Method for forming structural members

Abstract

To shorten a manufacturing period of a structure member formed including a laminated structure.SOLUTION: A molding method of a structure member 10 comprises: a step of discharging a first curing material from a first nozzle (a nozzle N1) to form a laminated structure 30 in which the first curing material is vertically laminated; a step of spraying a second curing material from a second nozzle (a nozzle N2) onto the laminated structure 30 while forming the laminated structure 30 to form a sprayed portion 40 integrated with the laminated structure 30.SELECTED DRAWING: Figure 3

Description

Technical Field

[0007]

[0001] The present disclosure relates to a method for forming a structural member.

Background Art

[0002] Patent Document 1 below discloses a construction method for a concrete structure in which a mortar frame is formed by laminating fiber-containing mortar in an uncured state, and fresh concrete in an uncured state is poured into the space inside the mortar frame.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the construction method of the concrete structure of Patent Document 1 above, a mortar frame is formed by a laminated structure of mortar, and then fresh concrete is poured into the space inside the mortar frame. That is, the formation of the mortar frame and the pouring of fresh concrete are carried out separately in time. Therefore, a predetermined time is required for the construction of the concrete structure.

[0005] Here, when forming a structural member including a laminated structure, the time required to complete depends on the working speed of manufacturing the laminated structure. However, from the viewpoint of shortening the construction period and the like, even when the working speed of manufacturing the laminated structure cannot be increased, it is required to shorten the manufacturing period of the structural member.

[0006] In consideration of the above facts, an object of the present invention is to shorten the manufacturing period of a structural member formed including a laminated structure.

Means for Solving the Problems

[0007] The method for forming a structural member according to claim 1 includes vertical and horizontal reinforcement. wall reinforcement The process of making it self-supporting, and the wall reinforcement The first hardening agent is discharged from the first nozzle along the line. , on one side of the wall reinforcement While forming a stacked structure in the vertical direction, From the other side of the aforementioned wall reinforcement The second hardening agent is sprayed from the second nozzle toward the laminated structure, Wall reinforcement is embedded. The process includes forming a sprayed portion integrated with the laminated structure, The laminated structure and the sprayed portion form a wall. .

[0008] In the method for forming a structural member according to claim 1, a first hardening agent is discharged from a first nozzle and laminated to form a laminated structure. While forming the laminated structure, a second hardening agent is sprayed from a second nozzle toward the laminated structure to form a sprayed portion.

[0009] In other words, the structural member is constructed by forming the laminated structure and the sprayed portion in parallel. This makes it possible to shorten the manufacturing period of the structural member, including the laminated structure, compared to, for example, when the process of forming the laminated structure and the process of forming the sprayed portion are carried out separately.

[0010] One aspect The method for forming structural members ,before The laminated structure is stacked along the assembled reinforcing bars, the second hardening agent is sprayed onto the reinforcing bars and the laminated structure, and the sprayed portion covers the reinforcing bars.

[0011] Using only the method of laminating the first hardening material makes it difficult to form reinforced structural members. One aspect In this method for forming structural members, the second hardening agent can be sprayed onto the laminated structure through the gaps in the reinforcing bars, thereby enabling the formation of structural members with reinforcing bars.

[0012] Claim 2 The method for forming structural members is: Claim 1 In the method for forming the structural member described above, the sprayed portion is formed on one side of the laminated structure.

[0013] Claim 2 In the method for forming a structural member, the spraying portion is formed on one side of the laminated structure. Therefore, one surface of the structural member is formed by the laminated structure. As a result, the finishing leveling work of the spraying portion can be reduced. Further, since the structural member can be constructed with two nozzles (one first nozzle and one second nozzle), the required equipment can be made smaller compared to the case of using three or more nozzles.

[0014] Claim 3 The method for forming a structural member Claim 1 In the method for forming a structural member described in

[0015] Claim 3 In the method for forming a structural member, the spraying portion is formed on both sides of the laminated structure. Therefore, the structural member can be constructed with three nozzles (one first nozzle and two second nozzles), and the forming speed of the structural member can be increased compared to the case of using only two nozzles.

[0016] The method for forming a structural member according to claim 4 The process includes: a step of making reinforcing bars, including vertical and horizontal bars, self-supporting; and a step of discharging a first hardening agent from a first nozzle along the reinforcing bars to form a laminated structure in the vertical direction, while simultaneously spraying a second hardening agent from a second nozzle toward the laminated structure to cover the reinforcing bars and form a sprayed portion integrated with the laminated structure. includes two first nozzles, and the spraying portion is formed at a position sandwiched between two of the laminated structures.

[0017] Claim 4 In the method for forming a structural member, the spraying portion is formed at a position sandwiched between the laminated structures. Therefore, both surfaces of the structural member are formed by the laminated structures. As a result, the finishing leveling work of the spraying portion can be reduced.

[0018] Further, the structural member can be constructed with three nozzles (two first nozzles and one second nozzle), and the forming speed of the structural member is increased compared to the case of using only two nozzles. Furthermore, even if the viscosity of the second curing material is reduced, it is difficult to flow out because it is sandwiched between the laminated structures. Therefore, the spraying workability can be improved. The method for forming a structural member according to claim 5 is the method for forming a structural member according to claim 4, wherein the laminated structure and the sprayed portion constitute a wall, and the laminated structures on both sides form a wall surface.

Advantages of the Invention

[0019] According to the present disclosure, the manufacturing period of a structural member formed including a laminated structure can be shortened.

Brief Description of the Drawings

[0020] [Figure 1] (A) is a side view showing a structural member according to an embodiment of the present invention, and (B) is a front view. [Figure 2] (A) is a side view showing a state of forming a laminated structure in a method of forming a structural member according to an embodiment of the present invention, and (B) is a front view. [Figure 3] (A) is a side view showing a state of forming a spraying portion while forming a laminated structure in a method of forming a structural member according to an embodiment of the present invention, and (B) is a front view. [Figure 4] (A) is a side view showing a modification in which spraying portions are formed on both sides of a laminated structure in a structural member according to an embodiment of the present invention, and (B) is a side view showing a modification in which a spraying portion is formed at a position sandwiched by the laminated structure. [Figure 5] (A) is a plan view showing a modification in which a laminated structure is formed surrounding a reinforcing bar in a structural member according to an embodiment of the present invention, and (B) is a plan view showing a modification in which a laminated structure is formed inside the reinforcing bar.

Modes for Carrying Out the Invention

[0021] Hereinafter, a structural member and a method of forming the structural member according to an embodiment of the present invention will be described with reference to the drawings. Components denoted by the same reference numerals in the respective drawings mean the same components. However, unless otherwise specified in the specification, each component is not limited to one, and a plurality of them may exist.

[0022] Furthermore, explanations of redundant components and reference numerals in each drawing may be omitted. This disclosure is not limited to the following embodiments, and modifications may be made as appropriate, such as omitting components or substituting them with different components, within the scope of the purpose of this disclosure.

[0023] <Structure> Figure 1 shows a structural member 10 according to an embodiment of the present invention. The structural member 10 is a wall body formed including reinforcing bars 20, a laminated structure 30, and a sprayed coating 40.

[0024] (reinforcement bars) The reinforcing bar 20 is composed of vertical bars 22 and horizontal bars 24. Of these, the vertical bars 22 are arranged along the vertical direction and are arranged in a row at predetermined intervals in the horizontal direction along the in-plane direction of the structural member 10, which is a wall. The horizontal bars 24 are arranged along the horizontal direction along the in-plane direction of the structural member 10 and are arranged in a row at predetermined intervals in the vertical direction.

[0025] The vertical reinforcement bars 22 and horizontal reinforcement bars 24 are connected to each other using restraining bars, etc., forming a grid-like wall reinforcement. Furthermore, the vertical reinforcement bars 22 and horizontal reinforcement bars 24 are arranged on one side and the other side of the structural member 10, respectively (so-called double reinforcement).

[0026] (Laminated structure, sprayed area) The laminated structure 30 is formed by laminating layers of discharged mortar (an example of the first hardening material in the present invention). On the other hand, the sprayed section 40 is formed by sprayed mortar (an example of the second hardening material in the present invention) that covers the reinforcing bars 20.

[0027] The thickness from the surface of the reinforcing bar 20 to the surface of the laminated structure 30 (the surface opposite to the sprayed portion 40) is set to be at least the predetermined cover thickness required for the wall. Similarly, the thickness from the surface of the reinforcing bar 20 to the surface of the sprayed portion 40 (the surface opposite to the laminated structure 30) is set to be at least the predetermined cover thickness required for the wall.

[0028] In addition to mortar, concrete containing coarse aggregate can also be used as the first and second hardening materials in this invention.

[0029] <Method for forming structural members> Both the laminated structure 30 and the sprayed portion 40 of the structural member 10 are formed using a 3D printer. To form the structural member 10, first, reinforcing bars 20, including vertical bars 22 and horizontal bars 24, are arranged (assembled) as shown in Figure 2. If the reinforcing bars 20 are not self-supporting, they are reinforced as appropriate using support materials to prevent them from collapsing.

[0030] Next, mortar is discharged from the nozzle N1 of the 3D printer (an example of the first nozzle in this invention) along the reinforcing bars 20 to form a laminated structure 30 in which the discharged mortar is stacked vertically.

[0031] Furthermore, as shown in Figure 3, while forming the laminated structure 30, spray mortar is sprayed from the nozzle N2 of the 3D printer (an example of the second nozzle in this invention) toward the laminated structure 30 to increase the thickness of the laminated structure 30. This forms a sprayed section 40 that is integrated with the laminated structure 30. The spray mortar covers the reinforcing bars 20 as it is sprayed toward the laminated structure 30. The surface of the sprayed section 40 is then leveled as needed to shape the sprayed section 40.

[0032] As a result, as shown in Figure 1, a structural member 10 is formed on one side of the laminated structure 30 with sprayed mortar applied to it.

[0033] Furthermore, nozzles N1 and N2 may be provided on different 3D printers, or they may be provided on a single 3D printer, provided that they can be controlled differently from each other.

[0034] <Mechanism and Effects> In the molding method for the structural member 10 according to the embodiment of the present invention, as shown in Figure 2, discharge mortar is discharged from nozzle N1 and layered to form a laminated structure 30. Also, as shown in Figure 3, while forming the laminated structure 30, spray mortar is sprayed from nozzle N2 toward the laminated structure 30 to form a sprayed portion 40.

[0035] In other words, the structural member 10 shown in Figure 1 is constructed by forming the laminated structure 30 and the sprayed portion 40 in parallel. This makes it possible to shorten the manufacturing period of the structural member 10, which includes the laminated structure 30, compared to, for example, when the process of forming the laminated structure 30 and the process of spraying the sprayed mortar onto the laminated structure 30 are carried out separately.

[0036] Furthermore, it is difficult to form a structural member 10 containing reinforcing bars 20 using only the method of laminating discharged mortar. In the method for forming a structural member 10 according to the embodiment of the present invention, spray mortar can be sprayed onto the laminated structure 30 through the gaps in the reinforcing bars 20, thereby enabling the formation of a structural member 10 containing reinforcing bars 20.

[0037] Furthermore, in the molding method for the structural member 10 according to the embodiment of the present invention, the sprayed portion 40 is formed on one side of the laminated structure 30. Therefore, one surface of the structural member 10 is formed by the laminated structure 30. This reduces the work required for finishing and leveling the sprayed portion 40.

[0038] Furthermore, since the structural member 10 can be installed using two nozzles (one nozzle N1 and one nozzle N2), the required equipment can be made smaller compared to cases where three or more nozzles are used.

[0039] <Other Embodiments> In the molding method for the structural member 10 according to the above embodiment, the sprayed portion 40 is formed on one side of the laminated structure 30, but the embodiments of the present invention are not limited thereto.

[0040] For example, as shown in Figure 4(A) for structural member 12, the sprayed portion 40 may be formed on both sides of the laminated structure 30. In this case, it is preferable to form the laminated structure 30 inside the double-reinforced reinforcing bars 20.

[0041] According to this molding method, the structural member 12 can be manufactured using three nozzles (one nozzle N1 and two nozzles N2), and the molding speed of the structural member can be increased compared to the case where only two nozzles are used.

[0042] Alternatively, as shown in Figure 4(B), for example, the sprayed portion 40 may be formed in a position sandwiched between two laminated structures 30. In this case, the laminated structure 30 is formed on the outside of the double-reinforced reinforcing bars 20.

[0043] According to this molding method, both sides of the structural member 14 are formed by the laminated structure 30. This reduces the finishing and leveling work required for the sprayed area 40. Furthermore, the structural member 14 can be applied using three nozzles (two nozzles N1 and one nozzle N2), resulting in a faster molding speed compared to using only two nozzles. In addition, even if the viscosity of the sprayed mortar is reduced, it is less likely to flow out because it is sandwiched between the laminated structure 30. Therefore, the workability of the spraying process can be improved.

[0044] Although the structural member 10 in the above embodiment is a wall, the embodiments of the present invention are not limited to this. For example, as shown in the structural members 16 and 18 in Figures 5(A) and (B), the structural members in the present invention may be columns. In the structural member 16, the reinforcing bars 20 are formed by column main reinforcement and hoop reinforcement, and the laminated structure 30 is formed by surrounding the reinforcing bars 20 in three directions in a plan view. The sprayed portion 40 is formed by spraying sprayed mortar from the portion where the laminated structure 30 is not formed, and covers the reinforcing bars 20.

[0045] On the other hand, in the structural member 18, the laminated structure 30 is formed in a position surrounded by the reinforcing bars 20 in a plan view. The sprayed portion 40 is formed by spraying from around the laminated structure 30 and covers the reinforcing bars 20.

[0046] Such structural members 18 can also be used as beams. In other words, structural members in this invention include walls, columns, and beams. Furthermore, structural members may also be slabs or the like.

[0047] Furthermore, although the structural members 10, 12, 14, 16, and 18 described above are all composed of reinforcing bars 20, the embodiments of the present invention are not limited to these. The structural members in the present invention do not need to include reinforcing bars 20, as long as they form the sprayed portion 40 while forming the laminated structure 30 with the nozzle N1. [Explanation of symbols]

[0048] 10 Structure 12 Structure 14 Structure 16 Structure 18 Structure 20 Reinforcement bars 22 Vertical reinforcement (reinforcement bars) 24. Horizontal reinforcement (reinforcement bars) 30 Laminated Structures 40 Spraying section N1 Nozzle (First Nozzle) N2 nozzle (second nozzle)

Claims

1. The process of making the wall reinforcement, including vertical and horizontal bars, self-supporting, The process involves discharging a first hardening agent from a first nozzle along the wall reinforcement, forming a laminated structure vertically on one side of the wall reinforcement, while simultaneously spraying a second hardening agent from a second nozzle towards the laminated structure from the other side of the wall reinforcement, thereby embedding the wall reinforcement and forming a sprayed portion integrated with the laminated structure. Equipped with, The laminated structure and the sprayed portion form a wall. A method for forming structural members.

2. The sprayed portion is formed on one side of the laminated structure. A method for forming a structural member according to claim 1.

3. The system is equipped with two of the aforementioned second nozzles, The sprayed portion is formed on both sides of the laminated structure. A method for forming a structural member according to claim 1.

4. The process of making the reinforcing bars, including vertical and horizontal bars, self-supporting, The process involves discharging a first hardening agent from a first nozzle along the reinforcing bar to form a laminated structure in the vertical direction, while simultaneously spraying a second hardening agent from a second nozzle toward the laminated structure to cover the reinforcing bar and form a sprayed portion integrated with the laminated structure. Equipped with, The system is equipped with two of the aforementioned first nozzles, The sprayed portion is formed in a position sandwiched between the two laminated structures. A method for forming structural members.

5. The laminated structure and the sprayed portion constitute a wall. The laminated structures on both sides form a wall surface. A method for forming a structural member according to claim 4.

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