Surface material application method

Abstract

To provide a construction method for a facing material capable of adhering the facing material with excellent workability using an additive manufacturing device.SOLUTION: A construction method for a facing material comprises a substrate construction process of discharging a hydraulic mixture 21 from an additive manufacturing device and constructing a substrate 2 and a facing material installation process of installing the facing material 3 on a face 2f of the substrate 2 before the hydraulic mixture 21 is set. In the facing material installation process, the facing material 3 is compressed onto the face 2f of the substrate 2 to install the facing material 3, and irregularities are formed on an installation face 3b installed on the face 2f of the substrate 2 at the facing material 3.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a method for applying a surfacing material. [Background technology]

[0002] Conventionally, surface materials such as tiles that are attached to the exterior walls or pillar members of buildings are often attached to the concrete members using materials such as adhesives or mortar after the concrete members have been constructed and allowed to harden.

[0003] Meanwhile, in recent years, a method has been proposed in which a cement-based material is extruded to a predetermined location using an additive manufacturing device or the like to construct a structure (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 6058685 Summary of the Invention [Problem to be solved by the invention]

[0005] Conventional methods for applying surface materials have the problem that it takes time to attach the surface material to the concrete member after the concrete member has set. In addition, if a structure is used for a long period of time, tiles may come loose or fall off, necessitating repair and other maintenance work, which incurs maintenance costs.

[0006] Therefore, the present invention has been made in consideration of the above circumstances, and provides a method for applying a surface material that can attach a surface material with good workability using an additive manufacturing device. [Means for solving the problem]

[0007] In order to achieve the above object, the present invention employs the following means. That is, the method for applying a surface material according to the present invention includes a base material construction step of constructing a base material by discharging a hydraulic mixture from an additive manufacturing device, and a surface material installation step of installing a surface material on the surface of the base material before the hydraulic mixture sets. In the base material construction step, the hydraulic mixture is layered to construct the base material, and the surface material has a surface portion to be placed on the surface of the base material and an attachment portion bent from an upper portion of the surface portion, and after the attachment portion is placed on the lower layer of the hydraulic mixture, the upper layer of the hydraulic mixture is layered on the attachment portion. .

[0008] In the method for applying a surface material configured in this manner, the surface material can be placed on the surface of a substrate made of a hydraulic mixture discharged from an additive manufacturing device before the hydraulic mixture sets. Therefore, materials such as adhesives for adhering the surface material are not required, and the surface material is installed on the substrate before the hydraulic mixture sets, so the workability is good. Note that "hydraulic mixture" refers to materials that include various cement-based materials (e.g., cement paste, mortar, concrete, etc.) and geopolymer compositions. The mounting portion of the surface material is sandwiched between the lower layer of hydraulic mixture and the upper layer of hydraulic mixture, and the mounting portion is pressed against the lower layer of hydraulic mixture by the weight of the upper layer of hydraulic mixture, so that the surface material is firmly fixed to the substrate.

[0009] In the surface material application method according to the present invention, the surface material installation step may include pressing the surface material against the surface of the base material.

[0010] In the method for applying the surface material thus configured, when the surface material is placed on the surface of the base material, the surface material is pressed against the surface of the base material, so that the surface material is firmly fixed to the surface of the base material.

[0011] In the method for applying a surface material according to the present invention, the surface material may have an installation surface that is installed on the surface of the base material and has projections and recesses.

[0012] In the method for applying the surface material thus configured, the installation surface of the surface material is formed with projections and recesses, so that when the surface material is installed on the surface of the base material, the hydraulic mixture before setting enters the recesses of the installation surface, and the surface material is firmly fixed to the surface of the base material.

[0015] The method for applying the surface material according to the present invention comprises the steps of: A substrate construction process for constructing a substrate by discharging a hydraulic mixture from an additive manufacturing device, and a surface material installation process for installing a surface material on a surface of the substrate before the hydraulic mixture sets,The surface material has a surface portion to be placed on the surface of the base material, and a stud dowel provided on an installation surface of the surface portion to be installed on the surface of the base material, The stud dowel has a fixing plate portion arranged along the installation surface and a shaft portion extending from the fixing plate portion toward the base material, In the surface material installation step, the stud The shaft portion may be fixed to the hydraulic mixture.

[0016] In the method for applying the surface material thus configured, the stud dowels of the surface material are fixed in the hydraulic mixture after setting, so that the surface material is firmly fixed to the base material. Effect of the Invention

[0017] According to the method of applying a surface material of the present invention, the surface material can be applied with good workability using an additive manufacturing device. [Brief description of the drawings]

[0018] [Figure 1] FIG. 2 is a front view showing the application method of the surface material according to the first embodiment of the present invention, illustrating the base material construction step. [Diagram 2] 1 is a cross-sectional view showing a method for applying a surface material according to a first embodiment of the present invention, illustrating a surface material installation step. [Diagram 3] FIG. 11 is a front view showing a method for applying a surface material according to a second embodiment of the present invention, illustrating the surface material installation step. [Figure 4] FIG. 11 is a perspective view showing a method for applying a surface material according to a second embodiment of the present invention, illustrating a surface material installation step. [Diagram 5] 11A and 11B are a cross-sectional view and a perspective view, respectively, showing a surface material used in a method for applying a surface material according to a third embodiment of the present invention. [Figure 6] 10 is a cross-sectional view showing a method for applying a surface material according to a third embodiment of the present invention, illustrating a surface material installation step. [Figure 7] FIG. 1 illustrates an additive manufacturing device for use in a modified embodiment of the first embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] First embodiment The method for applying a surface material according to the first embodiment of the present invention will be described with reference to the drawings. In this embodiment, a case where tiles are installed on concrete will be described. The method for applying a surface material includes a base material construction process and a surface material installation process.

[0020] As shown in FIG. 1, in the base material construction step, a base material 2 is constructed using an additive manufacturing device 1. The additive manufacturing device 1 has a nozzle 11, a lifter unit 12, a self-propelled unit 13, and a hose 14. The lifter unit 12 supports the nozzle 11 and a hose 14 that supplies an unhardened (unset) concrete fluid (hydraulic mixture) 21 to the nozzle 11, and raises and lowers the nozzle 11 to a predetermined height. The self-propelled unit 13 is connected to the lifter unit 12. The self-propelled unit 13 self-propels at a predetermined location and moves the nozzle 11 in conjunction with the lifter unit 12. The concrete fluid 21 is discharged from the nozzle 11. The concrete fluid 21 is discharged from the nozzle 11 in a pushed-out manner. The configuration of the additive manufacturing device 1 is not particularly limited. The additive manufacturing device 1 may be remotely operable.

[0021] The concrete fluid 21 is discharged from the nozzle 11 and layered from bottom to top to construct the base material 2 of a predetermined shape. Note that the concrete fluid 21 may be discharged from the nozzle 11 in a spraying (jetting) manner to construct the base material 2 of a predetermined shape.

[0022] Concrete fluid 21, an example of a hydraulic mixture, is a material that includes various cement-based materials (eg, cement paste, mortar, concrete, etc.), geopolymer compositions, and the like.

[0023] As shown in FIG. 2, in the surface material installation step, a tile (surface material) 3 is installed on the surface 2f of the base material 2 using a mechanical device such as a robot arm 41.

[0024] Before the concrete fluid 21 that forms the base material 2 sets, the tile 3 is placed on the surface 2f of the base material 2. The finishing surface 3f of the tile 3 is adsorbed to a vacuum suction pad 42 provided at the tip of a robot arm 41 extending from a robot main body (not shown). The tile 3 is pressed against the surface 2f of the base material 2. Note that "before the concrete fluid 21 sets" refers to a state where the penetration resistance value measured using a penetration resistance test device in the JISA1147:2019 Concrete Setting Time Test Method is 8 N / mm 2 The situation is as follows.

[0025] A recess 31 is formed on the mounting surface 3b of the tile 3, which is placed on the surface 2f of the base material 2, and is recessed in the thickness direction of the tile 3. The formation of the recess 31 gives the mounting surface 3b of the tile 3 an uneven shape.

[0026] The unhardened concrete fluid 21 enters the recess 31 of the tile 3, and the tile 3 and the base material 2 are integrated together. Once the installation of the tile 3 is complete, the air pressure in the vacuum suction pad 42 is released, and the vacuum suction pad 42 is removed from the finishing surface 3f of the tile 3. The robot main body may be a device separate from the additive manufacturing apparatus 1, or may be attached to the additive manufacturing apparatus 1.

[0027] While the concrete fluid 21 is being layered from the bottom to the top, tiles 3 may be placed on the surface 2f of the base material 2, starting from the lower portion that has already been layered.

[0028] In the method for applying the surface material configured in this manner, the tiles 3 can be placed on the surface 2f of the substrate 2 made of the concrete fluid 21 discharged from the additive manufacturing device 1 before the concrete fluid 21 sets. Therefore, materials such as adhesives for adhering the tiles 3 are not required, and the tiles 3 are placed on the substrate 2 before the concrete fluid 21 sets, resulting in quick completion and good workability. In addition, the integrity of the substrate 2 and the tiles 3 is improved, suppressing the tile 3 from falling off.

[0029] Furthermore, when placing the tile 3 on the surface 2f of the base material 2, the tile 3 is pressed against the surface 2f of the base material 2. Thus, the tile 3 is firmly fixed to the surface 2f of the base material 2.

[0030] In addition, unevenness (ant feet) is formed on the installation surface 3b of the tile 3. Therefore, when the tile 3 is installed on the surface 2f of the base material 2, the pre-setting concrete fluid 21 enters the recesses 31 of the installation surface 3b, and the tile 3 is firmly fixed to the surface 2f of the base material 2.

[0031] Second Embodiment Next, a method for applying a surface material according to a second embodiment of the present invention will be described mainly with reference to Figures 3 and 4. In the following embodiment, parts having substantially the same configuration as those in the first embodiment are given the same reference numerals and detailed description thereof will be omitted.

[0032] As shown in Fig. 4, in this embodiment, the tile 3A has an L-shape in cross section. The tile 3A has a surface plate portion (surface portion) 33 and an attachment plate portion (attachment portion) 34. In the description of the tile 3A, the directions are defined based on the posture in which the tile 3A is placed on the base material 2. The surface plate portion 33 is formed in a plate shape. The plate surface of the surface plate portion 33 is disposed along a vertical plane. The attachment plate portion 34 is bent from the upper end portion of the surface plate portion 33 at a substantially right angle to the surface plate portion 33. The plate surface of the attachment plate portion 34 faces the up-down direction.

[0033] In the surface material installation step, the mounting plate portion 34 of the tile 3A is placed on the upper surface 2u of the lower laminate 22 formed by extruding the concrete fluid 21 (base material 2), and the surface plate portion 33 of the tile 3A is arranged on the surface 2f of the base material 2. As shown in FIG. 3, the concrete fluid 21 is then extruded onto the mounting plate portion 34 of the tile 3A to stack the upper laminate 23. The mounting plate portion 34 is sandwiched between the lower laminate 22 and the upper laminate 23, and the mounting plate portion 34 is integrated with the base material 2. Note that in FIG. 3 and FIG. 4, the lower laminate 22 is composed of two layers 22a, 22b, and the upper laminate 23 is composed of two layers 23a, 23b, but the lower laminate 22 and the upper laminate 23 may be one layer or three or more layers. The work of installing the tile 3A on the base material 2 may be performed using a robot arm 41 (see FIG. 2).

[0034] In the method for applying the surface material configured in this manner, the tiles 3A can be placed on the surface 2f of the substrate 2 made of the concrete fluid 21 discharged from the additive manufacturing device 1 before the concrete fluid 21 sets. Therefore, materials such as adhesives for adhering the tiles 3A are not required, and the tiles 3A are placed on the substrate 2 before the concrete fluid 21 sets, resulting in quick completion and good workability.

[0035] Furthermore, the mounting plate portion 34 of the tile 3 is sandwiched between the lower layer (lower laminate 22) of the concrete fluid 21 and the upper layer (upper laminate 23) of the concrete fluid 21. Thus, the mounting plate portion 34 is pressed against the lower layer of the concrete fluid 21 by the weight of the upper layer of the concrete fluid 21, and the tile 3 is firmly fixed to the base material 2. The width of the mounting plate portion 34 may be the same as or smaller than that of the tile 3A (surface plate portion 33), or may be divided into multiple portions. The mounting plate portion 34 may be a mesh-like metal plate such as expanded metal.

[0036] Third embodiment Next, a method for applying a surface material according to a third embodiment of the present invention will be described mainly with reference to FIGS.

[0037] As shown in Fig. 5, in this embodiment, the tile 3B has a surface plate portion (surface portion) 35 and a stud dowel 36. In the description of the tile 3B, the direction is defined based on the posture in which the tile 3B is installed on the base material 2 (see Fig. 6). The surface plate portion 35 is formed in a plate shape. The plate surface of the surface plate portion 35 is disposed along a vertical plane (wall surface). The stud dowel 36 includes a stud reinforcing bar, a stud bolt, a headed stud, etc.

[0038] The stud dowel 36 is provided on the installation surface 3b, which is the back surface of the surface 2f (see FIG. 6) of the base material 2 of the front plate portion 33. The stud dowel 36 has a shaft portion 36b that is stud-welded to the fixing plate portion 36a, and a head portion 36c. The fixing plate portion 36a is a steel plate formed into a plate shape. The plate surface of the fixing plate portion 36a is disposed along a vertical surface (wall surface). The fixing plate portion 36a is formed on the installation surface 3b of the front plate portion 35, disposed in the recess 35a, and fixed to the recess 35a. The shaft portion 36b extends horizontally from the fixing plate portion 36a. The shaft portion 36b is formed into a rod shape. The head portion 36c of the headed stud is provided at the tip portion of the shaft portion 36b. The diameter of the head portion 36c is larger than the diameter of the shaft portion 36b.

[0039] As shown in Fig. 6, in the surface material installation process, before the concrete fluid 21 that will become the base material 2 sets, the stud dowel 36 of the tile 3B is pushed into the concrete fluid 21 (base material 2) and the shaft 36b of the stud dowel 36 is fixed to the base material 2, thereby integrating the tile 3B and the base material 2. Alternatively, as shown in Fig. 3, the stud dowel 36 of the tile 3B may be placed on the upper surface 2u of the lower laminate 22 formed by extruding the concrete fluid 21 (base material 2). The stud dowel 36 is sandwiched between the lower laminate 22 and the upper laminate 23, and the stud dowel 36 is integrated with the base material 2.

[0040] When the base material 2 is placed on the outer periphery and concrete 26 is poured inside the base material 2, the tip of the stud dowel 36 may reach the concrete 26 and the shaft 36b and head 36c of the stud dowel 36 may be fixed into the concrete 26. When concrete 26 is not poured, the stud dowel 36 may be placed inside the base material 2 and the shaft 36b and head 36c of the stud dowel 36 may be fixed to the base material 2.

[0041] In the method for applying the surface material configured in this manner, the tiles 3B can be placed on the surface 2f of the substrate 2 made of the concrete fluid 21 discharged from the additive manufacturing device 1 before the concrete fluid 21 sets. Therefore, materials such as adhesives for adhering the tiles 3B are not required, and the tiles 3B are placed on the substrate 2 before the concrete fluid 21 sets, resulting in quick completion and good workability.

[0042] In addition, the stud dowels 36 of the tiles 3 are fixed in the concrete fluid 21 after setting, so that the tiles 3 are firmly fixed to the base material 2 .

[0043] The assembly procedures, shapes and combinations of the components, etc. shown in the above-described embodiment are merely examples, and various modifications can be made based on design requirements, etc., without departing from the spirit of the present invention.

[0044] For example, in the above embodiment, tiles are used as the surface material, but the present invention is not limited to this. The surface material is a material in which the portion to be installed on the surface of the base material is formed in a substantially flat plate shape, and may be a solar panel, a lighting panel, or the like.

[0045] Furthermore, the installation surface 3b of the tile 3 may be a smooth surface without any unevenness.

[0046] In addition, in parallel with the surface material installation step, a finishing process may be performed in which unevenness is formed on the surface 2f of the base material 2. In other words, the tiles 3 are installed on a part of the surface 2f of the base material 2, and unevenness is formed on the other part of the surface 2f of the base material 2.

[0047] For example, as shown in FIG. 7, the additive manufacturing apparatus 1A includes a finishing unit 40. The finishing unit 40 includes a first processing unit 44 and a second processing unit 49. The first processing unit 44 is a brush or the like capable of smoothing the surface 2f of the concrete fluid 21 (processing to form a first type of unevenness). The second processing unit 49 is a spatula or the like capable of scraping or piling the concrete fluid 21 from the surface 2f of the concrete fluid 21 (processing to form a second type of unevenness). By performing the finishing process using the additive manufacturing apparatus 1A, the finishing unit 40 processes the surface 2f of the base material 2 to form unevenness before the concrete fluid 21 sets. Therefore, by forming unevenness on the surface 2f of the base material 2 to create a three-dimensional decorative finish, it is possible to construct a complex and intricate artistic surface finish for the base material 2 that cannot be achieved by simply spraying the concrete fluid 21. [Explanation of symbols]

[0048] 1. Additive manufacturing equipment 2...Base material 2f…Surface 3, 3A, 3B…Tile (surface material) 3b…Installation surface 3f…plane 21...Concrete fluid (hydraulic mixture) 33,35...Surface plate part (surface part) 34...Mounting plate portion (mounting portion) 36…Stud dowel

Claims

1. A substrate construction process in which a hydraulic mixture is discharged from an additive manufacturing device to construct a substrate; A surface material installation step of installing a surface material on the surface of the base material before the hydraulic mixture sets, In the base material construction step, the hydraulic mixture is laminated to construct the base material, The surface material is A surface portion disposed on a surface of the substrate; and an attachment portion bent from an upper portion of the surface portion, A method for applying a surface material, comprising: placing the mounting portion on the lower layer of the hydraulic mixture; and then laminating an upper layer of the hydraulic mixture on top of the mounting portion.

2. A substrate construction process in which a hydraulic mixture is discharged from an additive manufacturing device to construct a substrate; A surface material installation step of installing a surface material on the surface of the base material before the hydraulic mixture sets, The surface material is A surface portion disposed on a surface of the substrate; A stud dowel is provided on a mounting surface of the surface portion that is mounted on the surface of the base material, The stud dowel is A fixing plate portion disposed along the installation surface; a shaft portion extending from the fixed plate portion toward the base material, In the surface material installation step, the shaft portion of the stud dowel is fixed to the hydraulic mixture.

3. 3. The method for applying a surface material according to claim 1, wherein the surface material applying step comprises pressing the surface material against the surface of the base material.

4. 4. The method for applying a surface material according to claim 1, wherein said surface material has a mounting surface that is mounted on the surface of said base material, said mounting surface having projections and recesses.

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