Method for forming molded objects, method for constructing structures, and structures

Abstract

This paper proposes a method for forming objects, a method for constructing structures, and a structure that can minimize gaps when 3D-printed objects are joined together. [Solution] A method for forming a molded object comprising an end plate installation step of installing an end plate 7, and a layering step of layering a hydraulic composition 5 extruded from a nozzle 8 while moving the nozzle 8 of a 3D printer. The tip of the nozzle 8 has a straight cylindrical body 81. The movement route of the nozzle 8 in the layering step includes an end plate adjacent section R1 in which the nozzle 8 is moved along the end plate 7. In this end plate adjacent section R1, the cylindrical body 81 is tilted so that its base end is further away from the end plate 7 than its tip, and the hydraulic composition 5 is extruded from the lower end of the cylindrical body 81 toward the end plate 7, bringing the hydraulic composition 5 into contact with the end plate 7.

Description

Technical Field

[0001] The present invention relates to a method for forming a shaped object using a 3D printer, a method for constructing a structure, and a structure.

Background Art

[0002] In recent years, in the construction industry, a structure may be formed using a 3D printer (additive manufacturing apparatus). For example, Patent Document 1 discloses a method of constructing a wall made of reinforced concrete using a 3D printer. Since the filament discharged from the nozzle is laminated in a state with rounded sides in the width direction, lamination marks (concavities and convexities) occur on the side surfaces of the member (hereinafter referred to as "shaped object") formed by the 3D printer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When constructing a structure, a plurality of shaped objects may be connected. At this time, when the lamination marks of the shaped objects are abutted against each other, gaps are generated due to the concavities and convexities. In order to reduce the gaps, it is necessary to perform surface treatment (cutting or cutting of the lamination marks) of the shaped objects or to fill the joints between the shaped objects, which is laborious.

[0005] From such a viewpoint, an object of the present invention is to propose a method for forming a shaped object, a method for constructing a structure, and a structure capable of reducing gaps when a shaped object formed by a 3D printer is abutted against another shaped object.

Means for Solving the Problems

[0006] To solve the aforementioned problems, the present invention provides a method for forming a molded object comprising a 3D printer nozzle installation step of installing a 3D printer nozzle, and a lamination step of layering a hydraulic composition (filament) extruded from the nozzle while moving the nozzle. The tip of the nozzle has a straight cylindrical body. The nozzle's movement route in the lamination step includes a section adjacent to the 3D printer nozzle, along which the nozzle is moved. In the section adjacent to the 3D printer nozzle, the cylindrical body is tilted such that its base end is further away from the 3D printer nozzle than its tip, and the hydraulic composition is extruded from the lower end of the cylindrical body toward the 3D printer nozzle. This brings the hydraulic composition into contact with the 3D printer nozzle. The present invention relates to a method for constructing a structure that utilizes a molded object formed by the above-mentioned molded object forming method, wherein multiple molded objects are joined together with their end plate sides abutting against each other.

[0007] According to this method for forming molded objects and constructing structures, by extruding the hydraulic composition (filament) so that it is in contact with the end plate, the side surface of the molded object on the end plate side becomes flat. Therefore, when the molded objects are joined together by butting them, the formation of gaps due to unevenness in the layer lines can be suppressed. In addition, in the section adjacent to the end plate where the nozzle moves along the end plate during the layering process, the nozzle is moved at an angle, so that the nozzle does not come into contact with the end plate. If the tip of the nozzle (tube) is bent, there is a risk of blockage at the bend, and the angle may shift when attaching or detaching the tube, which may reduce the molding accuracy of the molded object, but these risks can be avoided by using a straight tube. Furthermore, by extruding the hydraulic composition with the nozzle at an angle, the hydraulic composition is pressed against the end plate side, making the flatness of the side surface more certain.

[0008] Furthermore, the aforementioned movement route includes a section where the nozzle is moved at a position away from the end plate. ruIn the gap between the end plates, the hydraulic composition is not brought into contact with the end plates, thereby forming longitudinally continuous recesses on the end plate side surfaces. When constructing a structure using these molded objects, the process is carried out by an arrangement step of arranging the multiple molded objects with their end plate side surfaces abutting against each other, and a joining step of filling the recesses with a filler material. In this way, the molded objects are integrally joined via the filler material that fills the cylindrical space formed by abutting the recesses of the molded objects together, thereby constructing a structure.

[0009] Furthermore, through holes are formed horizontally in the portion of the end plate corresponding to the recess, and the joint member passing through the through holes is sandwiched between the laminate of the hydraulic composition. for The molded objects are joined together more rigidly and integrally in the horizontal direction via joint members protruding from each molded object. It is preferable that the through holes in the end plates be formed so that the joint members do not interfere with each other. [Effects of the Invention]

[0010] According to the present invention, the method for forming a molded object, the method for constructing a structure, and the structure itself can reduce the effort required when constructing a structure using multiple molded objects formed by a 3D printer. [Brief explanation of the drawing]

[0011] [Figure 1] This is a perspective view showing a structure according to an embodiment of the present invention. [Figure 2] This is a perspective view showing the sculpted object. [Figure 3] This is a perspective view showing the joint component. [Figure 4] This is a flowchart showing the procedure for constructing a structure. [Figure 5] This is a perspective view showing the process of installing the end plate. [Figure 6] This diagram shows the lamination process, where (a) is a cross-sectional view and (b) is a plan view. [Figure 7] This is a plan view showing the layout process and the concrete pouring process. [Modes for carrying out the invention]

[0012] In this embodiment, a case in which a structure 1 (for example, a wall) is constructed by combining multiple molded objects 2,2 will be described. Figure 1 shows the structure 1. As shown in Figure 1, the structure 1 consists of a pair of molded objects 2,2, a filler material 3 filled in the joint between the molded objects 2, and concrete 4 filled inside the molded objects 2. Although not shown in the figure, reinforcing bars may be placed in at least one of the filler material 3 and the concrete 4.

[0013] Figure 2 shows the fabricated object 2. As shown in Figure 2, the fabricated object 2 is formed by layering hydraulic composition 5 (filament) extruded from the nozzle of a 3D printer. The fabricated object 2 is a hollow cylindrical member. A step is provided on the side surface of the fabricated object 2 that joins with other fabricated objects 2 (butt surface). A pair of fabricated objects 2 are joined by fitting these stepped portions together. In addition, a U-shaped (or U-shaped in a plan view) recess 22 is formed on the joint surface 21 of the fabricated object 2, which is continuous in the layering direction of the hydraulic composition 5. Furthermore, a joint member 6 is provided in the recess 22, which is inserted inside and outside the fabricated object 2.

[0014] Figure 3 shows the joint member. As shown in Figure 3, the joint member 6 consists of a steel rod (including reinforcing bars and threaded rods, etc.) 61 and anchoring parts 62, 62 formed at both ends of the steel rod 61. In this embodiment, the anchoring part 62 consists of a rectangular steel plate fixed to the tip of the steel rod 61 by friction welding (mechanical anchoring). Note that the anchoring part 62 is not limited as long as it has a width greater than the diameter of the steel rod 61, and may be, for example, a circular steel plate. Also, the anchoring part 62 may be a hook or a knot formed by processing the end of the steel rod 61. Furthermore, the anchoring part 62 may be a nut or the like fixed (screwed) to the end of the steel rod 61.

[0015] Next, a method for constructing the structure 1 using the shaped object 2 will be described. The procedure of the structure construction method is shown in FIG. 4. As shown in FIG. 4, the structure construction method includes the procedures of installing ledger plates S1, laminating S2, arranging S3, joining S4, and placing S5. In the present embodiment, the shaped object 2 is formed by the procedures of installing ledger plates S1 and laminating S2 (shaped object forming method), and the structure is constructed by the procedures of arranging S3 to placing S5 using the formed shaped object 2.

[0016] FIG. 5 shows the construction status of the procedure of installing ledger plates S1. In the procedure of installing ledger plates S1, as shown in FIG. 5, ledger plates 7 are installed. The ledger plates 7 are provided on the joint surface 21 side of the shaped object 2. The ledger plates 7 of the present embodiment are made of plate materials having steps in plan view and are supported by support members 72 provided on the back surface. Further, a plurality of through holes 71 are formed in the horizontal direction in the portion of the ledger plates 7 corresponding to the concave portions 22 of the shaped object 2. The through holes 71 of the ledger plates 7 are formed at positions different from (non-overlapping positions) the through holes 71 of the ledger plates 7 used when forming other shaped objects 2 to be joined.

[0017] FIG. 6 shows the lamination process S2. In the lamination process S2, as shown in FIGS. 6(a) and (b), a hydraulic composition (filament) 5 is laminated to form the shaped object 2. The hydraulic composition 5 is discharged from the nozzle 8 while moving the nozzle 8 of the 3D printer. The nozzle 8 of the present embodiment is supported by a robot arm (not shown) so as to be movable vertically, horizontally, forward, backward, left, and right. Note that the support method and movement method of the nozzle 8 are not limited to those by the robot arm.

[0018] The nozzle 8 has a linear cylindrical body 81 at its tip. As shown in Fig. 6(b), the movement route of the nozzle 8 includes a gusset plate adjacent section R1 for moving the nozzle 8 along the gusset plate 7. That is, the gusset plate adjacent section R1 is the section corresponding to the joint surface 21 of the shaped object 2. In the gusset plate adjacent section R1, as shown in Fig. 6(a), with the cylindrical body 81 inclined, the hydraulic composition 5 is discharged from the lower end of the cylindrical body 81 toward the gusset plate 7. Specifically, the cylindrical body 81 is inclined so that the proximal end (upper end) of the cylindrical body 81 is farther from the gusset plate 7 than the distal end (lower end), and with the lower end of the cylindrical body 81 being closest to the gusset plate 7, the hydraulic composition 5 is discharged from the lower end of the cylindrical body 81 toward the gusset plate 7. Thereby, the hydraulic composition 5 is brought into contact with the gusset plate 7. On the other hand, in the movement route of the nozzle 8 in the general section R2 other than the joint surface of the shaped object 2 (other than the gusset plate adjacent section R1) (see Fig. 6(b)), with the cylindrical body 81 vertical, the hydraulic composition 5 is discharged from the lower end of the cylindrical body 81 toward the existing (directly below) hydraulic composition 5.

[0019] As shown in Fig. 6(b), the movement route of the nozzle 8 in the gusset plate adjacent section R1 along the gusset plate 7 includes a gusset plate separation section R3 for moving the nozzle 8 away from the gusset plate 7. In the gusset plate separation section R3, the tip of the nozzle 8 is moved in a U-shaped (or C-shaped) manner in plan view, and by not bringing the hydraulic composition 5 into contact with the gusset plate 7, a concave portion 22 that is continuous in the vertical direction is formed on the surface on the gusset plate 7 side.

[0020] As shown in Fig. 6(a), in the lamination step S2, with the joint member 6 penetrating the through hole 71, the hydraulic composition 5 is laminated. Thereby, the joint member 6 is provided in the concave portion 22 in a state of being sandwiched between the upper and lower laminates (hydraulic composition 5). After forming the shaped object 2, it is cured until the desired strength is manifested.

[0021] Fig. 7 shows the placement step S3 to the placing step S5. In the placement process S3, the molded objects 2 to be joined are placed as shown in Figure 7. The molded objects 2 are placed with their joining surfaces 21 facing each other. When the joining surfaces 21 are brought together, the recesses 22 are brought together, forming a cylindrical space extending in the vertical direction. At this time, the joint members 6 provided on each molded object 2 are positioned so as not to interfere with each other. In this embodiment, the joint members 6 are arranged alternately so as to be connected by an overlapping joint via a filler material 3. A waterproofing material (not shown) is interposed between the abutting surfaces of the joining surfaces 21 as needed. In addition, vertical reinforcement bars may be placed in the space formed by the recesses 22 as needed.

[0022] In joining step S4, as shown in Figure 7, the molded objects 2 are joined by butting their joining surfaces 21 together. Furthermore, in joining step S4, the molded objects 2 are joined by filling the cylindrical space formed by butting their respective recesses 22 together with a filler material 3. The filler material 3 is poured in such a way that it encloses the joint members 6 of both molded objects 2 that protrude into the space (cylindrical space) within the recesses 22. In this embodiment, non-shrink mortar is used as the filler material 3. However, the material constituting the filler material 3 is not limited and may be, for example, fiber-reinforced mortar.

[0023] In the concrete pouring process S5, concrete 4 is poured into the interior of the structure 2, as shown in Figure 7. The concrete 4 is poured with the base end of the joint member 6 wrapped around it. After pouring the concrete 4, it is allowed to cure until the predetermined strength is achieved. As a result, the pair of structures 2 become a continuous structure via the joint member 6.

[0024] According to the structure construction method of this embodiment, the hydraulic composition (filament) 5 is extruded so as to be in contact with the end plate 7, so the side surface of the molded object 2 on the end plate 7 side becomes flat. Therefore, when the molded objects 2 are joined together in a butt-joined state, the formation of gaps due to unevenness in the layer lines can be suppressed.

[0025] In the stacking process S2, in the section R1 adjacent to the end plate where the nozzle 8 moves along the end plate 7, the nozzle 8 is moved at an angle, thus preventing contact between the nozzle 8 and the robot arm (not shown) gripping the nozzle 8 and the end plate 7. If the cylindrical body 81 at the tip of the nozzle 8 is bent, there is a risk of blockage at the bend, or the angle may shift when attaching or detaching the cylindrical body 81, potentially reducing the yield (printing accuracy) of the molded object 2. In this embodiment, a straight cylindrical body 81 is used, thus avoiding these risks. Furthermore, by discharging the hydraulic composition 5 with the nozzle 8 at an angle, the hydraulic composition 5 is pressed against the end plate 7, ensuring more reliable flatness of the side surface.

[0026] A vertically continuous recess 22 is formed on the joint surface 21 of the molded object 2, and a filler material 3 is filled into the cylindrical space formed by butting the recesses 22 of the molded object 2 together, so that a structure 1 can be constructed in which the molded objects 2 are joined together integrally via the filler material 3. Furthermore, the molded objects 2 are joined more rigidly and integrally in the horizontal direction via the joint member 6 disposed in the recess 22.

[0027] The present invention is not limited to the embodiments described above, and each of the above-described components can be modified as appropriate without departing from the spirit of the present invention. In the above embodiment, a case in which the nozzle 8 is supported by a robot arm was described, but the support means (movement means) for the nozzle 8 is not limited, and for example, it may be supported by a support means that moves along rails provided on a frame. [Explanation of Symbols]

[0028] 1 structure 2 Sculptures 21 Joint surface 22 recess 3 Filling material 4. Concrete 5 Hydraulic composition 6 Joint Members 61 steel rod 62 Fixing section 7 Wife board 71 Through Hole 8 ノズル 81 Cylinder S1 Wife Board Installation Project S2 Layered Engineering S3 Supporting Facilities S4 Joining Engineering S5 Construction Project

Claims

1. The process of installing the end plate, The process includes a lamination step of stacking a hydraulic composition extruded from a nozzle while moving the nozzle of a 3D printer, The tip of the nozzle has a straight cylindrical body, The nozzle movement route in the lamination process includes a section adjacent to the end plate where the nozzle is moved along the end plate, and a section separated from the end plate where the nozzle is moved at a position away from the end plate. In the section adjacent to the end plate, the cylindrical body is tilted so that its base end is further away from the end plate than its tip, and the hydraulic composition is discharged from the lower end of the cylindrical body toward the end plate, bringing the hydraulic composition into contact with the end plate. In the section between the end plates, by not allowing the hydraulic composition to come into contact with the end plates, a vertically continuous recess is formed on the surface of the end plate. A horizontal through hole is formed in the portion of the end plate corresponding to the recess, A method for forming a molded object, characterized by sandwiching a joint member through the aforementioned through hole between layers of the hydraulic composition.

2. A method for constructing a structure by combining multiple molded objects, The process of installing the end plate, A lamination process in which a hydraulic composition extruded from a 3D printer nozzle is layered while the nozzle is moved, It includes a joining process for joining multiple molded objects together, The tip of the nozzle has a straight cylindrical body, The nozzle movement route in the lamination process includes a section adjacent to the end plate along which the nozzle moves. In the section adjacent to the end plate, the cylindrical body is tilted so that its base end is further away from the end plate than its tip, and the hydraulic composition is discharged from the lower end of the cylindrical body toward the end plate, bringing the hydraulic composition into contact with the end plate. A method for constructing a structure, characterized in that, in the joining step, the surfaces of the multiple molded objects on the end plate side are joined together with the end plate sides of the molded objects butted against each other.

3. A method for constructing a structure by combining a plurality of molded objects formed by the molded object forming method described in claim 1, The arrangement step involves arranging the aforementioned multiple molded objects with their end plate sides facing each other, A method for constructing a structure, characterized by comprising a joining step of filling the recess with a filler material.

4. A method for constructing a structure by combining a plurality of molded objects formed by the molded object forming method described in claim 1, The arrangement step involves arranging the aforementioned multiple molded objects with their end plate sides facing each other, The process includes a joining step of filling the recess of the molded object with a filler, A method for constructing a structure, characterized in that the end plate has through holes formed in it so that the joint members do not interfere with each other during the installation process.

5. A structure comprising multiple objects formed using a 3D printer, One of the two adjacent molded objects has a recess formed on the side facing the other molded object, and the surface that abuts against the other molded object does not have a layering mark formed by laminating the hydraulic composition. A structure characterized in that two adjacent molded objects are joined together via a filler material filled in the recess.

6. The structure according to claim 5, characterized in that a joint member is provided protruding from both molded objects into the space within the recess.

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