figure 11] Perspective view showing the reinforcing wire embedding process. [Figure 12] Perspective view showing the hydraulic mixture discharging process following FIG. 11.

Mode for Carrying Out the Invention

[0019] (First Embodiment) Hereinafter, the structural member and the method for manufacturing the structural member according to the first embodiment of the present invention will be described based on FIGS. 1 to 9. As shown in FIG. 1, the structural member 1 according to the first embodiment is an RC truss beam. The structural member 1 has a concrete part 2 (laminated body) in which a plurality of layers 22 (FIG. 2) formed of a concrete material 21 (hydraulic mixture) are laminated, and reinforcing bars 3 (reinforcing wires) embedded in the concrete part 2. The reinforcing bars 3 are provided along the space between adjacent layers 22, 22 (interlayer 23) along the lamination direction. The lamination direction is the direction in which the layers 22 are laminated. In the present embodiment, the layers 22 of the concrete part 2 are laminated in the beam width direction of the structural member 1.

[0020] The structural member 1 which is a truss beam has an upper chord member 41, a lower chord member 42, and a plurality of diagonal members 43, 44. Among the plurality of diagonal members 43, 44, the diagonal members provided at both ends in the length direction of the truss beam are referred to as first diagonal members 43, and the diagonal members 44 other than the first diagonal members 43 are referred to as second diagonal members 44. The upper chord member 41 is longer in the length direction than the lower chord member 42. The structural member 1 has a trapezoidal shape when viewed from the beam width direction.

[0021] As shown in FIGS. 1 to 5, the reinforcing bars 3 have a first reinforcing bar 31 continuously provided on the upper chord member 41, the lower chord member 42, and the first diagonal members 43, 43, and a second reinforcing bar 32 provided on the second diagonal member 44. As shown in Figure 4, the first reinforcing bar 31 is provided in such a way that it forms a trapezoidal shape when the structural member 1 is viewed from the beam width direction. As shown in Figures 2 and 4, the first reinforcing bar 31 is provided in a double layer when viewed from the beam width direction, and two of these double first reinforcing bars 31 are provided spaced apart in the beam width direction.

[0022] As shown in Figure 5, the second reinforcing bar 32 has a longitudinal middle portion 321 that extends diagonally along the second diagonal member 44, one longitudinal end portion 322 that is bent and extends along the upper chord member 41, and the other longitudinal end portion 323 that is bent and extends along the lower chord member 42 or the first diagonal member 43. The second reinforcing bar 32 is bent into a Z-shape or a C-shape. One end portion 322 in the longitudinal direction of the second reinforcing bar 32 is positioned approximately at the center of the four first reinforcing bars 31 in the upper chord member 41. The other end portion 323 in the longitudinal direction of the second reinforcing bar 32 is positioned approximately at the center of the four first reinforcing bars 31 in the lower chord member 42 or the first diagonal member 43. The first reinforcing bar 31 and the second reinforcing bar 32 are positioned so as not to interfere with each other. As shown in Figure 2, the first reinforcing bar 31 located on one side in the width direction, the first reinforcing bar 31 located on the other side in the width direction, and the second reinforcing bar 32 are located in different interlayers 23 of the concrete section 2.

[0023] A method for manufacturing structural members according to the first embodiment will be described. In the first embodiment, layers 22 of the concrete portion 2 are stacked from the bottom to the top in a direction where the beam width direction of the truss beam of the structural member 1 is the vertical direction. When the structural member 1 is manufactured, one side in the beam width direction becomes the bottom end and the other side becomes the top end. The upper chord 41, lower chord 42 and multiple diagonal members 43, 44 of the truss beam of the structural member 1 are manufactured as a single unit rather than as individual members.

[0024] Of the first reinforcing bars 31, when the structural member 1 is positioned in the above orientation, the first reinforcing bar 31 positioned on the lower side will be referred to as the lower first reinforcing bar 31, and the first reinforcing bar 31 positioned on the upper side will be referred to as the upper first reinforcing bar 31. The second reinforcing bar 32 is positioned at the height between the lower first reinforcing bar 31 and the upper first reinforcing bar 31. The portion of structural member 1 shown in Figures 6 to 9, which illustrates the manufacturing method of the structural member, corresponds to the same cross-sectional position as in Figure 2 (cross-section along line AA in Figure 1).

[0025] First, as shown in Figure 6, concrete material 21 is discharged from the additive manufacturing apparatus 5 to create the lower layer 22 (hydraulic mixture discharge process). In the orientation described above, concrete material 21 is discharged and layered up to the height where the lower first reinforcing bar 31 is to be installed.

[0026] As shown in Figure 7, the lower first reinforcing bar 31 is installed along the top of the stacked layers 22 (reinforcing wire installation process). As described above, the first reinforcing bar 31 is provided on the upper chord 41, the lower chord 42, and the first diagonal member 43. Therefore, on the stacked layers 22, there are parts where the first reinforcing bar 31 is installed and parts where it is not installed.

[0027] As shown in Figure 8, concrete material 21 is discharged onto the layer 22 on which the lower first reinforcing bar 31 is installed to create a new layer 22 (hydraulic mixture discharge process). The lower first reinforcing bar 31 is covered by a layer 22 that is stacked on top of the layer 22 in which the lower first reinforcing bar 31 is installed. In the drawing, the first reinforcing bar 31 is covered by a single layer 22, but it may also be covered by multiple layers 22. After covering the lower first reinforcing bar 31 with concrete material 21, the concrete material 21 is discharged and layered up to the height where the second reinforcing bar 32 will be installed.

[0028] As shown in Figure 9, the second reinforcing bar 32 is installed along the stacked layers 22 (reinforcing wire installation process). As described above, the second reinforcing bar 32 is provided on the second diagonal member 44. Therefore, on the stacked layers 22, there are parts where the second reinforcing bar 32 is installed and parts where it is not installed.

[0029] Concrete material 21 is discharged onto the layer 22 on which the second reinforcing bar 32 is installed to create a new layer 22 (hydraulic mixture discharge process). The second reinforcing bar 32 is covered with a layer 22 that is stacked on top of the layer 22 in which the second reinforcing bar 32 is installed. The layer 22 covering the second reinforcing bar 32 may be a single layer 22 or multiple layers 22. After covering the second reinforcing bar 32 with concrete material 21, the concrete material 21 is discharged and layered up to the height where the upper first reinforcing bar 31 will be installed.

[0030] The upper first reinforcing bar 31 is installed along the stacked layers 22 (reinforcement wire installation process). Concrete material 21 is discharged onto the layer 22 on which the first reinforcing bars 31 are installed to create a new layer 22 (hydraulic mixture discharge process). The upper first reinforcing bar 31 is covered with concrete material 21. The upper first reinforcing bar 31 is covered with another layer 22, which is laid on top of the layer 22 in which the upper first reinforcing bar 31 is installed. Once the upper first reinforcing bar 31 is covered with concrete material 21, the concrete material 21 is laid up to the top edge. In this way, concrete material 21 is layered, the reinforcing bars 3 are placed along the layer 22 at the height where the reinforcing bars 3 will be placed, and the concrete material 21 is layered on top of the reinforcing bars 3 to manufacture the structural member 1.

[0031] Next, the operation and effects of the structural member and the method for manufacturing the structural member according to the first embodiment described above will be explained. In the structural member 1 and the method for manufacturing the structural member according to the first embodiment, the reinforcing bars 3 are installed along the interlayers 23 of the concrete material 21, making the structural member 1 highly load-bearing. Furthermore, since formwork is not required and there is flexibility in the shape of the layers 22 of the stacked concrete material 21 and the reinforcing bars 3 installed in the interlayers 23, there is a high degree of design freedom for the structural member 1. Furthermore, by automatically printing the structural members 1 on-site using the additive manufacturing equipment 5, construction time and costs can be reduced. In addition, since the additive manufacturing equipment 5 does not require the use of molds, CO2 emissions can be reduced.

[0032] In the structural member 1 and the method for manufacturing the structural member according to the first embodiment, the reinforcing bars 3 that intersect when viewed from the stacking direction are installed in different interlayers 23. This configuration prevents the intersecting reinforcing bars 3 from intersecting each other when viewed from the stacking direction, making it easier to arrange the reinforcing bars 3 and embed them in the concrete material 21.

[0033] (Second Embodiment) Next, the second embodiment will be described based on the attached drawings. However, the same reference numerals will be used for members and parts that are the same as or similar to those in the first embodiment described above, and their descriptions will be omitted. A description of the configuration that differs from the first embodiment will be provided. As shown in Figure 10, in the structural member 1B of the second embodiment, similar to the structural member 1 of the first embodiment, the first reinforcing bar 31 and the second reinforcing bar 32 are embedded in a concrete section 2 in which multiple layers 22 made of concrete material 21 are stacked. In the structural member 1B of the second embodiment, the reinforcing bar 3 is embedded inside the layers 22, rather than between the layers 22 made of concrete material 21.

[0034] The first reinforcing bar 31 and the second reinforcing bar 32 are positioned so as not to interfere with each other. The first reinforcing bar 31 and the second reinforcing bar 32, which intersect in the direction of lamination, are embedded in different layers 22 of the concrete section 2.

[0035] A method for manufacturing structural members according to a second embodiment will be described. In the second embodiment as well, layers 22 of the concrete portion 2 are stacked from the bottom to the top in a direction where the beam width direction of the truss beam of the structural member 1B is the vertical direction.

[0036] Of the first reinforcing bars 31, when the structural member 1 is positioned in the above orientation, the first reinforcing bar 31 positioned on the lower side will be referred to as the lower first reinforcing bar 31, and the first reinforcing bar 31 positioned on the upper side will be referred to as the upper first reinforcing bar 31. The second reinforcing bar 32 is positioned at the height between the lower first reinforcing bar 31 and the upper first reinforcing bar 31.

[0037] A method for manufacturing structural members according to a second embodiment will be described. First, similar to the first embodiment, concrete material 21 is discharged from the additive manufacturing apparatus 5 to create the lower layer 22 (hydraulic mixture discharge process, see Figure 6), and the lower first reinforcing bars 31 are installed along the stacked layer 22 (reinforcing wire installation process, see Figure 7).

[0038] Next, as shown in Figure 11, the first reinforcing bar (reinforcement wire) 31, which is installed on top of layer 22, is pushed into layer 22 and embedded (reinforcement wire embedding process). As shown in Figure 12, concrete material 21 is discharged onto the layer 22 in which the lower first reinforcing bar 31 is embedded to create a new layer 22 (hydraulic mixture discharge process). Concrete material 21 is discharged and layered up to the height where the second reinforcing bar 32 will be installed.

[0039] The second reinforcing bar 32 is installed along the stacked layers 22 (reinforcing wire installation process), and the second reinforcing bar 32 is pushed into the layers 22 and embedded (reinforcing wire embedding process). A new layer 22 is created by discharging concrete material 21 onto the layer 22 in which the second reinforcing bar 32 is embedded (hydraulic mixture discharging process). Concrete material 21 is discharged and layered up to the height where the upper first reinforcing bar 31 is to be installed. The upper first reinforcing bar 31 is installed along the stacked layers 22 (reinforcing wire installation process), and the upper first reinforcing bar 31 is pushed into the layers 22 and embedded (reinforcing wire embedding process). The upper first reinforcing bar 31 is embedded in the layer 22, and concrete material 21 is discharged onto the layer 22 to create a new layer 22 (hydraulic mixture discharge process). Structural member 1B is manufactured in this manner.

[0040] In the structural member 1B and the manufacturing method of the structural member according to the second embodiment, the reinforcing bars 3 are embedded in the layer 22 of the concrete material 21, making the structural member 1B highly load-bearing. Furthermore, since formwork is not required and there is flexibility in the shape of the layer 22 of the stacked concrete material 21 and the reinforcing bars 3 embedded in the layer 22, there is a high degree of design freedom for the structural member 1. Furthermore, by automatically printing the structural members 1 on-site using the additive manufacturing equipment 5, construction time and costs can be reduced. In addition, since the additive manufacturing equipment 5 does not require the use of molds, CO2 emissions can be reduced.

[0041] In the structural member 1B and the method for manufacturing the structural member according to the second embodiment, the reinforcing bars 3 that intersect when viewed from the stacking direction are embedded in different layers 22. This configuration prevents the intersecting reinforcing bars 3 from intersecting each other when viewed from the stacking direction, thus simplifying the placement of the reinforcing bars 3.

[0042] Although embodiments of the structural member and the method for manufacturing the structural member according to the present invention have been described above, the present invention is not limited to the embodiments described above and can be modified as appropriate without departing from the spirit of the invention. For example, in the above embodiment, the structural member 1 is a truss beam, but it may be a beam other than a truss beam, or a structural member such as a column, wall, or slab. Also, the structural member may be a member having a curved surface.

[0043] In the above embodiment, reinforcing bars 3 are installed as reinforcing wires in the structural member 1, but other reinforcing wires may be installed. As reinforcing wires, metal wires (iron, stainless steel, etc.) such as PC steel bars, strands, and wires may be installed. Alternatively, rods made of fiber-reinforced plastic may be used. The fibers used in the fiber-reinforced plastic may be glass fibers, carbon fibers, aramid fibers, polyethylene fibers, Zylon fibers, boron fibers, etc., and the plastics may be polyester resin, epoxy resin, vinyl ester resin, phenolic resin, thermoplastic resin, etc. Furthermore, in addition to wire, metal mesh and FRP mesh may also be used. The mesh may be woven or perforated metal. In the above embodiment, concrete material 21 is used as the hydraulic mixture, but materials other than concrete material 21 may also be used. Examples of hydraulic mixtures include cement-containing compositions (e.g., cement paste, mortar, concrete) and geopolymer compositions.

[0044] In the above embodiment, the intersecting reinforcing bars 3, when viewed from the stacking direction (beam width direction), are installed in different interstitial spaces 23. However, intersecting reinforcing bars 3 may be installed in the same interstitial space 23. Even when intersecting reinforcing bars 3 are installed in the same interstitial space 23, each reinforcing bar 3 is installed along the interstitial space 23.

[0045] In the above embodiment, the concrete material 21 is stacked from bottom to top with the beam width direction of the structural member 1 being the vertical direction. However, the concrete material 21 may also be stacked with the vertical direction of the beam remaining the same as the vertical direction. Even if the structural member 1 is a member other than a beam, the direction in which the concrete material 21 is stacked can be set as appropriate, as long as it intersects with the direction in which reinforcing wires such as reinforcing bars or wires extend. Reinforcing materials such as steel bars and wires may extend in a curved shape.

[0046] In the reinforcing wire installation step of the structural member manufacturing method, a portion of the reinforcing wire, such as the reinforcing bar 3, in the longitudinal direction may be inserted into a layer of hydraulic mixture such as concrete material 21. This configuration allows for greater flexibility in the placement of the reinforcing wire in relation to the layer of hydraulic mixture. [Explanation of symbols]

[0047] 1,1B Structural members 2. Concrete section (laminated structure) 3. Reinforcing bars (reinforcement wires) 5. Additive manufacturing equipment 21. Concrete materials (hydraulic mixtures) 22 layers 31. First reinforcing bar (reinforcement wire) 32. Second reinforcing bar (reinforcement wire)

Claims

1. A laminate in which multiple layers made of a hydraulic mixture are stacked, It comprises reinforcing wires installed between adjacent layers along the stacking direction, The reinforcing wires that intersect when viewed from the stacking direction are installed between different layers. The reinforcing wire is a structural member installed along the upper surface of the stacked layers.

2. The reinforcing wire comprises a first reinforcing bar and a second reinforcing bar, The structural member according to claim 1, wherein the first reinforcing bar and the second reinforcing bar are arranged in different layers and are positioned at different locations when viewed from the stacking direction.

3. The reinforcing wire comprises a first reinforcing bar and a second reinforcing bar, The first reinforcement bar and the second reinforcement bar are arranged in different layers. The laminate has portions that extend in multiple directions when viewed from the front, The first reinforcing bar is arranged along the upper surface of the layer in a portion that extends in at least one direction, The structural member according to claim 1, wherein the second reinforcing bar is arranged along the upper surface of the layer in a portion that extends in a second direction different from the first direction.

4. The structural member according to claim 2 or 3, wherein the first reinforcing bar and the second reinforcing bar have different diameters.

5. The aforementioned structural member is a truss beam, The portions extending in the first direction are the upper chord and the lower chord, The structural member according to claim 3, wherein the portion extending in the second direction is a second diagonal member, which is one of a plurality of diagonal members connecting the upper chord and the lower chord, excluding the first diagonal members provided at both ends in the longitudinal direction of the truss beam.

6. A hydraulic mixture discharge step in which a hydraulic mixture is discharged from an additive manufacturing apparatus to laminate layers of the hydraulic mixture, The process includes a reinforcing wire installation step, in which reinforcing wires are installed on the layer of the hydraulic mixture, In the hydraulic mixture discharge step, the reinforcing wires installed in the reinforcing wire installation step are covered with a newly laminated layer of hydraulic mixture. A method for manufacturing a structural member, wherein, in the reinforcing wire installation step, the reinforcing wires that intersect when viewed from the stacking direction are installed between different layers, and the reinforcing wires are installed along the upper surface of the stacked layers.

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