Method for constructing a structure and structure

Abstract

To provide a method for constructing a structure or the like capable of suitably constructing the structure.SOLUTION: An outer shell part 101 is constructed by a step of manufacturing a cylindrical base layer part 1 by laminating a molding material such as a cement-based material by a 3D printer, and a step of forming a surface layer part 2 on the outside of the base layer part 1 by spraying a spraying material such as the cement-based material on a surface of the base layer part 1. Thereafter, reinforcing bars 3 are arranged in a hollow part 102 inside the outer shell part 101, and concrete 4 is filled in the hollow part 102 to construct a column member 100.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a method for constructing a structure and to the structure. [Background technology]

[0002] When constructing a reinforced concrete structure, a formwork is constructed to pour the concrete into. Relatively rigid materials are used for the formwork, which reduces deformation during and after pouring of the concrete.

[0003] However, when the structure has curved surfaces or complex shapes, constructing the formwork is difficult and time-consuming. In addition, there has been a significant shortage of construction workers, especially carpenters, in recent years, and it is expected that it will become difficult to secure carpenters in the future.

[0004] In response to this, Patent Document 1 describes a method of constructing the skeleton by using a 3D printer to create the outer shell of the skeleton and then filling the inside with concrete, etc. This not only makes it possible to omit the conventional work of constructing formwork, but also makes it possible to easily construct skeletons with curved surfaces and complex shapes. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2019-147338 A Summary of the Invention [Problem to be solved by the invention]

[0006] When creating the outer shell of the structure using a 3D printer and filling the inside with concrete, the outer shell must function as a formwork, so it must be highly rigid and waterproof.In addition, the outer shell must be highly durable, as it will be the outermost layer of the structure when in service.

[0007] However, due to the nature of the 3D printer's modeling method, which involves discharging modeling material and layering it in layers, joints (interlayer joints) may occur between the layers in the outer shell produced by the 3D printer, which may result in weak areas in terms of rigidity, watertightness, durability, etc. In addition, since production efficiency depends on the amount of modeling material dispensed, there is also the issue that if the outer shell is made thicker to ensure rigidity, etc., a significant amount of production time is required.

[0008] The present invention has been made in consideration of the above problems, and has an object to provide a method for constructing a structure that can suitably construct a structure. [Means for solving the problem]

[0009] The first invention for solving the above-mentioned problems is a method for constructing a structure, comprising the steps of: stacking a modeling material using a 3D printer to produce a base layer; and, after the modeling material has hardened, spraying a spray material onto the surface of the base layer to form a surface layer, wherein the modeling material forms planar irregularities on the surface of the base layer to improve adhesion to the surface layer. The second invention is a method for constructing a structure, comprising the steps of: stacking a modeling material using a 3D printer to produce a base layer; after the modeling material has hardened, spraying a spraying material onto the surface of the base layer to form a surface layer; and using at least the surface layer as a formwork to pour concrete. The third invention is a method for constructing a structure, comprising the steps of: stacking a modeling material using a 3D printer to produce a base layer; and, after the modeling material has hardened, spraying a spray material onto the surface of the base layer to form a surface layer, wherein the base layer is cylindrical with a hollow portion or a part of its circumference, the surface layer is provided on the outside of the base layer, and a filling material is filled in the hollow portion inside the surface layer. The fourth invention is a method for producing a model by a 3D printer. From above A step of laminating the layers to produce a base layer, and a step of applying a layer of the layers to the surface of the base layer. From the side and forming a surface layer by spraying a spray material, wherein a plurality of the base layers and the surface layers are alternately stacked.

[0010] In this invention, a structure is constructed by spraying a spray material onto the surface of a base layer created by a 3D printer. Because the base layer is created by a 3D printer, it can be easily produced even if it has a curved surface or a complex shape, and a free-form structure can be constructed according to the shape of the base layer by the simple task of simply spraying the spray material, which can also address the shortage of construction technicians.

[0011] In addition, the joints between layers where modeling materials are layered by a 3D printer can be seamlessly covered with the spray material, making it possible to compensate for weak areas in rigidity, water stoppage, durability, etc. Furthermore, since the method of the present invention thickens the base layer produced by a 3D printer with the spray material, the minimum shape of the base layer that can stand on its own against spraying, etc. is produced by the 3D printer, and the necessary functions of the structure, such as rigidity, are satisfied by the surface layer formed by the easy-to-perform spraying work, making it possible to produce a structure with high rigidity, etc., in a short period of time.

[0012] The second invention This makes it possible to build a variety of structures, such as columns and walls with openings.

[0013] In the third invention, The base layer part In The hollow portion is cylindrical or a part of the cylindrical portion in the circumferential direction, the surface layer portion is provided outside the base layer portion, and the hollow portion inside the surface layer portion is filled with a filler. It is also possible to fill the hollow portion with the filler after disposing a reinforcing material in the hollow portion. This allows the base layer and the surface layer to be formed into a cylindrical shape or a part of the cylindrical shape in the circumferential direction with a hollow space, and a solid structure can be constructed by filling the hollow space with a filler such as concrete. Reinforcing materials for the structure such as steel bars can be inserted into the hollow space in advance.

[0014] In the fourth invention, A plurality of the base layers and the surface layers are stacked alternately. do. It is also preferable that a reinforcing material is embedded in the surface layer. This makes it possible to improve structural performance such as rigidity and strength.

[0015] The fifth invention is a method for manufacturing a 3D printer comprising: a base layer produced by laminating a modeling material for a 3D printer; and a surface layer formed on the surface of the base layer by a spray material; and a planar unevenness for improving adhesion to the surface layer is formed on the surface of the base layer by the modeling material. The thickness of the surface layer is greater than that of the base layer. The structure is characterized in that

[0016] The sixth invention is a structure comprising a base layer produced by stacking modeling material of a 3D printer, a surface layer formed on the surface of the base layer by spraying material, and concrete poured using the base layer and the surface layer as a formwork, wherein the thickness of the surface layer is greater than that of the base layer. The seventh invention is a structure having a base layer produced by layering modeling material of a 3D printer, and a surface layer formed on the surface of the base layer by spraying a material, the base layer being cylindrical with a hollow portion or a part of the cylindrical portion in the circumferential direction, the surface layer being provided on the outside of the base layer, the hollow portion inside the surface layer being filled with a filling material, and the surface layer being thicker than the base layer. 。 Effect of the Invention

[0017] The present invention can provide a method for constructing a structure that can suitably construct a structure. [Brief description of the drawings]

[0018] [Figure 1] 1A and 1B are diagrams showing an outer shell portion 101 of the pillar member 100 and a method of constructing the pillar member 100. [Diagram 2] An example of the outer shell portion 101a. [Diagram 3] An example of a pillar member 100a. [Figure 4] An example of constructing a wall member 100b having an opening 103. [Diagram 5] An example of alternating layers of base layers 1, 1a and surface layers 2, 2a. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0020] 1 is a diagram showing a method for constructing a structure according to an embodiment of the present invention. In this embodiment, the outer shell 101 of a pillar member 100 is constructed as a structure, and then a filler such as concrete 4 is filled inside the outer shell 101 to construct the pillar member 100.

[0021] Figures 1(a) to (d) show each process up to constructing the column member 100. The upper figures of Figures 1(a) to (d) are horizontal cross-sectional views taken along line aa in the lower figures, and the lower figures are vertical cross-sectional views taken along line bb in the upper figures. This also applies to Figures 2(a) and 3, which will be described later.

[0022] In this embodiment, as shown in Fig. 1(a), a cylindrical base layer 1 having a closed cross section is first produced by stacking modeling material using a 3D printer. The modeling material is discharged from a nozzle c of the 3D printer and stacked. The 3D printer is not particularly limited as long as it stacks modeling material, and for example, an extrusion-type 3D printer disclosed in Patent Document 1 can be used.

[0023] In this embodiment, a cement-based material such as mortar is used as the modeling material, and after the cement-based material of the base layer 1 hardens, the spraying material is sprayed onto the surface of the base layer 1 from the side of the base layer 1 using a spraying machine d as shown in Fig. 1(b). As a result, a surface layer 2 is formed on the outside of the base layer 1. In the example of Fig. 1, the thickness of the surface layer 2 is made larger than that of the base layer 1, but this is not limited to the above.

[0024] In this embodiment, a cement-based material such as mortar is used for the sprayed material, and by using a high-performance cement-based material such as a fiber-reinforced cement-based material, particularly an ultra-high-strength fiber-reinforced mortar, high rigidity and durability can be expected as a formwork when filling with concrete 4, and as the outermost layer of the column member 100 when in service. The surface of the sprayed material is smoothed by manual trowel finishing, for example.

[0025] As the sprayed material hardens, an outer shell portion 101 (structural body) of the pillar member 100 is constructed, which is made up of a base layer 1 and a surface layer 2. It is also possible to add a known hardening accelerator to the sprayed material in order to accelerate hardening.

[0026] In this embodiment, thereafter, as shown in Fig. 1(c), reinforcing bars 3 are placed in the hollow portion 102 inside the outer shell portion 101. The reinforcing bars 3 are reinforcing materials for the column member 100, and are, for example, preassembled as a reinforcing bar cage and inserted into the hollow portion 102. Note that instead of the reinforcing bars 3, other steel materials such as shaped steel may be used as reinforcing materials.

[0027] 1(d), the outer shell portion 101 is used as a formwork to pour and fill the hollow portion 102 with concrete 4, thereby constructing the inner portion of the pillar member 100. In this manner, the pillar member 100 (structural body) is constructed. In some cases, only a portion of the circumferential direction of the cylindrical outer shell portion 101 may be formed from the base layer 1 and the surface layer 2 by the method of this embodiment, and the remaining portion may be closed by another structural body or the like.

[0028] As described above, in this embodiment, the outer shell 101 of the pillar member 100 is constructed by spraying a spray material onto the surface of the base layer 1 produced by a 3D printer. Since the base layer 1 is produced by a 3D printer, even curved surfaces and complex shapes can be easily produced, and the outer shell 101 of a free shape that conforms to the shape of the base layer 1 can be constructed by the simple task of simply spraying the spray material, which can also address the shortage of construction technicians.

[0029] In addition, the interlayer joints of the base layer 1, which is made by layering modeling material using a 3D printer, can be seamlessly covered with sprayed material, making it possible to compensate for weak points in rigidity, water resistance, durability, etc.

[0030] Furthermore, since the method of this embodiment involves thickening the base layer 1 produced by a 3D printer by spraying material, the minimum shape of the base layer 1 that can stand on its own against spraying, etc. is produced by the 3D printer, and the necessary functions of the outer shell portion 101, such as rigidity, are satisfied by the surface layer 2 formed by an easy-to-perform spraying operation, making it possible to produce the outer shell portion 101 with high rigidity, etc., in a short period of time.

[0031] In this embodiment, the base layer 1 and the surface layer 2 form a cylindrical outer shell portion 101 having a hollow portion 102 or a part of it in the circumferential direction, and the outer shell portion 101 is used as a formwork to pour and fill the hollow portion 102 with concrete 4, thereby constructing a solid pillar member 100. In this embodiment, the outer shell portion 101 functions as a formwork when pouring the concrete 4, so formwork work is omitted, making it possible to respond even if there is a shortage of carpenters. Also, reinforcing materials for the pillar member 100, such as reinforcing bars 3, can be inserted in advance into the hollow portion 102.

[0032] However, the present invention is not limited to the above embodiment. For example, as shown in Fig. 2(a), reinforcing material 5 made of reinforcing bars or other steel materials may be placed on the outside of base layer 1, and spraying material may be sprayed to envelop them to form surface layer 2, forming outer shell portion 101a. By embedding reinforcing material 5 in surface layer 2, it is possible to improve the structural performance of outer shell portion 101a, such as the strength, and to reduce costs by lowering the grade of spraying material.

[0033] As shown in the plan view of Fig. 2(b), by providing irregularities on the outer and inner surfaces of the base layer 1 (corresponding to the upper and lower parts of Fig. 2(b), respectively), the adhesion between the base layer 1 and its outer surface layer 2, and between the base layer 1 and its inner concrete 4, may be improved. In the example of Fig. 2(b), the aforementioned reinforcing material 5 is housed in the recesses in the outer surface of the base layer 1.

[0034] In this embodiment, the pillar member 100 is constructed by pouring and filling the hollow portion 102 of the cylindrical outer shell portion 101 consisting of the base layer 1 and the surface layer 2 with concrete 4. However, it is also possible to remove the base layer 1 from the outer shell portion 101, and then use the surface layer 2 as a formwork as shown in Figure 3, and pour and fill the concrete 4 in the inner hollow portion to construct the pillar member 100a.

[0035] Furthermore, in this embodiment, the hollow portion 102 is filled with ordinary concrete 4 as a filler, but the filler is not limited to this, and improved soil, high-fluidity concrete, gravel, etc. may also be used.

[0036] In this embodiment, the base layer 1 is cylindrical, but the shape of the base layer 1 is not particularly limited as long as the spraying material can be sprayed thereon, and it may be cylindrical or rectangular, and is not limited to a cylindrical shape with a closed cross section. The shape of the base layer 1 can be freely set to construct various structures, and it is possible to construct wall members and beam members in addition to the column members 100. It is also possible to omit filling with concrete 4 and construct a structure consisting of only the base layer 1 and the surface layer 2. In this way, this embodiment can be applied to the construction of a wide range of structures.

[0037] Figure 4(a) shows an example of such a case, in which a wall member having an opening has its edge constructed from a base layer 1 and a surface layer 2. Reinforcement bars 6 of the wall member are arranged on the outside of the opening edge, and as shown in Figure 4(b), the opening edge consisting of the base layer 1 and the surface layer 2 is used as a formwork to pour concrete 7 outside of it, thereby constructing a wall member 100b (structural body) having an opening 103.

[0038] Furthermore, in this embodiment, a cement-based material is used as the modeling material when producing the base layer 1 by a 3D printer, but the modeling material is not limited to this.

[0039] The molding material can be substituted with materials other than cement-based materials as long as the amount of deformation during layering and spraying of the spraying material can be tolerated and adhesion to the spraying material and concrete 4 can be ensured. This is expected to reduce material costs and shorten hardening time. For example, resin materials that harden with ultraviolet light can be used as the molding material, making it possible to manufacture beam members that stand in the air and structures with complex shapes.

[0040] Furthermore, the sprayed material forming the surface layer 2 is not limited to cement-based materials, so long as it has pumpability during transportation, self-supporting properties after spraying, and finishability.

[0041] 5(a), a spray material is sprayed onto the surface of the wall-shaped base layer 1 to form a surface layer 2, and then a modeling material is again stacked by a 3D printer on the surface of the surface layer 2 opposite the base layer 1 to form a base layer 1a, and as shown in FIG. 5(b), a spray material is further sprayed onto the surface of the base layer 1a opposite the surface layer 2 to form a surface layer 2a, thereby stacking multiple base layers 1, 1a and surface layers 2, 2a alternately inside and outside. This can improve structural performance such as rigidity.

[0042] In the example of Fig. 5, the base layer 1a is a mesh-like member, which can reduce material costs and shorten the curing time, and can also improve adhesion to the surface layer 2a. In addition, by using materials such as resins and metals that have high tensile strength and rigidity when manufacturing the mesh-like base layer 1a, the base layer 1a functions as a tensile material, and can provide the structure with great strength and rigidity. The mesh-like base layer 1a and the surface layer 2a may be stacked one layer at a time to form a structure.

[0043] Although the preferred embodiment of the present invention has been described above with reference to the accompanying drawings, the present invention is not limited to the above examples. It is clear that a person skilled in the art can come up with various modified or altered examples within the scope of the technical ideas disclosed in this application, and it is understood that these also naturally belong to the technical scope of the present invention. [Explanation of symbols]

[0044] 1, 1a: Base layer 2, 2a: Surface layer 3, 6: Reinforced concrete 4, 7: Concrete 5: Reinforcement 100, 100a: Column member 100b: Wall component 101: Outer shell 102:Hollow part 103: Opening

Claims

1. A process of layering the modeling material using a 3D printer to create a base layer; After the molding material has hardened, a step of spraying a spray material onto a surface of the base layer to form a surface layer; having A method for constructing a structure, characterized in that the surface of the base layer has planar irregularities formed by the molding material to improve adhesion to the surface layer.

2. A process of layering the modeling material using a 3D printer to create a base layer; After the molding material has hardened, a step of spraying a spray material onto a surface of the base layer to form a surface layer; A step of pouring concrete using at least the surface layer as a formwork; A method for constructing a structure comprising the steps of:

3. A process of layering the modeling material using a 3D printer to create a base layer; After the molding material has hardened, a step of spraying a spray material onto a surface of the base layer to form a surface layer; having The base layer portion is a cylindrical portion having a hollow portion or a part of the cylindrical portion in the circumferential direction, The surface layer is provided on the outside of the base layer, A method for constructing a structure, comprising filling a hollow portion inside the surface layer with a filling material.

4. A process of layering the modeling material from above using a 3D printer to create the base layer; A step of spraying a spray material from the side onto the surface of the base layer to form a surface layer; having A method for constructing a structure, characterized in that a plurality of said base layers and said surface layers are stacked alternately.

5. 5. The method for constructing a structure according to claim 1, wherein a reinforcing material is embedded in the surface layer.

6. The base layer is made by layering 3D printer modeling materials, a surface layer formed on the surface of the base layer by a spraying material; having A planar unevenness for improving adhesion to the surface layer is formed on the surface of the base layer by the molding material; A structure characterized in that the thickness of the surface layer is greater than that of the base layer.

7. The base layer is made by layering 3D printer modeling materials, a surface layer formed on the surface of the base layer by a spraying material; Concrete poured using the base layer and the surface layer as formwork; having A structure characterized in that the thickness of the surface layer is greater than that of the base layer.

8. The base layer is made by layering 3D printer modeling materials, A surface layer portion formed on the surface of the base layer portion by a spraying material; having The base layer portion is a cylindrical portion having a hollow portion or a part of the cylindrical portion in the circumferential direction, The surface layer is provided on the outside of the base layer, A filler is filled in the hollow portion inside the surface layer portion, A structure characterized in that the thickness of the surface layer is greater than that of the base layer.

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