Wall cladding panel

Abstract

The present invention relates to wall cladding panels manufactured using additive technologies. The technical result consists in an increase in the geometric precision and structural and decorative characteristics of panels, a reduction in the manufacturing complexity of panels with an arbitrary three-dimensional shape, and a reduction in the material and time costs entailed in the production and installation of panels. A wall cladding panel comprises: a shaping structure which is produced by 3D printing and defines the shape of the panel, said shaping structure containing fastening elements which are formed integrally with the shaping structure and are intended for the mounting thereto of intermediate fastening elements; intermediate fastening elements mounted to said fastening elements; and a structural load-bearing layer applied to the shaping structure and partially covering the intermediate fastening elements in order to secure same to the panel. A method for manufacturing a wall cladding panel is also claimed.

Description

[0001] WALL CLADDING PANEL

[0002] Field of technology

[0003] The present invention relates to the field of construction, in particular to wall cladding panels produced using additive technologies.

[0004] Prior art

[0005] The technology currently used to produce certain architectural and construction products, such as wall panels for interior decoration or facade panels for cladding the facades of buildings and various structures, essentially involves three stages. In the first stage, a master model (prototype) of the future product is produced. Depending on the complexity, the model can be made from plasticine, clay, or gypsum. Some large-scale models are manufactured by milling from wood or plywood. In the second stage, an inverse matrix is ​​produced using the master model. In the final stage, the final product is manufactured by applying materials to the inverse matrix. A panel produced in this manner may have insufficient geometric accuracy, is labor-intensive, and is especially difficult to manufacture when such a panel must have a complex shape according to the design.

[0006] Thus, in the state of the art there is a need for the production of panels of arbitrary shape that do not have the listed disadvantages.

[0007] Brief summary of the invention

[0008] The present invention is directed to solving at least some of the above problems.

[0009] According to the present invention, a wall panel is provided, comprising:

[0010] - a form-generating structure made using the 3D printing method, defining the shape of the panel and containing fastening elements made in one piece with the form-generating structure and intended for the installation of intermediate fastening elements; intermediate fastening elements installed on the said fastening elements;

[0011] - a structural supporting layer applied to the form-forming structure and partially covering the intermediate fastening elements for their fixation on the panel.

[0012] According to one embodiment, the panel is a wall panel for interior decoration of premises.

[0013] According to another embodiment, the panel is a facade panel for external cladding of buildings.

[0014] According to another embodiment of the panel, the intermediate fastening elements are intended for connection with the corresponding fastening elements on the wall.

[0015] According to another embodiment of the panel, each intermediate fastening element on the panel has a protrusion for interaction with a complementary groove of the corresponding mating fastening element.

[0016] According to another embodiment of the panel, each intermediate fastening element on the panel has a groove for interaction with a complementary projection of the corresponding mating fastening element.

[0017] According to another embodiment of the panel, part of the intermediate fastening elements have projections, and the other part of the intermediate fastening elements have grooves for interaction with a complementary groove or projection of the corresponding mating fastening element.

[0018] According to another embodiment of the panel, the said protrusion has a T-shaped, cross-shaped, square, triangular or rectangular shape.

[0019] According to another embodiment of the panel, the form-forming structure has a cellular structure.

[0020] According to another embodiment of the panel, the form-forming structure has a continuous surface with stiffening ribs.

[0021] According to another embodiment of the panel, the supporting layer is made of a cement-sand mixture, reinforced polymer composite, foamed concrete or polymer building material with a given shrinkage.

[0022] According to another embodiment of the panel, the fastening element includes at least one protrusion or at least one groove for installing an intermediate fastening element.

[0023] According to another embodiment of the panel, the intermediate fastening element includes at least one groove complementary to said at least one projection of the fastening element or at least one projection complementary to said at least one groove of the fastening element.

[0024] According to a second aspect of the present invention, a method for producing a panel is provided, comprising the steps of:

[0025] - form a three-dimensional digital model of the panel;

[0026] - based on the generated digital model, 3D printing (three-dimensional printing) of the form-generating structure of the panel is carried out, defining the shape of the panel, with fastening elements made in one piece with the form-generating structure; intermediate fastening elements are installed on the said fastening elements; a structural supporting layer is applied to the form-generating structure in such a way that it partially covers the intermediate fastening elements for their fixation on the panel.

[0027] According to one embodiment of the method, at the stage of printing the form-generating structure of the panel, detachable edge elements are formed on the edges of the form-generating structure of the panel using 3D printing, made in one piece with the form-generating structure, in order to form the edge of the panel, wherein the detachable edge elements are separated from the form-generating structure after the application of the structural supporting layer.

[0028] According to another embodiment, the method further comprises the step of applying an outer layer to said carrier layer, which is configured to perform a decorative and / or protective function. According to another embodiment, the method further comprises the step of mechanically processing the panel after applying the carrier layer, wherein the mechanical processing includes at least one of milling, grinding, and rolling.

[0029] According to another embodiment of the method, at the stage of applying the carrier layer, a temporary mask or template is used to prevent the intermediate fastener from being completely covered by the carrier layer.

[0030] According to another embodiment of the method, the material of the carrier layer is applied by means of SD printing to form the panel structure layer by layer with integrated intermediate fasteners.

[0031] The present invention provides for an increase in the geometric accuracy, structural and decorative characteristics of panels, a reduction in the complexity of the process of manufacturing panels of arbitrary three-dimensional shape, an increase in the reliability of panel fastening, and a reduction in material and time costs for the production and installation of panels.

[0032] Brief description of the drawings

[0033] The invention is further explained by a description of preferred embodiments of the invention with reference to the accompanying drawings, in which:

[0034] Fig. 1 shows a block diagram of a method for producing panels for wall cladding.

[0035] Fig. 2a-2b show options for joining adjacent panels with stepped edges.

[0036] Fig. 3a-3g depict an exemplary embodiment of fastening elements and counter fastening elements.

[0037] Description of preferred embodiments of the invention

[0038] The present invention discloses a technology for manufacturing architectural and construction products using additive technologies to create a form-forming structure followed by the application of one or more layers of one or more materials to achieve the desired strength and surface appearance. This technology can be used to manufacture architectural or construction products, such as wall cladding panels, such as facade panels for exterior cladding of buildings, wall panels for interior decoration, or decorative elements, small architectural forms, etc.

[0039] In accordance with one aspect of the present invention, a method is provided for manufacturing architectural construction products using 3D printing to create a form-forming structure of a product of any shape, onto which a carrier layer and an outer layer are then applied.

[0040] For simplicity, the following description of an exemplary embodiment of the present invention will be disclosed with respect to three-dimensional (3D) wall cladding panels using the example of free-form facade panels intended for cladding buildings or structures of complex shape. However, it is obvious that the features of the present invention can be similarly applied in the manufacture of other types of products, for example, wall panels for interior decoration, etc.

[0041] The essence of the technical solution consists of a combination of additive manufacturing (SD printing) to create the internal form-forming structure of façade panels (façade elements), followed by the application of a reinforcing load-bearing layer made of structural materials used for the production of façade panels, such as glass fiber-reinforced concrete, polymer composites with glass fiber, and others (hyposofiber, polymer concrete, polymers, etc.). This allows for the production of durable 3D façades of various shapes and configurations without compromising technical characteristics, but without the use of molds for their production.

[0042] In this application, the terms "additive manufacturing" and "3D printing" are used interchangeably.

[0043] The method for manufacturing facade panels in accordance with the present invention includes the following steps, in which:

[0044] - the shaping structure of the facade panel is printed using SD printing, and detachable edge elements made in one piece with the shaping structure are formed on the edges of the shaping structure of the facade panel using 3D printing to form the precise edge of the facade panel; a structural load-bearing layer is applied to the shaping structure;

[0045] - separate the detachable edge elements from the form-forming structure;

[0046] - apply an outer layer to the said carrier layer.

[0047] In the context of building materials, the term "structural load-bearing layer" refers to the layer that provides the primary mechanical characteristics of a structure, such as strength, rigidity, and stability. This layer is the foundation that bears all loads and transfers them to other structural elements.

[0048] Further, an exemplary embodiment of the said method for manufacturing facade panels will be described in detail with reference to Fig. 1.

[0049] First, at stage S1, the façade is modeled. Architects develop the design of the façade system for the structure (building) and create 3D models of the objects. Using specialized software or 3D modeling, the façade system is "cut" into individual façade panels of the required dimensions (this can be done either automatically or manually).

[0050] Generative 3D design algorithms can be used for this purpose. Such algorithms can automatically generate various design options based on pre-defined rules and parameters. Examples of such generative 3D design algorithms include fractal generation algorithms, machine learning methods, Voronoi and Delaunay diagrams, random generation methods, etc. Generative 3D design algorithms provide the creation of various options for façade shapes and structures. These algorithms take into account various parameters, such as appearance, strength, lighting, etc. Thus, design concepts can be quickly created and visualized. Generative algorithms are also used to optimize façade parameters. For example, an algorithm can be configured to find the optimal dimensions and arrangement of façade elements to achieve the required characteristics, such as aerodynamics.Furthermore, generative design can be used to automatically create façade details. This includes not only geometry generation but also the creation of textures, relief, ornamentation, and other details that make a façade unique. These algorithms enable an iterative design process, rapid prototyping, and evaluation of various façade options. This allows for design optimization and consideration of different consumer needs. A significant advantage is that generative design can integrate analysis and simulation algorithms to evaluate façade performance, such as thermal conductivity, sound insulation, and other physical properties.

[0051] Next, based on the resulting façade panel model, the form-generating structure (frame) of the façade panel is modeled. For this purpose, the façade panel frame, onto which the supporting layer will be applied, is generated using specialized software, and files for 3D printing are created. The façade panel frame is modeled using various 3D modeling programs, such as CAD systems (AutoCAD, SolidWorks, CATIA, Fusion 360) or specialized architectural modeling programs (Revit, Rhino). At this stage, algorithms can be used to automatically calculate and create the frame, taking into account the required strength, flexibility, and other design parameters. Such algorithms can optimize the size and shape of the frame elements to achieve the desired characteristics.Examples of the mentioned algorithms include, but are not limited to: finite element method (FEM), finite volume method (FVM), finite difference method (FDM), boundary element method (BEM).

[0052] After modeling the form-generating structure, the structural load-bearing layer and outer layer are modeled. Various methods and software tools can be used to perform engineering calculations and computer modeling of the mechanical characteristics of the façade panel, depending on its thickness and the materials used. Stress and strain calculations in materials are performed using the basic principles of strength of materials. Equations such as Hooke's formula for elasticity and Tresca's theory for estimating strength under different stresses can be used to estimate the strength and elasticity of the material.

[0053] Computer modeling is a practical solution for these tasks. Finite element analysis (FEA) programs such as ANSYS, Abaqus, COMSOL, and others can be used to simulate the mechanical properties of a façade panel. For example, using ANSYS, you can create a 3D model of the element, specify materials with dimensions (e.g., fiberglass-reinforced epoxy resin, frame layer), define boundary conditions (how the façade is attached to the building), and then run an analysis that shows the stress distribution in the element depending on its thickness and loads.

[0054] The thickness of the façade panel is also selected based on the desired elasticity. Elasticity theory determines how a material will deform and return to its original shape under load.

[0055] The main factors taken into account when designing a facade are wear resistance, wind and moisture protection, fire resistance of the material and frost resistance.

[0056] The main design characteristics of facade panels taken into account during design include thickness, panel size, weight, service life, etc.

[0057] The result of stage S 1 is the formation of a model of an architectural or construction product (facade panel) and its transfer to further production.

[0058] Next, at stage S2, 3D printing of the form-forming structure of the facade panel is carried out based on the generated model.

[0059] The shaping structure in a preferred embodiment has a cellular (mesh) structure.

[0060] In an alternative embodiment, the forming structure may have a solid surface with stiffening ribs integrated into the structure to maintain the shape of the product and provide strength and rigidity.

[0061] When printing, resins with the addition of fiberglass can be used to strengthen the facade and increase strength, as well as other materials such as concrete, gypsum, sand, metal, polymers, etc. Table 1 below shows some examples of polymers for 3D printing, as well as temperature ranges for their use and heating the platform during 3D printing:

[0062] Table 1

[0063]

[0064] The selection of materials for printing the form-generating structure is carried out on the basis of the required functions and specified characteristics of the product.

[0065] The use of 3D printing to create the form-forming structure of facade panels allows us to achieve a high degree of geometric complexity and individuality of facade structures.

[0066] The present invention provides for the possibility of using detachable edge elements on the edges of the form-forming structure of a façade panel. The detachable edge elements, designed as borders, are additional elements that are printed together with the form-forming structure of the façade panel during the 3D printing process.

[0067] Detachable edge elements can be produced as smooth borders. By 3D printing these edge elements onto the edges of the forming structure, the geometric accuracy of all shapes and sizes of the manufactured façade panels is guaranteed, ensuring precise joining of the façade panels. This also solves the problem of difficult cleaning of façade panel edges and ensures a tight fit between the façade panels.

[0068] Alternatively, the detachable edge elements may have, for example, a stepped profile, which results in the formation of a stepped edge of the façade panel. The shape of the stepped edge of the façade panel may be complementary to the shape of the edge of the adjacent façade panel, which allows them to be installed close to each other without a gap (see Fig. 2a), or with a minimal gap (see Fig. 2b). In such a case, the overlapping stepped edges of adjacent façade panels reduce the likelihood of displacement of the said panels relative to each other.

[0069] In a preferred embodiment, the edge elements are printed from the same material as the façade panel's core structure. The edge elements are connected to the core structure by a perforated section, allowing for their temporary connection to the core structure and the possibility of their removal.

[0070] Alternatively, the edge elements can be combined with the form-forming structure of the product by point connection.

[0071] In an alternative embodiment, the edge elements may be printed from a material different from the material of the forming structure, and may be, for example, water-soluble.

[0072] Additionally, fasteners are printed at this stage, allowing for a unified structure consisting of the shaping structure, edge elements, and fasteners. Using a 3D model of the fasteners for the building's façade panels, the fasteners are printed directly in the desired locations on the façade panel. This structure is created using appropriate materials that ensure strength and reliability. The façade's shaping structure, edge elements, and fasteners are printed as a single, integrated element. This allows them to be connected without the need for additional fasteners. To avoid the need for a subsequent coating of the fasteners, printing parameters in the locations of the fasteners can be adjusted to increase the infill and the number of outer layers.This means that more material is used in these areas to print the fasteners onto the molding structure, ensuring a strong and secure connection. This also ensures that the carrier layer does not completely cover the fasteners when applied, leaving the fasteners exposed.

[0073] This approach ensures a strong and reliable connection between the form-forming structure of the façade panel and the fastening elements, which allows them to perform their function without the need for complete filling with a supporting layer.

[0074] These fasteners can also be used by robotic manipulators during the production process to grip, move, and secure the façade panel at various stages. For this purpose, the robotic manipulators use the façade panel model at subsequent stages to determine the locations of the fasteners on the façade panel. Automating the façade panel positioning process using technical fasteners simplifies the application of the base layer, subsequent processing, application of the top layer, and painting of the façade. Furthermore, securing the façade panel with fasteners during production prevents deformation of the façade panel's form-forming structure during the application of the base layer and until it dries.

[0075] It should be noted that in some embodiments of the present invention (e.g., when producing decorative elements or small architectural forms), the manufactured article need not necessarily have fasteners. Furthermore, such articles may require the application of an outer layer on all sides of the article, which eliminates the presence of fasteners on the manufactured article. In such a case, the fasteners used during the manufacturing process to move and secure the article may be formed on detachable edge elements and then, after the application of the supporting layer, be separated from the article along with said edge elements.

[0076] 3D printing of a 3D molding structure of arbitrary shape with edge and fastening elements allows for increased speed and reduced complexity of the manufacturing process.

[0077] The result of stage S2 is a single structural design ready for transfer to stage S3.

[0078] Once printing is complete, the robotic arm detaches the part (the frame of the façade panel) from the printing platform and transfers it to the conveyor line for further processing, or this can be done manually.

[0079] Next, at step S3, the façade panel's form-generating structure is transferred to the area for applying the reinforcing load-bearing layer, where it is installed on a fixed mount using fasteners on the frame. A robotic manipulator initiates the process of applying the structural load-bearing layer to the form-generating structure in accordance with a previously developed model. Various materials can be used in the process, such as phenolic resin, silicone resin, polyester resins with glass fibers, fiberglass, glass fiber-reinforced concrete, epoxy resins, reinforced polyurethanes, acrylic resins, polyester materials, glass fiber-reinforced concrete, polymer composites with glass fiber, gypsum fiber, polymer concrete, and other applicable binders with a reinforcing component, etc. The load-bearing layer is predominantly made of a cement-sand mixture, reinforced polymer composite, foamed concrete, or polymer building material with a specified shrinkage.

[0080] The supporting layer, after drying, gives the facade panel the necessary strength and stability, ensuring the reliability and durability of the facade panels.

[0081] In a preferred embodiment, the carrier layer is applied to the molding structure on only one side, which is designated as the face of the future product. This embodiment allows for a product to be produced with specified requirements, featuring a low thickness and weight, while also minimizing the material consumption of the carrier layer. At the same time, the carrier layer can be prevented from interfering with the fasteners, which are primarily formed on the back of the future product.

[0082] Alternatively, the carrier layer is applied to the form-forming structure both from the side that is specified as the front side of the product and from the back side on which the fastening elements are located, while the fastening elements are not covered with the carrier layer.

[0083] The use of various materials to strengthen the facade ensures high strength and adaptability to various architectural requirements.

[0084] Table 2 provides some examples of binder and glass fiber application systems that can be used in this technology.

[0085] Table 2 High i application speed, resin mixing system and fiberglass

[0086] After the base layer has been applied and the product has achieved its initial strength, the detachable edge elements can be carefully separated from the façade panel's core structure at step S4. This is accomplished by carefully breaking the perforated joint, similar to tearing paper along a cut. This mechanism allows the edge elements to be easily separated without damaging the façade panel's core structure. After separation of the edge elements, each façade panel fits snugly against the next, allowing them to snap or join together with high precision. This ensures a tight fit between the façade panels in the façade system and conforms to all shapes and sizes.

[0087] The result of stage S4 is a single structural structure with the applied load-bearing layer, ready for transfer to the machining area.

[0088] After applying the carrier layer and drying, the resulting part is moved to the mechanical processing zone.

[0089] Next, at step S5, the part is secured in a special fixture, and a robotic manipulator performs its mechanical processing. Mechanical processing may include, for example, milling, grinding, rolling, etc. This processing can also be performed manually.

[0090] The mechanical finishing step after applying the base layer is not always mandatory and depends on the specific requirements of the final product and its design characteristics. If the design calls for a textured surface that does not require absolute smoothness, then mechanical finishing can be omitted. Mechanical finishing allows for surface smoothing, improvement of the surface texture of the part, and removal of excess base layer. If the facade surface must be absolutely smooth and free of defects, then milling or other methods can be used to level the surface. If excess material appears during the application of the base layer and must be removed, for example, to ensure the product conforms to certain dimensions or shape, then mechanical finishing may be necessary.

[0091] After mechanical processing, the part is moved to the final processing area.

[0092] Next, at step S 6, an outer layer is applied to the product. Said outer layer is configured to perform a decorative and / or protective function. In some embodiments, this step may be optional.

[0093] The application of the outer layer to the product can be performed in various ways (e.g. airless spraying, pneumatic spraying, electric arc metallization, UV printing, etc.), and the choice of method depends on the specific requirements, as well as the type of outer decorative or protective layer of the product. A robotic manipulator or a person applies a layer of façade paint, plaster, metallic spraying or other final coating to the façade.

[0094] To accurately apply patterns using a robotic arm, it is essential to accurately digitally model the appearance of the façade panel. This model is then used to program the robotic arm. To accurately apply patterns to the façade panel, the robot can be calibrated using markers or marks on the façade. These markers are applied to the panel during the surface preparation stage before applying patterns using the robotic arm and help the robot determine its position and orientation on the surface. Furthermore, it is important to configure the robot so that it moves with the required precision and speed to create the desired pattern or texture.

[0095] Special types of paints or coatings may be required to create certain effects or textures. It is worth noting that in some embodiments of the present invention, the step of applying the outer layer may be optional.

[0096] Thus, the manufacturing method described above allows for the production of façade panels of arbitrary three-dimensional shapes with high geometric precision and superior structural and decorative properties. Furthermore, the present invention reduces the complexity of the manufacturing process, as well as the material and time costs for production and installation.

[0097] According to another aspect of the present invention, an architectural construction product is provided that includes an internal form-forming structure manufactured using SD printing technology, a carrier layer applied to the form-forming structure, and an outer layer applied to the structural carrier layer.

[0098] In an exemplary embodiment, said product is a façade panel. Said façade panel further includes fastening elements integral with the internal form-forming structure for attaching the façade panel, for example, to a building wall.

[0099] According to another aspect of the present invention, a fastening system for façade panels is proposed. The fastening elements of the façade panel according to the present invention will now be described in more detail, which allow for the automation of production and the precise positioning of façade panels during their installation, i.e., the same fastening elements can be used both at the production stage and for installing the façade panels on the building façade. Robots during the production process can use these fastening elements to grip, move and fix the product, which simplifies the process of applying the base layer, subsequent mechanical processing and applying the outer layer. This contributes to improving production quality and reducing the time required to complete the work. In an alternative embodiment, different fastening elements are used at the production stage and during the installation of the façade panels on the building.

[0100] In general, the fastening system consists of at least two fastening elements located on the façade panel and at least two counter fastening elements installed, for example, on the wall of the building where the façade panels are to be secured. According to the present invention, for each respective pair of fastening element and counter fastening element, the following is accomplished: one of the fastening element and counter fastening element includes a shaped projection, while the other of the fastening element and counter fastening element includes a complementary groove for receiving said shaped projection.

[0101] The number of fasteners and counter fasteners is specified at stage S 1 of modeling to ensure reliable fixation of the facade panel.

[0102] In an exemplary embodiment of the present invention, the fastening elements (see Fig. 3a) are parts that include "T-shaped" protrusions and are located on the back side of the facade panel. Fixation (connection) occurs with the help of complementary elements, such as mating fastening elements with "T-shaped" grooves (see Figs. 3b, 3g), which are installed on the wall of the building.

[0103] The shape of the fastener projection may be different from a T-shape. For example, the fastener projection may be cross-shaped, square, triangular, rectangular, etc., and the mating fastener must have a groove of the corresponding shape to accommodate the projection.

[0104] In an exemplary embodiment, all fasteners on the facade panels have a protrusion, while all counter fasteners on the building wall to which the facade panels are to be fastened have a corresponding groove. In an alternative embodiment, all fasteners on the facade panels have a groove, while all counter fasteners have a corresponding protrusion. In yet another alternative embodiment, a mixed implementation of fasteners and counter fasteners is possible, i.e., on the facade panels, some of the fasteners have protrusions, while another part of the fasteners have grooves, and the counter fasteners on the building wall have corresponding complementary grooves and protrusions.

[0105] The fastening of the mating fastening elements to the wall of the building can be carried out by means of adhesive, threaded or welded connections, or other suitable known fastening methods.

[0106] Counter fasteners can also be produced using additive manufacturing (AW printing).

[0107] According to another alternative embodiment, the counter fasteners installed, for example, on the wall of a building, may be any known (standard) fasteners from the prior art. They may be made of plastic, metal, composite materials, etc. In such a case, the fasteners located on the façade panel are formed at step S2 in such a way as to be able to interact (connect) with said known counter fasteners.

[0108] Alternatively, fasteners located on the façade panel are configured to accept (connect to) other fasteners, which in this case act as intermediate fasteners intended for connection with the aforementioned mating fasteners. The intermediate fasteners and mating fasteners may be known from the prior art (standard) elements. The intermediate fasteners may be made of plastic, metal, composite materials, etc. This allows for the use of a wide variety of commercially available fasteners with known properties.

[0109] In this case, the method of manufacturing panels includes the following stages, in which:

[0110] - a three-dimensional digital model of the panel is formed; - based on the formed digital model, 3D printing is carried out of the form-generating structure of the panel, defining the shape of the panel, with fastening elements made in one piece with the form-generating structure; intermediate fastening elements are installed on the said fastening elements; a structural bearing layer is applied to the form-generating structure in such a way that it partially covers the intermediate fastening elements for their fixation on the panel.

[0111] Once the supporting layer has achieved sufficient strength, the intermediate fasteners become integrated ("monolithic") into the panel structure. This ensures secure panel fastening while maintaining high precision and ease of positioning on the wall, increasing resistance to vandalism, climatic, and mechanical influences.

[0112] Optionally, said method includes the step of forming detachable edge elements at the edges of the forming structure, as described above.

[0113] During the application of the carrier layer, a temporary mask or template can be used to prevent the intermediate fastener from being completely covered by the carrier layer. The carrier layer material can be applied using 3D printing to layer-by-layer form the panel structure with integrated intermediate fasteners.

[0114] The result is a panel containing:

[0115] - a form-generating structure made using the 3D printing method, defining the shape of the panel and containing fastening elements made in one piece with the form-generating structure and intended for the installation of intermediate fastening elements; intermediate fastening elements installed on the said fastening elements;

[0116] - a structural load-bearing layer applied to the form-forming structure and partially covering the intermediate fasteners for their fixation to the panel. The load-bearing layer is applied in such a way that the portion of the intermediate fastener intended for connection with the mating fastener remains exposed. In general, the fastener is a section of the form-forming structure with increased thickness (more layers are formed) to improve the reliability of the fastener, intended for connection (interaction) with the mating or intermediate fastener.

[0117] The connection of fastening elements with intermediate fastening elements can also be carried out using shaped projections and corresponding complementary grooves. For example, a fastening element is a section of a forming structure that includes at least one projection or at least one groove for accommodating and retaining (installing) an intermediate fastening element. The intermediate fastening element can include at least one groove complementary to the at least one projection of the fastening element or at least one projection complementary to the at least one groove of the fastening element. The connection of intermediate fastening elements with mating fastening elements can be carried out in a similar manner.

[0118] The fasteners and counter-fasteners are connected using a key-and-lock method. This means that the fasteners and counter-fasteners are uniquely matched, and specific façade panels can only be installed in specific locations using these fasteners. This prevents incorrect installation and improves the accuracy of façade panel positioning. Thus, the key-and-lock method ensures precise alignment and protection against incorrect installation.

[0119] A one-to-one correspondence between the fastening elements and the mating fastening elements is ensured by specifying the shape, position and orientation (angle of rotation, angle of inclination) of the fastening element (see Fig. 36) and the complementary shape, position and orientation of the mating fastening element. The shape, position and orientation of the fastening elements and the mating fastening elements are specified at stage S1 of façade modelling.

[0120] According to another alternative embodiment, the facade panels can be connected to each other by means of fasteners and corresponding counter fasteners placed on adjacent facade panels.

[0121] After connecting the fastener and the mating fastener, the key-lock connection is secured by means of an adhesive joint, a glueless joint, or by means of additional fasteners such as latches, clips, rivets, hardware, etc.

[0122] Thus, the fastening system in accordance with the present invention ensures strong and reliable fastening of facade panels to the support (wall of the building) and connection of facade panels to each other, prevents their incorrect installation, and also facilitates the processes of applying the bearing layer, mechanical processing, applying the outer layer and moving the product during the production process.

[0123] In one embodiment, the fastening elements in the form of "dowels" (see Fig. 3g), to which the thermal insulation materials are attached, in this solution additionally serve as counter fastening elements for the fastening elements of the façade panels. The said counter fastening elements are first used to fasten the thermal insulation materials to the wall. Then, the façade panels are fastened to them by means of their fastening elements. That is, the counter fastening elements may be intended not only for fastening the façade panels themselves, but also for fastening other related materials and products.

[0124] In addition to the above-described system for fastening facade panels, the present invention can also use other methods for fastening facade panels to a building, such as glue, a profiled subsystem, brackets, etc.

[0125] According to another aspect of the present invention, a method for positioning fasteners in a facade panel is provided. According to said method, mating fasteners are installed on the surface of a structure (building) to be covered with facade panels, wherein a special coating is applied to the ends of the mating fasteners, which facilitates their detection by a camera. Said coating can be one of the following: a luminescent coating (e.g., GloNation Paint), which emits light in the visible range after irradiation with ultraviolet (UV) rays (100-400 nm). Such coatings can be used for visualization and marking on surfaces, facilitating detection and scanning; a fluorescent coating (e.g., Rust-Oleum 214944) that absorbs light in one range of wavelengths and emits it in another range (e.g., absorbs UV (100-400 nm) for excitation and emits visible light (400-700 nm)).These coatings provide bright visibility of markers under UV light, facilitating their precise positioning; an infrared (IR) reflective coating (e.g., 3M Scotchlite 7610) reflects infrared rays. Such coatings are used for thermal scanning and object detection in low visibility conditions.

[0126] - fiduciary markers / labels applied to fasteners, including Aruco, April Tag, ARToolKit and others; paint coating to form a “color target / label”.

[0127] Next, the structure is scanned, for example, using one of the following methods:

[0128] - laser scanning, which enables the creation of precise, highly detailed three-dimensional maps of objects and terrain. This is accomplished using lidar (e.g., Leica BLK360); photogrammetry, which is used to collect images to create three-dimensional models of buildings and objects. This is accomplished using drones with a high-resolution camera (e.g., DJI Phantom 4 RTK); scanning using structured light. This is accomplished using projectors and cameras that create and record deformations of the light pattern on the object (e.g., Artec Eva scanner). By scanning the building, a digital map is created with markings of the corresponding fasteners. The digital map is a three-dimensional model of the building or object, created using one of the above-mentioned scanning methods.This model includes precise data on the locations of all mating fasteners and other structural components, enabling efficient planning and execution of installation work. This digital map of mating fasteners on the building is used in the S1 stage of façade panel modeling to determine the location of fasteners on the façade panels. The required positions for complementary fasteners on the façade panels are determined based on the 3D model of the building façade and the map of mating fasteners on the building to ensure a one-to-one correspondence between the aforementioned fasteners and the corresponding mating fasteners. This ensures precise alignment of fasteners and mating fasteners, and therefore, accurate installation of the façade panels.

[0129] Then, the facade panels are manufactured with fasteners in the mentioned specific positions, as described above.

[0130] There are several ways to specify the position of the mating fasteners on a building.

[0131] One alternative method is to pre-determine the attachment points for façade panels on a digital 3D model of the building. During construction, a projector can be used to project the attachment points onto the wall based on the digital model. Construction workers can follow this projection to accurately place the mating fasteners on the building. Based on this digital model, façade panels are formed as described above and mounted on the building wall. Alternatively, the attachment points for the mating fasteners can be marked on the building façade in advance at pre-determined intervals, such as every meter. Construction workers can use levels and laser pointers to maintain these marks. After installing the mating fasteners, their placement can be verified, for example, by photographing the wall and processing the resulting image using appropriate software.Alternatively, the correct placement of the counter-fasteners can be verified by scanning the building wall, as described above. Then, based on the digital model, façade panels are formed as described above and mounted on the building wall.

[0132] Additionally, based on the developed digital building model, mobile devices and augmented reality apps can display fastening points on the building's façade in real time. Builders can follow these points to correctly place counter-fasteners.

[0133] When restoring a building's façade, existing fasteners can be used, such as those left over from the removal of old façade panels. In this case, these fasteners are coated with the aforementioned coating to facilitate their detection. Subsequent scanning of the fasteners and the formation of fasteners on the façade panels at specified locations are carried out as described above.

[0134] Thus, the present invention makes it possible to ensure high structural (e.g., strength and durability) and decorative (individual design, high degree of detail and architectural expressiveness of facades) characteristics of architectural and construction products, high geometric accuracy of the shapes and sizes of products and to accelerate the process of their production. In addition, the present invention makes it possible to produce three-dimensional products of arbitrary shape. The automated process of production and positioning of products during the production process using fasteners simplifies the production and processing of products and eliminates the impact of human error. The above-mentioned factors as a whole make it possible to increase the efficiency of the production of architectural and construction products and reduce material and time costs for production.

Claims

Invention formula 1. A panel for wall cladding, comprising: - a form-generating structure made using the 3D printing method, defining the shape of the panel and containing fastening elements made integral with the form-generating structure and intended for the installation of intermediate fastening elements; intermediate fastening elements installed on the said fastening elements; - a structural supporting layer applied to the form-forming structure and partially covering the intermediate fastening elements for their fixation on the panel.

2. The panel according to paragraph 1, wherein the panel is a wall panel for interior decoration of premises.

3. The panel according to paragraph 1, wherein the panel is a facade panel for external cladding of buildings.

4. The panel according to claim 1, in which the intermediate fastening elements are intended for connection with the corresponding fastening elements on the wall.

5. The panel according to item 4, wherein each intermediate fastening element on the panel has a projection for interaction with a complementary groove of the corresponding mating fastening element.

6. The panel according to claim 4, wherein each intermediate fastening element on the panel has a groove for interaction with a complementary projection of the corresponding mating fastening element.

7. The panel according to item 4, wherein some of the intermediate fastening elements have projections, and the other part of the intermediate fastening elements have grooves for interaction with a complementary groove or projection of the corresponding mating fastening element.

8. A panel according to any one of paragraphs 5-7, wherein said projection has a T-shaped, cross-shaped, square, triangular or rectangular shape.

9. The panel according to claim 1, wherein the form-forming structure has a cellular structure.

10. The panel according to item 1, in which the form-forming structure has a continuous surface with stiffening ribs.

11. The panel according to item 1, in which the supporting layer is made of a cement-sand mixture, reinforced polymer composite, foamed concrete or polymer building material with a given shrinkage.

12. The panel according to claim 1, in which the fastening element includes at least one projection or at least one groove for installing an intermediate fastening element.

13. The panel according to claim 12, in which the intermediate fastening element includes at least one groove complementary to said at least one projection of the fastening element or at least one projection complementary to said at least one groove of the fastening element.

14. A method for manufacturing a panel according to any of paragraphs 1-13, including the steps of: - form a three-dimensional digital model of the panel; - based on the generated digital model, 3D printing (three-dimensional printing) of the form-generating structure of the panel is carried out, defining the shape of the panel, with fastening elements made in one piece with the form-generating structure; intermediate fastening elements are installed on the said fastening elements; a structural supporting layer is applied to the form-generating structure in such a way that it partially covers the intermediate fastening elements for their fixation on the panel.

15. The method according to claim 14, in which, at the stage of printing the form-generating structure of the panel, detachable edge elements are formed on the edges of the form-generating structure of the panel by means of 3D printing, made in one piece with the form-generating structure, in order to form the edge of the panel, wherein the detachable edge elements are separated from the form-generating structure after the application of the structural supporting layer.

16. The method according to claim 14, further comprising a step in which an outer layer is applied to said carrier layer, which layer is designed to perform a decorative and / or protective function.

17. The method according to claim 14, further comprising the step of, after applying the carrier layer, mechanically processing the panel, wherein the mechanical processing includes at least one of milling, grinding and rolling with a roller.

18. The method according to claim 14, in which, at the stage of applying the carrier layer, a temporary mask or template is used that prevents the intermediate fastener from being completely covered by the carrier layer.

19. The method according to claim 14, in which the material of the carrier layer is applied by means of SD printing to form in layers the structure of the panel with integrated intermediate fasteners.

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