Manufacturing method of system template insert

Abstract

A method for manufacturing a system template insert includes a first preparation step, a second preparation step, a feeding and heating step, and a removal step. The first preparation step involves preparing a first outer shell. The second preparation step involves preparing a second outer shell. The second outer shell is accommodated within the first outer shell, is a hollow shell with a feeding port, and is formed using 3D printing. The outline of the internal space of the second outer shell forms the shape of a target insert. The feeding and heating step involves placing the second outer shell inside the first outer shell and filling it with a preparation material through the feeding port. After sealing the feeding port and the first outer shell, heating and pressurizing are applied to melt the preparation material and fill it into the second outer shell. The removal step involves removing the solidified preparation material from the second outer shell; the solidified preparation material possesses the shape of the target insert.

Description

[Technical Field]

[0001] This invention relates to a method for manufacturing building objects, and more particularly to a method for manufacturing a system template insert. [Previous Technology]

[0002] Existing timber formwork (referred to as timber formwork) is formed by splicing together timber boards, which is the formwork building material generally used in the construction industry before concrete grouting operations. However, timber formwork will have the following disadvantages after grouting operations:

[0003] First, wood easily absorbs mud and water, and can only be reused 5 to 6 times before its surface becomes rough and unusable. When dismantling formwork on the construction site, special prying tools are often required to remove it by force, resulting in a very high damage rate for many wooden formwork materials, making them difficult to reuse.

[0004] Second, it requires experienced craftsmen or workers to cut and assemble according to the site conditions, resulting in a long construction period and high technical requirements for construction personnel, which cannot effectively improve assembly efficiency. At the same time, the transmission of experience is also a major problem, leading to high construction costs, which necessitates improvement.

[0005] In recent years, some companies have developed plastic / metal formwork for construction to replace traditional wooden formwork and overcome the above-mentioned shortcomings. The turnover rate of plastic and metal formwork has been greatly increased to 50-200 times, and the waste materials can be recycled and reused, achieving the goal of reducing carbon emissions. However, plastic and metal formwork is not easy or even impossible to cut on the construction site. It usually needs to be prefabricated in the factory to a specific size and shape, which is generally referred to as "system formwork" in the industry. In order to achieve precise assembly to meet various building designs, there are at least dozens or even hundreds of standard shapes and sizes of "system formwork". The assembly method of the formwork units must be planned in advance according to the project. This step is called "formwork matching". However, even with hundreds of specifications and sizes, "system formwork" still cannot meet the needs of modern construction sites full of various novel designs with standard formwork units. It is necessary to separately manufacture irregular parts (or inserts) of different sizes or special shapes according to the specifications of each construction site to finish the edges of special-shaped buildings for grouting operations. Therefore, how to quickly and in large quantities produce inserts, especially large inserts, is a problem that relevant businesses urgently need to solve. [Summary of the Invention]

[0006] Therefore, the object of the present invention is to provide a method for manufacturing system template inserts that can quickly produce large inserts.

[0007] A method for manufacturing a system template insert includes a first preparation step, a second preparation step, a feeding and heating step, and a removal step. The first preparation step involves preparing a first outer shell. The second preparation step involves preparing a second outer shell. The second outer shell is accommodated within the first outer shell, is a hollow shell with a feeding port, and is formed by 3D printing. The outline of the internal space of the second outer shell is the shape of a target insert. In the feeding and heating step, the second outer shell is placed inside the first outer shell, and a preparation material is filled through the feeding port of the second outer shell. After sealing the feeding port and the first outer shell, heating and pressurizing are applied to melt the preparation material and fill it into the second outer shell. The removal step involves first cooling to solidify the preparation material and then opening the first outer shell to remove the second outer shell. Then, the second outer shell is opened again, and the solidified preparation material is removed. The solidified preparation material possesses the shape of the target insert.

[0008] Another technical means of the present invention is that the second outer shell is made of an outer shell material, the melting point of which is higher than the melting point of the material used to make the shell.

[0009] Another technical means of the present invention is that in the feeding heating step, the heating temperature is higher than the melting point of the prepared material and lower than the melting point of the shell material.

[0010] Another technical means of the present invention is that the first outer shell is made of metal.

[0011] Another technical aspect of the present invention is that the second outer shell is recyclable and reusable.

[0012] The advantage of this invention is that the second outer shell is first made by 3D printing, and then the target insert is made by heating and melting the second outer shell. This can effectively shorten the manufacturing time of the insert with a larger volume and reduce the manufacturing cost.

Implementation Method

[0013] The features and technical content of the related patent applications of this invention will be clearly presented in the following detailed description of the preferred embodiments with reference to the accompanying drawings. Before proceeding with the detailed description, it should be noted that similar elements are represented by the same numbers. The directional terms mentioned in the following embodiments, such as up, down, left, right, front, back, bottom, and top, are only for reference to the accompanying drawings. Therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0014] Referring to Figure 1, a preferred embodiment of the manufacturing method of the system template insert of the present invention is shown, which includes a first preparation step 21, a second preparation step 22, a feeding and heating step 23, and a removal step 24. It should be noted that the insert referred to in the present invention refers to a supplementary part of irregular size or special shape required for edge sealing and grouting when using system templates to fit a building with a special shape. Referring to Figure 2, the special-shaped building 10 is first filled with a large area of ​​grouting surface using a system template of a large size, such as a plurality of first standard system templates 11 and a plurality of second standard system templates 12, and then edge sealing and grouting is performed using an insert 2 of irregular size or special shape. The present invention is a manufacturing method for this insert 2.

[0015] Referring to Figures 1 and 3, the first preparation step 21 is to prepare a first outer shell 3. In this embodiment, the first outer shell 3 is made of metal. The second preparation step 22 is to prepare a second outer shell 4, which can be accommodated within the first outer shell 3. The second outer shell 4 is a hollow shell with a feed port 41, and is formed by 3D printing. The outline of the internal space of the second outer shell 4 is the shape of the insert 2. The feeding and heating step 23 is to place the second outer shell 4 inside the first outer shell 3, and fill the preparation material through the feed port 41 of the second outer shell 4. After sealing the feed port 41 and the first outer shell 3, heating and pressurizing are performed to melt the preparation material and fill the internal space of the second outer shell 4. More specifically, the second outer shell 4 is made of an outer shell material, and the melting point of the outer shell material is higher than the melting point of the preparation material. Therefore, in the feeding and heating step 23, the heating temperature is higher than the melting point of the preparation material and lower than the melting point of the outer shell material. In this way, during the feeding and heating step 23, the preparation material will melt and fill the second outer shell 4, but since the heating temperature does not exceed the melting point of the outer shell material, the shape of the second outer shell 4 will not change.

[0016] Step 24 involves first cooling the material to solidify it and then opening the first outer shell 3 to remove the second outer shell 4. Next, as shown in Figure 4, the second outer shell 4 is opened to remove the solidified material, which has the shape of the insert 2. Finally, the second outer shell 4 can be recycled and reused.

[0017] It is particularly important to emphasize that the second outer shell 4 is prepared by 3D printing in the second preparation step 22 of this invention. This is because the size, shape, and quantity of the insert 2 will vary depending on the needs of different projects. Therefore, it would be very time-consuming and costly to make molds for each type of insert 2. In addition, the second outer shell 4 is a hollow rather than solid design. The preparation material is filled into the second outer shell 4 and then heated, melted, and cooled to produce the target insert. Especially for large-volume inserts, compared to directly producing the entire insert by 3D printing, it can effectively reduce production time and cost.

[0018] The advantage of the manufacturing method of the template insert of the present invention is that: the second shell 4 is first made by 3D printing, and then the insert 2 is made by heating and melting the second shell 4. It is equivalent to making the insert 2 by "composite sandwich printing", which can effectively shorten the manufacturing time of the insert 2 and reduce the manufacturing cost.

[0019] However, the above description is only a preferred embodiment of the present invention and should not be construed as limiting the scope of the present invention. All simple equivalent changes and modifications made in accordance with the scope of the patent application and the description of the invention shall still fall within the scope of the patent of the present invention. [Simplified Explanation of the Diagram]

[0020] Figure 1 is a flowchart illustrating a preferred embodiment of the manufacturing method of the template insert of the present invention; Figure 2 is a schematic diagram illustrating the reason for the need for inserts; Figure 3 is a schematic diagram illustrating a first preparation step and a second preparation step; and Figure 4 is a schematic diagram illustrating a removal step.

Claims

1. A method for manufacturing a system template insert, comprising: a first preparation step of preparing a first outer shell; and a second preparation step of preparing a second outer shell, wherein, The second outer shell can be housed within the first outer shell. The second outer shell is a hollow shell with a feed port and is formed by 3D printing. The outline of the internal space of the second outer shell is the shape of a target insert. A feeding and heating step involves placing the second outer shell inside the first outer shell and filling the preparation material through the feed port of the second outer shell. After sealing the feed port and the first outer shell, heating and pressurizing are performed to melt the preparation material and fill it into the second outer shell. A removal step involves first cooling the preparation material to solidify it and then opening the first outer shell to remove the second outer shell. Then, the second outer shell is opened again to remove the solidified preparation material, which has the shape of the target insert.

2. A method for manufacturing the system template patch as described in claim 1, wherein, The second outer shell is made of a shell material whose melting point is higher than that of the material used to make the shell.

3. A method for manufacturing the system template patch as described in claim 2, wherein, In this feeding and heating step, the heating temperature is higher than the melting point of the material being prepared, but lower than the melting point of the outer shell material.

4. A method for manufacturing the system template patch as described in claim 1, wherein, The first outer shell is made of metal.

5. A method for manufacturing the system template patch as described in claim 1, wherein, The second casing is recyclable and can be reused.

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