JP2023126194A - Method for producing panel - Google Patents

Abstract

To provide a component of a building capable of reducing a time (construction period) and a cost while maintaining strength withstanding a natural disaster or the like compared with the conventional building.SOLUTION: In a method for producing a panel composing a part of a building, an A face member 11 made of concrete or the like is formed by discharging the concrete or the like from a header of a 3D printer. By discharging an adiabatic foam material from the header of the 3D printer to a prescribed face of the A face member 11 to apply the adiabatic foam material to the prescribed face of the A face member 11, an adiabatic member 12 made of the adiabatic foam material is laminated. By discharging the concrete or the like from the header of the 3D printer to the prescribed face of the adiabatic face 12 to apply the concrete or the like to the prescribed face of the adiabatic member 12, a B face member 13 made of the concrete or the like is laminated on the prescribed face of the adiabatic member 12 to produce a panel in which the adiabatic member 12 is sandwiched between the A face member 11 and the B face member 13.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for producing panels.

BACKGROUND ART Conventionally, buildings, especially houses, have had a problem in that the construction costs and time (construction period) are extremely high.
In order to solve this problem, a technology for producing buildings using a 3D printer (for example, see Patent Document 1) is being considered.

Japanese Patent Application Publication No. 2017-128073

The present invention was made in view of this situation, and provides a building that maintains the strength to withstand natural disasters and can reduce time (construction period) and cost compared to conventional buildings. The purpose is to provide parts for things.

In order to achieve the above object, a method for producing a panel according to one embodiment of the present invention includes:
In the production method of panels that constitute part of a building,
A first step of forming a first member made of the first material by discharging a first material of concrete, mortar, or ceramic from a header of a 3D printer based on digital data of the building;
By discharging a second material, which is a heat insulating foam material, from the header of the 3D printer onto a predetermined surface of the first member and applying the second material to the predetermined surface of the first member, the first member is a second step of laminating a heat insulating member made of the second material on the predetermined surface;
Either the first material is applied onto the predetermined surface of the heat insulating member by discharging the first material from the header of the 3D printer onto the predetermined surface of the heat insulating member, or the first material is manually applied to the predetermined surface of the heat insulating member. By applying the second member made of the first material to the predetermined surface of the heat insulating member, the heat insulating member is sandwiched between the first member and the second member. a third step of manufacturing the panel;
including.

According to the present invention, it is possible to provide building components that can reduce time (construction period) and cost while maintaining strength to withstand natural disasters and the like, compared to conventional buildings.

FIG. 2 is an isometric view of a panel manufactured by a panel production method according to an embodiment of the present invention, in which the reference shape of both outer surfaces is based on a plane. FIG. 2 is a cross-sectional view of the panel shown in FIG. 1; FIG. 2 is an isometric view of a panel manufactured by a method for producing a panel according to an embodiment of the present invention, which is different from FIG. 1 and is based on a compound curved configuration in which the reference shape of both outer surfaces is curved. FIG. 4 is a cross-sectional view of the panel shown in FIG. 3; Unlike FIGS. 1 to 4, the panel produced by the panel production method according to an embodiment of the present invention has one outer surface reference shape based on a plane and another method outer surface reference shape based on a curved surface. FIG. 6 is a cross-sectional view of the panel shown in FIG. 5. FIG. FIG. 7 is an isometric view of a panel manufactured by a panel production method according to an embodiment of the present invention, which is different from FIGS. 1 to 6 and whose reference shapes on both outer surfaces are based on two independent compound curves. 8 is a cross-sectional view of the panel shown in FIG. 7. FIG.

Embodiments of the present invention will be described below with reference to the drawings.
Hereinafter, explanation will be given using examples of panels of four types of shapes. Therefore, the panels in the examples of FIGS. 1 and 2 are panel 1-1, the panels in FIGS. 3 and 4 are panel 1-2, the panels in FIGS. 5 and 6 are panel 1-3, and the panels in FIGS. 7 and 8 are The panels in this example are called panels 1-4. Note that when there is no need to distinguish panels 1-1 to 1-4 individually, they are collectively referred to as "panel 1."
Further, as will be described in detail later, the members constituting each of the panels 1-2 to 1-4 correspond to the members constituting the panel 1-1. Therefore, when referring to the panel 1 as "panel 1", when explaining the members constituting the panel 1, the reference numerals of the members constituting the panel 1-1 will be used as appropriate.

FIG. 1 is an isometric view of a panel manufactured by a panel production method according to an embodiment of the present invention.
FIG. 2 is a cross-sectional view of the panel shown in FIG.
The panel 1-1 shown in FIGS. 1 and 2 is composed of an A-side member 11, a heat insulating member 12, and a B-side member 13.
The panel 1 manufactured by the panel production method according to an embodiment of the present invention is manufactured using a 3D printer that performs additive manufacturing that is located in a factory.

First, the significance of using 3D printer-printed building assembly parts in architecture will be explained below.

The 3D printer ejects the material for the panel from the 3D printer's header.
First, the concept of ejecting material from a 3D printer will be explained using a three-dimensional orthogonal coordinate system consisting of xyz, although not shown.
For example, when a 3D printer forms one layer by arranging materials on a predetermined plane approximately parallel to the xy plane based on a three-dimensional model of a panel prepared in advance, the 3D printer also prints a header approximately in the z direction. (substantially vertically) to form the next layer so as to stack on top of the layer. In this way, the 3D printer forms the wall surface of the house by stacking a plurality of layers in the approximately z direction (approximately vertical direction, direction of gravity).
As described above, one embodiment of the production method of the present invention is based on a three-dimensional model of a panel (for example, panel 1) prepared in advance, and produces concrete, mortar, or This production method employs a method (hereinafter referred to as "3D printing additive manufacturing method") in which the walls of house 1 are formed by layering ceramic materials in the approximately z direction (approximately vertical direction).

Specifically, much of the cost of conventional houses was accounted for by the logistics costs of lumber. In other words, wood was felled in Europe and Canada, transported to Japanese ports, and then transported to Japanese factories for processing. As a result, for about 100 days, carpenters and plasterers had to drive to the site to construct the conventional houses. In this way, half of the cost of a conventional house is logistics costs.
Furthermore, in Japan, the decline in the number of carpenters and plasterers is a major issue, and labor costs will also account for a large portion of the cost of traditional houses.
On the other hand, by adopting the 3D printing additive manufacturing method, there is no need for wood, and there is no need for many carpenters and plasterers, except for the minimum number of people required to operate the 3D printer, which makes it possible to eliminate the need for many carpenters and plasterers. Compared to building a house, it is possible to reduce costs and time (construction period).

By the way, it is also possible to use the 3D printing additive manufacturing method to build a house consisting of rectangular parallelepiped walls without curves.
However, since such a house requires a structure such as reinforcing steel, the cost and construction cost reduction effect is small compared to a conventional house.
Therefore, as an embodiment of the production method of the present invention, not only the 3D printing additive manufacturing method is adopted, but also parts of buildings (houses) are manufactured using the 3D printing additive manufacturing method, as shown in FIGS. 1 to 8. A method is used to produce panels that form a certain wall surface.

Further, it is preferable that the wall surface of a building (for example, a house) is not a rectangular parallelepiped-shaped wall surface without curves, but a house composed of wall surfaces that are approximately "spherical". That is, the ``spherical'' shape of a building that can be manufactured using a 3D printer itself serves as a structure that can maintain strength to withstand natural disasters, so structures such as reinforcing bars are not required. As a result, one embodiment of the production method of the present invention can maintain strength to withstand natural disasters, etc., compared to producing conventional houses or producing rectangular parallelepiped houses using 3D printers. , it becomes possible to significantly reduce costs and time (construction period).
However, when using the 3D printing additive manufacturing method, it is difficult to ensure sufficient heat insulation for a house simply by using concrete, mortar, or ceramic materials.

Here, conventionally, in buildings, heat insulation is usually performed by sandwiching a heat insulating material between two predetermined plate-like structures. BACKGROUND OF THE INVENTION In many cases, glass wool processed into a sheet having a predetermined width and thickness is used as insulation material for houses. For example, in the case of a wooden building, glass wool is spread between the studs inside the pillar wall.

However, traditional insulation requires manual sandwiching. Therefore, as described above, it is not compatible with reducing costs by increasing work efficiency using a 3D printer. Therefore, in this embodiment, this disadvantage can be solved by installing a heat insulating material between the two plate-like structures using a 3D printer.

Specifically, the panel 1 of this embodiment has a heat insulating member 12 made of expanded polyurethane or other similar insulating foam material, an A-side member 11 made of two layers of concrete or other cementitious material, and It relates to a building or part of a building, consisting of a sandwich structure glued between B-side members 13.
The heat-insulating foam material is a material that is ejected from the header of a 3D printer as a viscous material under predetermined conditions, and hardens after a predetermined period of time after being ejected to exhibit a heat-insulating function.

The panel 11, which is such a component, is manufactured through the following first to third steps.

In the first step, a 3D printer to which the 3D printing additive manufacturing method is applied 3D prints at least one layer of the outer concrete layer (here, the layer of the A-side member 11), and the first layer ( This is a step in which the A-side member 11) forms the external dimensions of the panel 11, which is an assembled product.
Specifically, for example, the A-side member 11, which is the first layer, may be printed in free space or in an existing shape using a 3D printer. As mentioned above, the material ejected and printed from the 3D printer is concrete, mortar, or ceramic material.

Here, printing in free space means that the 3D printer laminates concrete, mortar, or ceramic materials in the X-axis direction in FIG. 2, which is the direction of gravity. As a result, the A-plane member 11 is formed substantially parallel to the XY plane. After the A-side member 11 is hardened to an appropriate hardness, the A-side member 11 is rotated so that the direction of gravity is in the negative direction of the Z-axis shown in FIG. Then, a heat insulating member 12, which will be described later, is formed in the positive direction of the axis Z.
By printing in the free space in this way, there is no need for the mold or the removal work from the mold, which will be described later. That is, it is possible to reduce the cost of the work involved in the process of using the mold.

Moreover, printing on an existing shape is as follows. That is, a mold having an existing shape (a mold made of metal or the like having a desired flat or curved shape) is prepared. This mold is arranged so that its surface is substantially perpendicular to the direction of gravity. The 3D printer then laminates concrete, mortar, or ceramic material on the top surface of this mold (the surface in the opposite direction to gravity). Then, after the A-side member 11 is hardened to an appropriate hardness, a heat insulating member 12, which will be described later, is formed in the positive direction of the axis Z.
That is, the surface of the mold is used as a member that holds the surface of the A-side member in the negative direction of the axis Z. In this way, by printing on the (desired) existing shape, steps such as rotation of the A-side member can be made unnecessary. That is, it is possible to reduce the cost of the work involved in the process of rotating.

Here, the printed A-side member 11 may optionally include reinforcing materials such as steel or fiberglass, or other tensile modifiers known in the concrete forming process. These may be sandwiched during 3D printing or applied afterwards.

The panel 1, which is the final assembled product, is manufactured through the following second and third steps.

The second step is as follows.
That is, the 3D printer prints the A-side member 11 by discharging and curing the foam material on a predetermined surface (inner surface of the panel 1) of the A-side member 11 of the first layer printed first. The heat insulating member 12 is laminated on the predetermined surface.

The third step is as follows.
The 3D printer discharges a material such as concrete (the same material as in the first step) to the heat insulating member 12 that has been hardened in the second step and hardens it (3D printing). Then, the second layer (outer layer) B-side member 13 is laminated.
Note that in the third step, the material such as concrete may be applied to the heat-generating heat insulating seat 12 manually instead of using a 3D printer.

Through these first to third steps, the panel 1, which is the final assembled product, is manufactured.
This finished part (panel 1) becomes a wall element, a roof and/or floor element, a foundation and/or foundation element, or any other structural part used in a building assembly. The final assembly then has low load-bearing elements, low thermal conductivity, low moisture conductivity, low noise conductivity, low radiation conductivity, low electrical conductivity, etc. That is, it is designed to function as an insulating element that retards energy transfer like all other related insulating properties.
That is, in the above description, the heat insulating member 12 is used between the A side member 11 and the B side member 13, but in order to provide the desired function, a member corresponding to the function may be used. Often, a 3D printer may eject materials that are mixed to have multiple desired functions.

The panel 1 produced by the production method of this embodiment is used in the structural assembly of a building element constructed from existing materials that are clearly already used for other building elements.
Here, conventional thermal insulation panels for buildings have been manufactured using linear forms such as steel plates, plywood, or ready-made pressed wood.

On the other hand, the production method of this embodiment removes the defining characteristics related to the defined formwork and uses 3D printing to create straight lines (substantially plane) or linear curves and compound curves (curved surfaces). A defined element shape can be created that may also include both curved elements.
That is, although FIGS. 1 and 2 show a panel 1-1 having a substantially flat shape, the production method of this embodiment is also useful when producing a panel having at least one curved surface. . Panels 1-2 to 1-4, at least one of which has a curved surface, will be described later with reference to FIGS. 3 to 8.
This makes it possible to realize the above-mentioned substantially spherical building at reduced cost.

Additionally, by applying this technology, insulating panels for buildings can take shapes that are not limited to a single cross-sectional dimension, since the elements are This is because it can have thicker and thinner sections to meet enhanced or improved requirements or islands of requirements.

Panel 1 is the final assembly of all elements included in a ready-made architectural panel for architectural applications. The panel 1 has two outer layers made of concrete (A-side member 11 and B-side member 13) and one inner layer (insulation member 12) made of insulation foam. Panel 1 may include more elements of reinforcement made from other materials, but the use of these additional materials is not exclusively necessary to form the present assembly. do not have. Panel 1 is manufactured by printing at least one of the outer layers (eg, the layer of A-side member 11) to form a shape that serves as a reference for the remaining parts in making the assembly.

In this way, the production method of the present embodiment can produce panels 1 of various shapes, and therefore can produce sophisticated structural assemblies.
Load-bearing design can take into account more complex geometries available to engineers or architects that are not possible with architectural insulated panels using traditional assembly methods. The production method of the present embodiment allows the panels 1 to be produced to include arcuate, spherical, parabolic and gyroid shapes, resulting in lower mass or lower production than previously realized. High load-bearing performance is possible at low cost. Essentially, this product can create assembly techniques that could not be realized before the panel 1 of this embodiment. Traditional formwork used to create concrete elements may have limitations that 3D printing does not have. That is, when considering the manufacture of parts, when it is impossible to manufacture concrete parts due to mechanical interference when removing the formwork, it may be possible to manufacture the parts with 3D printing. When this degree of creative freedom is applied to the panel 1, the present technology enables assemblies that have never existed before.

To make panel 1, the manufacturing process involves using viscous materials (materials 11 and 13, such as concrete, and material 12, insulation foam) that are extruded into place and hardened to form the final shape. A stacking automatic deposition system (3D printer) is used. This cured material, which is a component of the final assembly, is a blowing agent (insulating foam) that is impermeable to and encapsulates air or other gases. This foaming agent (insulating foam material) cures into a hard agglomerate of the foaming agent itself and the trapped gas, which agglomerate forms the bonding site for the layer of the B side member 13, and the B The layers of face member 13 are manufactured by using the same process as auto-deposited A-side member 11 or an entirely new deposition process with comparable structural integrity as A-side member 11. The surface of the cured foam adhesive site may be modified to more accurately define the layers of B-side member 13 and the overall shape of the final assembly.

FIG. 3 is an isometric view of a panel manufactured by the panel production method according to an embodiment of the present invention, which is different from FIG. .
FIG. 4 is a cross-sectional view of the panel shown in FIG. 3.

The panel 1-2 shown in FIGS. 3 and 4 is composed of an A-side member 21, a heat insulating member 22, and a B-side member 23.
The A-side member 21 of the panel 1-2 shown in FIGS. 3 and 4 corresponds to the A-side member 11 of the panel 1-1 shown in FIGS. 1 and 2 described above.
The heat insulating member 22 of the panel 1-2 shown in FIGS. 3 and 4 corresponds to the heat insulating member 12 of the panel 1-1 shown in FIGS. 1 and 2 described above.
The B-side member 23 of the panel 1-2 shown in FIGS. 3 and 4 corresponds to the B-side member 13 of the panel 1-1 shown in FIGS. 1 and 2 described above.

The production method of the panel 1-2 shown in FIGS. 3 and 4 is basically the same as the production method of the panel 1-1 described in the above embodiment, but compared to the example of FIGS. 1 and 2. , has the following characteristics.
As shown in FIGS. 3 and 4, the shapes of the A-side member 21, the heat insulating member 22, and the B-side member 23 of the panel 1-2 are all based on a compound curved (curved) shape based on the A-side member 21. There is. The sandwich structure (A-side member 21 and B-side member 23) and infill (insulating member 22) are then all in parallel planes of their respective elements.

In FIG. 5, the reference shape of one outer surface is based on a flat surface, and the reference shape of the outer surface of the other method is a curved surface, unlike FIGS. FIG. 2 is an isometric view of a panel based on FIG.
FIG. 6 is a cross-sectional view of the panel shown in FIG. 5.

The panel 1-3 shown in FIGS. 5 and 6 is composed of an A-side member 31, a heat insulating member 32, and a B-side member 33.
The A-side member 31 of the panel 1-3 shown in FIGS. 5 and 6 corresponds to the A-side member 11 of the panel 1-1 shown in FIGS. 1 and 2 described above.
The heat insulating member 32 of the panel 1-3 shown in FIGS. 5 and 6 corresponds to the heat insulating member 12 of the panel 1-1 shown in FIGS. 1 and 2 described above.
The B-side member 33 of the panel 1-3 shown in FIGS. 5 and 6 corresponds to the B-side member 13 of the panel 1-1 shown in FIGS. 1 and 2 described above.

The production method of the panel 1-3 shown in FIGS. 5 and 6 is basically the same as the production method of the panel 1-1 described in the above embodiment, but compared to the example of FIGS. 1 and 2. , has the following characteristics.
First, in the examples shown in FIGS. 1 and 2, the 3D printer discharges each material to generate each member in the positive direction of the Z-axis, but in the examples shown in FIGS. 5 and 6, each member is produced in the negative direction of the Z-axis. generate.
As shown in FIGS. 5 and 6, only the A-side member 31 of the panel 1-3 is based on a linear (planar) configuration. Then, the initial reference of the heat insulating member 12 (the shape in the positive direction of the Z axis is the shape of the A-side member 31). Then, the 3D printer discharges the heat insulating foam material so that it has the specified thickness in the axis Z direction at each position on the XY plane. As a result, a heat insulating member 32 having a different thickness depending on the position on each XY plane is generated. That is, the shape of the surface of the heat insulating member 32 in the negative Z-axis direction is a predetermined curved shape. Then, a B-side member 33 is formed on the surface of such a heat insulating member 32 in the Z-axis negative direction. As a result, a panel 1-3 having a heat insulating member of an arbitrary thickness at an arbitrary position on the XY plane is produced.

FIG. 7 is an isometric view of a panel in which the reference shapes of both outer surfaces are based on two independent compound curves.
FIG. 7 is an isometric view of a panel manufactured by the panel production method according to an embodiment of the present invention, which is different from FIGS. 1 to 6 and whose reference shapes on both outer surfaces are based on two independent compound curves. It is.
FIG. 8 is a cross-sectional view of the panel shown in FIG. 7.

The panel 1-4 shown in FIGS. 7 and 8 is composed of an A-side member 41, a heat insulating member 42, and a B-side member 43.
The A-side member 41 of the panel 1-4 shown in FIGS. 7 and 8 corresponds to the A-side member 11 of the panel 1-1 shown in FIGS. 1 and 2 described above.
The heat insulating member 42 of the panel 1-4 shown in FIGS. 7 and 8 corresponds to the heat insulating member 12 of the panel 1-1 shown in FIGS. 1 and 2 described above.
The B-side member 43 of the panel 1-4 shown in FIGS. 7 and 8 corresponds to the B-side member 13 of the panel 1-1 shown in FIGS. 1 and 2 described above.

The production method of the panel 1-4 shown in FIGS. 7 and 8 is basically the same as the production method of the panel 1-1 described in the above embodiment, but compared to the example of FIGS. 1 and 2. , has the following characteristics.
As shown in FIGS. 7 and 8, the A-side member 41 of the panel 1-4 is formed using a predetermined curved surface (ie, the curved surface of the mold) as a reference shape. Then, the initial reference of the heat insulating member 12 (the shape in the Z-axis negative direction is the shape of the A-side member 41) is based. Then, the 3D printer discharges the heat insulating foam material so that it has the specified thickness in the axis Z direction at each position on the XY plane. As a result, a heat insulating member 42 having a different thickness depending on the position on each XY plane is generated. That is, the shape of the surface of the heat insulating member 42 in the Z-axis positive direction becomes a predetermined curved shape. Then, a B-side member 43 is formed on the surface of such a heat insulating member 42 in the Z-axis positive direction. As a result, a panel 1-4 having a heat insulating member 42 of an arbitrary thickness at each point on the XY plane is produced based on the different curved shapes of the A-side member 41 and the B-side member 43, respectively.

In this way, the production method of this embodiment uses a 3D printer to reduce costs while printing each of the surfaces of the panel 1 (A-side member 11 and B-side member 13) in any shape (flat or flat). It is possible to realize curved surfaces.

1, 1-1, 1-2, 1-3, 1-4...insulation panel, 11, 21, 31, 41...A side, 12, 22, 32, 42...insulation member, 31 , 32, 33, 43...B side

Claims (2)

In the production method of panels that constitute part of a building,
A first step of forming a first member made of the first material by discharging a first material of concrete, mortar, or ceramic from a header of a 3D printer based on digital data of the building;
By discharging a second material, which is a heat insulating foam material, from the header of the 3D printer onto a predetermined surface of the first member and applying the second material to the predetermined surface of the first member, the first member is a second step of laminating a heat insulating member made of the second material on the predetermined surface;
Either the first material is applied onto the predetermined surface of the heat insulating member by discharging the first material from the header of the 3D printer onto the predetermined surface of the heat insulating member, or the first material is manually applied to the predetermined surface of the heat insulating member. By applying the second member made of the first material to the predetermined surface of the heat insulating member, the heat insulating member is sandwiched between the first member and the second member. a third step of manufacturing the panel;
Panel production methods including. The second material includes a material that foams when applied to the first member.
A method for producing the panel according to claim 1.

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