WO2020048468A1 - 一种3d打印编织一体化成型建筑的建造方法 - Google Patents

一种3d打印编织一体化成型建筑的建造方法 Download PDF

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Publication number
WO2020048468A1
WO2020048468A1 PCT/CN2019/104274 CN2019104274W WO2020048468A1 WO 2020048468 A1 WO2020048468 A1 WO 2020048468A1 CN 2019104274 W CN2019104274 W CN 2019104274W WO 2020048468 A1 WO2020048468 A1 WO 2020048468A1
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Prior art keywords
weaving
printing
structural
wire
printed
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Ceased
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English (en)
French (fr)
Inventor
孙晓燕
王海龙
陈杰
汪群
高超
张治成
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Zhejiang University
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Zhejiang University
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Priority to US17/268,399 priority Critical patent/US12097661B2/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/523—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement containing metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/30—Auxiliary operations or equipment
    • B29C64/386—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/35—Extraordinary methods of construction, e.g. lift-slab, jack-block
    • E04B1/3505—Extraordinary methods of construction, e.g. lift-slab, jack-block characterised by the in situ moulding of large parts of a structure
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02—Conveying or working-up concrete or similar masses able to be heaped or cast
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/02—Conveying or working-up concrete or similar masses able to be heaped or cast
    • E04G21/04—Devices for both conveying and distributing
    • E04G21/0418—Devices for both conveying and distributing with distribution hose
    • E04G21/0445—Devices for both conveying and distributing with distribution hose with booms
    • E04G21/0463—Devices for both conveying and distributing with distribution hose with booms with boom control mechanisms, e.g. to automate concrete distribution
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
    • E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
    • E04G21/14—Conveying or assembling building elements
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/13—Architectural design, e.g. computer-aided architectural design [CAAD] related to design of buildings, bridges, landscapes, production plants or roads
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/20—Design optimisation, verification or simulation
    • G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2077/00—Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • B29K2305/08—Transition metals
    • B29K2305/12—Iron
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F2113/00—Details relating to the application field
    • G06F2113/10—Additive manufacturing, e.g. three-dimensional [3D] printing

Definitions

  • the invention relates to the technical field of building construction, in particular to a method for constructing a 3D printed woven integrated molding building.
  • the current 3D printing technology also lacks a combination of a matrix and traditional reinforcing materials, such as the combination with steel bars.
  • the type of printing structure is limited by material properties, and most of them are small spaces and small spans. Small civil buildings.
  • CN107603162A discloses a high-strength and high-toughness 3D printing material for construction;
  • CN107619230A discloses a concrete material for 3D printing;
  • CN107200536A discloses a rapid-forming 3D printing paste for construction Materials and preparation methods thereof;
  • CN107177155A discloses a high-intensity and UV-resistant 3D printing material for the construction field and a preparation method thereof;
  • CN107141799A discloses an oxidation-resistant high-intensity 3D printing material for a construction project and a preparation method thereof;
  • CN107417180A has announced Graphene geopolymer cement and preparation method thereof;
  • CN107032669A discloses a 3D printed building material.
  • the types and strengths of printing materials have been significantly improved, but how to print and integrate with reinforcing ribs to overcome many shortcomings of printing buildings using only cement-based materials is a key technical problem to be solved at this stage.
  • 3D printed substrates do not require molds, and are self-made by adding materials. However, most of them are brittle materials with low strength and poor deformation ability. A strong spatial network needs to be formed by combining with a flexible, high-strength, geometrically variable material to ensure that the structure can be used in a variety of ways. Load-bearing capacity, deformation capacity and durability under operating conditions. Traditional construction steel and composite fiber materials are mostly manufactured in the form of tendons, which need to be cut, tied and positioned according to the design to form a rigid skeleton. The construction process is complicated, and it is difficult to integrate and integrate with the existing 3D printing technology.
  • Cipheral Patent Document No. CN106760532A has published a method for building construction based on 3D printing.
  • Chinese Patent Document No. CN105756187A Announced a construction and construction method combining 3D printing technology with concrete; these methods use 3D printing technology to print the shell or main support, then cut the steel bars, bind, position and hoist, and finally cast ordinary in a 3D template Concrete assembles the two.
  • the purpose of the present invention is to provide a method for constructing a 3D printed woven integrated molding building.
  • the construction method provided by the invention solves the defects in strength and toughness of the existing 3D printing substrate, and also makes up for the lack of structural space spanning capacity and bearing capacity.
  • the construction is convenient and quick to apply, and has high toughness, fatigue resistance and long Advantages such as longevity; make each part of the building not only meet the different requirements of structural mechanics, but also achieve economical aesthetics and artistic molding on the basis of safety and reliability.
  • a method for constructing a 3D printed woven integrated molding building includes the following steps:
  • step (2) perform 3D printing of the matrix and weave the wires, and build one layer after layering, stacking, and hardening to form a 3D printed weaving integrated molding building; or After segment printing, the 3D printed weaving integrated molding building is obtained through the preset tenon joint segment connection.
  • the method of programming the wires is: in the parallel printing direction, the 3D printing matrix is integrated into the wire and integrated at the weaving anchor point.
  • the jet screw is positioned, and the knitted wire is wound on the jet screw; in the vertical printing direction, after 3D printing the substrate, the jet screw is positioned at the weaving anchor point, and the wire is knitted before the printing material is initially set, and the knitted wire is wound around Spatial grids are formed on the sprayed screws.
  • the basic structural member is selected from an arch, a beam, a slab, a column, or a wall.
  • the method of structural space optimization is selected from a bidirectional progressive optimization algorithm and a body shape topology optimization
  • the body topology optimization is selected from a homogenization method, a variable density method, a progressive structure optimization method (ESO), or a level Set methods.
  • step (2) the method of determining the weaving range and weaving density of the wire according to the weak area and size of the structural force is:
  • the actual value is a building importance level, a regional seismic fortification intensity, and the like.
  • the step (2) further includes setting a positioning point for the knitting range of the wire rod for positioning the knitted wire rod.
  • the 3D printing material is selected from one or a combination of at least two of a cement-based material, a gypsum material, or a nylon material.
  • 3D printed materials have the characteristics of rapid prototyping and convenient construction, and have higher strength and shaping ability than ordinary cement-based materials.
  • the 3D printing material further includes a reinforcing component selected from one or at least two of fibers and polymers, expanded microbeads or hollow particles, and nanomaterials. combination.
  • the reinforcing component can have various scales and various forms.
  • the wire is selected from one or a combination of at least two kinds of steel wires, fiber composite wires or nano wires.
  • the wire is used instead of steel bars. It is lightweight, high-strength, geometrically variable, and multi-stranded wire braided. It has a high surface friction coefficient and works in concert with the integrated molding of the substrate to ensure the mechanical properties, seismic performance, and fatigue of the new and strong structure. Performance and durability.
  • the spray screw can be used as a positioning pin to realize the three-dimensional weaving of the toughened wire, guarantee the weaving accuracy, make the design accurate, the structure is safe and the structure is more reasonable.
  • the parallel printing direction can be integrated into the rope material.
  • the key points can be nailed to ensure geometric weaving.
  • the vertical printing direction can be nailed to layer by layer to form a spatial grid. Spraying screws in the printing substrate to achieve spatial positioning can ensure printing and weaving. Precision.
  • step (4) the segmented printing method is as follows: 3D printing the substrate and the wire are pre-printed in sections according to the structural requirements of the structural members, and the components are connected by the post-pouring / post-tension printing woven tenon structure.
  • the wire is also called a rope.
  • the invention combines the technical superiority of the existing 3D printing materials with rapid prototyping and the superior material properties of lightweight, high strength and geometrically variable high-strength wires, while weaving a certain proportion of high-strength wires while 3D printing the matrix to improve the structural strength and toughness.
  • Insufficient degree forming a new type of building structure that is different from the integrated molding of traditional reinforced concrete structures, not only solves the defects of the existing 3D printed substrates in strength and toughness, but also makes up for the lack of structural space spanning capacity and bearing capacity. .
  • the invention has the advantages of convenient construction and rapid application, and has the advantages of high toughness, fatigue resistance, long life, etc., so that each part of the building can not only meet the different requirements of structural mechanics, but also achieve economical beauty and shape on the basis of safety and reliability.
  • Art Eliminates the formwork engineering and the reinforcement cage binding process in traditional building construction, which not only reduces building construction procedures, but also reduces labor intensity.
  • the 3D printing and weaving technology of the present invention is adopted to more easily realize the structural facade modeling; and this construction method can also be combined with the existing tendons for construction.
  • the internal weaving process of the structure, the space positioning control through the spray screws, the high-strength wire space is precisely and toughly braided, and it forms a space-strength structure with a coordinated force and a uniform deformation with the printing substrate to achieve the optimal combination of space forces, which effectively improves
  • the 3D printed substrate has tensile, shear, abrasion and crack resistance properties, with higher load-bearing capacity, deformation capacity, crack resistance and seismic ductility, meeting multiple functional needs of the structure, and achieving an effective combination of space span and 3D modeling , Make the advantages of 3D printed buildings fully prominent, no longer limited to small building structures.
  • weaving parts can be printed separately in different regions, and then assembled into a whole, using the preset tenon member and post-tensioning prestressing process to enhance the integrity; the prepared 3D printing weaving integrated molding
  • the building can also be combined with traditional building structures, with flexible compatibility and universality.
  • FIG. 1 is a schematic flowchart of a construction method provided by the present invention.
  • FIG. 2 is a comparison diagram of multiple schemes for spatial modeling optimization of a bridge structure in an embodiment
  • FIG. 3 is an x-direction stress distribution diagram of the bridge structure provided by the solution b in the embodiment
  • FIG. 4 is a main tensile stress distribution diagram of the bridge structure provided by the solution b in the embodiment.
  • FIG. 6 is a schematic diagram of printing weaving in the embodiment.
  • the method for constructing a 3D printed weaving integrated molding building includes the following steps:
  • step (2) Perform the 3D printing matrix according to the printing process and the weaving process in step (2), weave the wire, build it layer by layer, superimpose it, and harden it at one time to form a 3D printed weaving integrated building; or after segment printing
  • the 3D printed woven integrated molding building is obtained by connecting the preset tenoning structural segments.
  • Bridges usually choose beam or arch structures as their main stress members. 3D printed cement-based materials usually have high compressive strength and low tensile strength. Choosing an arch shape as the main stress member of a bridge structure can make full use of the material's resistance. Compressive properties while avoiding structural tensile failure.
  • the spatial modeling and structural stress of the arch structure are selected by structural topology optimization.
  • structural topology optimization In order to avoid missing the global optimal solution, two methods or a combination of truss discrete structure and continuum topology can be used.
  • the optimized structure form is shown in Figure 2 after being regularized, including scheme a and scheme b. 3D printing of bridges can be used as a preliminary structural choice.
  • the second scheme (ie, scheme b) in the portal arch shown in Figure 2 is more clear in the force transmission path, which is selected as the basic form of the bridge structure for force analysis. Based on the use of the structure's stress at the load level and the uniform stress distribution coefficient as the basis for structural optimization, the spatial layout of the continuum / truss composite structure was determined.
  • Figs. 3 and 4 The stress distribution of the structure obtained based on the finite element analysis is shown in Figs. 3 and 4, in which the stress in the middle part of the arch ring and the end of the arch frame is relatively large, and it is an area that needs local reinforcement.
  • the 3D printing substrate starts printing and weaving after the preset thickness.
  • the parallel printing direction can be directly integrated into the rope.
  • the weaving anchor point is sprayed with screws to ensure that weaving is in place and the rope is knitted. Moderate tension during entry is beneficial to the overall force of the printed woven structure after molding.
  • the vertical printing direction can be incorporated layer by layer after positioning with the help of spray screws.
  • the high-strength rope and the 3D printed matrix are solidified and integrated to form a spatial grid stress skeleton inside, which improves the crack resistance, deformation and seismic performance of the structure.
  • a is a schematic diagram of a printing direction, where A ′ is a printing starting point, and an arrow direction is a printing direction; b is Schematic diagram of weaving direction, the direction of arrow is the weaving direction, point A is the starting point of weaving, AB, BC, LK, KJ, FG, GH, HI, JK, KL and MA sections are encrypted weaving areas, CD, DL, JE, EF, The IJ and LM sections are ordinary knitting areas; the AM points are screws for positioning that are sprayed at the knitting anchor points.
  • the 3D printing material is a cement-based material
  • the wire is a steel strand.

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  • Architecture (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Theoretical Computer Science (AREA)
  • Geometry (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Computer Hardware Design (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
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  • Pure & Applied Mathematics (AREA)
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Abstract

本发明公开了一种3D打印编织一体化成型建筑的建造方法，包括：选取基本建筑结构构件，空间建模后采用有限元分析，结合应力云图，设定判别域，进行结构空间优化，得到结构构件骨架；对结构构件骨架进行计算分析，根据结构受力薄弱区域和大小确定线材的编织范围和编织密度，再根据结构构件骨架以及线材的编织范围和编织密度确定打印流程和编织流程；配制3D打印材料；根据打印流程和编织流程3D打印基体并将线材编入，逐层建造后叠加一次性形成；或分段打印后通过预设榫接构造段连接。本发明提供的建造方法具有高韧性、耐疲劳和长寿命等优点；使建筑物各个部位既能满足结构力学的不同要求，又可以在安全可靠的基础上达到经济美观，造型艺术。

Description

一种3D打印编织一体化成型建筑的建造方法 技术领域
本发明涉及建筑建造施工技术领域，特别是涉及一种3D打印编织一体化成型建筑的建造方法。
背景技术
由于现有打印材料的强度和耐久性一直亟待提升，当前3D打印技术也缺乏基体与传统增强材料，如与钢筋的组合形式，导致打印结构型式受限于材料性能，多为小空间小跨度的小型民用建筑。
现有3D建筑材料非常丰富，CN107603162A公开了一种建筑用高强度高韧性3D打印材料；CN107619230A公开了一种用于3D打印的混凝土材料；CN107200536A公布了一种用于建筑的快速成型3D打印浆料及其制备方法；CN107177155A公开了一种建筑领域用高强度耐紫外线的3D打印材料及其制备方法；CN107141799A公开了一种建筑工程用耐氧化高强度3D打印材料及其制备方法；CN107417180A公布了一种石墨烯土聚水泥及其制备方法；CN107032669A公布了一种3D打印建筑材料。目前打印材料的种类和强度均有了明显提升，但是如何与增强筋材一体打印成型以克服单纯利用水泥基材料打印建筑的诸多缺陷，是现阶段有待解决的关键技术问题。
3D打印基体无需模具，增材自制，但多为脆性材料，强度较低，变形能力差，需要与一种柔韧高强，几何可变的材料组合形成强韧的空间网络，才能保障结构在多种使用工况下的承载能力、变形能力和耐久性能。传统的建筑钢材和复合纤维材料多以筋材形式制造，需要根据设计进行切割，绑扎，定位，形成刚性骨架，施工工序繁杂，难以与现有3D打印技术融合集成。
现阶段进行了各种技术尝试将3D打印与传统的钢筋材料进行结合，公开号为CN106760532 A的中国专利文献公布了一种基于3D打印的建筑物施工方法，公开号为CN 105756187A的中国专利文献公布了一种3D打印工艺与混凝土结合的建造、施工方法；这些方法都是利用3D打印工艺的形塑能力打印外壳或者主要支架，然后切割钢筋，绑扎，定位吊装，最后在3D模板里浇筑普通混凝土将二者进行组装。
现有的这些建造方式没有充分利用3D打印技术形成一体化自动化的智能建造技术，仅仅利用了3D打印技术节省了模板工程，而且这些模板和支架在内部混凝土浇筑过程中很容易导致变形过大而发生胀裂。虽然各种刚性筋材很难与3D打印混凝土一体化机械化构建成型，但是各种现代高强柔性线材，如高强钢绞线，钢-FRP复合线材，纳米高强复合线材等，给一体化自动建造强韧混凝土结构提供了可行途径。
因此，如何采用现有的3D打印技术和已有的水泥基胶凝材料，与高强高韧复合材料相结合是克服现有3D打印建筑诸多限制、制造新型建筑结构 的关键问题。
发明内容
本发明的目的在于提供一种3D打印编织一体化成型建筑的建造方法。本发明提供的建造方法解决了现有3D打印基体在强度和韧性上的缺陷，又弥补了结构空间跨越能力和承载力的不足，施工便捷，快速适用的同时，具有高韧性、耐疲劳和长寿命等优点；使建筑物各个部位既能达到结构力学的不同要求，又可以在安全可靠的基础上达到经济美观，造型艺术。
本发明提供如下技术方案：
一种3D打印编织一体化成型建筑的建造方法，包括以下步骤：
(1)选取基本建筑结构构件，空间建模后采用有限元分析，结合应力云图，设定判别域值，进行结构空间优化，得到结构构件骨架；
(2)对结构构件骨架进行计算分析，根据结构受力薄弱区域和大小确定线材的编织范围和编织密度，再根据结构构件骨架以及线材的编织范围和编织密度确定打印流程和编织流程；
(3)配制3D打印材料；
(4)根据步骤(2)中的打印流程和编织流程进行3D打印基体和将线材编入，逐层建造后、叠筑、硬化后一次性成型，形成3D打印编织一体化成型建筑；或分段打印后通过预设榫接构造段连接得到3D打印编织一体化成型建筑；所述的线材的编入方法为：在平行打印方向上，3D打 印基体时一体化编入线材，在编织定位点喷射螺钉定位，编入的线材缠绕在喷射的螺钉上；在垂直打印方向上，3D打印基体后，在编织定位点喷射螺钉定位，在打印材料初凝前编入线材，编入的线材缠绕在喷射的螺钉上形成空间网格。
其中，所述基本结构构件选自拱、梁、板、柱或墙。
所述的步骤(1)中，结构空间优化的方法选自双向渐进优化算法、体型拓扑优化，所述的体型拓扑优化选自均匀化方法、变密度法、渐进结构优化法(ESO)或水平集方法。
在步骤(2)中，根据结构受力薄弱区域和大小确定线材的编织范围和编织密度的方法为：
(2-1)根据应力/强度比值确定的安全系数确定编织范围；
(2-2)根据安全系数与阀值的大小，确定加密编织和普通编织范围，所述阀值根据实际取值确定。
所述实际取值为建筑重要性等级、地域抗震设防烈度等。
所述的步骤(2)还包括在线材的编织范围设置定位点，用于为编织线材定位。
在步骤(3)中，所述的3D打印材料选自水泥基材料、石膏材料或尼龙材料中一种或至少两种的组合。
3D打印材料具有快速成型和便捷施工的特点，与普通水泥基材料相比具有较高的强度和塑形能力。
在步骤(3)中，所述的3D打印材料还包括增强组分，所述增强组分选自纤维及其聚合物、膨化微珠或中空微粒、纳米材料中的一种或至少两种的组合。
其中，增强组分可以为各种尺度和各种形态。
在步骤(4)中，所述的线材选自钢绞线、纤维复合线材或纳米线材中的一种或至少两种的组合。
采用线材代替钢筋，轻质高强、几何可变、多股线材绞绕编织，具有较高的表面摩擦系数，与基体一体化成型协同受力，保障强韧性新型结构的力学性能、抗震性能、疲劳性能和耐久性。
在3D打印基体结构过程中喷射螺钉作为定位针可以实现增韧线材的立体编织，保障编织精度，使设计准确实施，结构受力安全，结构造型更为合理。平行打印方向可以一体化编入绳材，关键点射钉定位保证几何编织造型，垂直打印方向可以射钉定位逐层编入形成空间网格；在打印基体中喷射螺钉实现空间定位，可以保障打印编织精度。
在步骤(4)中，所述的分段打印的方法为：3D打印基体和线材按照结构构件的构造要求分段打印预制，各构件通过后浇/后张法打印编织榫接结构连接。
在本发明中，线材又称为绳材。
与现有技术相比，本发明的技术效果体现在：
本发明通过融合了现有3D打印材料快速成型的技术优越性和高强线 材轻质、高强和几何可变的优越材料性能，在3D打印基体的同时编织入一定比例的高强线材以改善结构强度韧度不足，形成有别于传统钢筋混凝土结构的一体化成型的新型建筑结构形式，既解决了现有3D打印基体在强度和韧性性能上的缺陷，又弥补了结构空间跨越能力和承载力的不足。
本发明在施工便捷，快速适用的同时，具有高韧性、耐疲劳、长寿命等优点；使建筑物各个部位既能达到结构力学的不同要求，又可以在安全可靠的基础上达到经济美观，造型艺术；省却了传统建筑建造施工中的模板工程和钢筋笼绑扎工序，不仅减少了建筑施工程序，还降低了劳动强度。
在建筑工程中采用本发明的3D打印编织技术，更易实现结构立面造型；并且这种建造方法也可以与现有的筋材绑扎组合施工。
根据预设结构空间造型分层打印建筑构件或者功能辅件，进行应力云图分析并在不同应力域根据打印路径设计适宜的编织图案；在采用3D打印材料打印建筑基体的同时，结合层叠浇筑工艺设计结构内部编织流程，通过喷射螺钉进行空间定位控制高强线材空间精准地强韧编织成型，与打印基体形成协同受力、一致变形的空间强韧结构，实现空间受力的最优组合，有效改善了3D打印基体抗拉、抗剪、抗磨和抗裂性能，具有更高的承载能力、变形能力、抗裂能力和抗震延性，满足结构多种功能需要，实现了空间跨度和3D造型的有效结合，使3D打印建筑物的优势全面凸显，不再局限于小型建筑结构。
本发明提供的建造方法，对于大型空间复杂结构，可以分区域单独打 印编织局部，再组装成为整体，采用预设榫接构件和后张预应力工艺加强整体性；制备的3D打印编织一体化成型建筑也可以与传统建筑结构组合，具有灵活多变的兼容性和普适性。
附图说明
图1为本发明提供的建造方法的流程示意图；
图2为实施例中桥梁结构的空间造型优化多方案对比图；
图3为实施例中b方案提供的桥梁结构的x方向应力分布图；
图4为实施例中b方案提供的桥梁结构的主拉应力分布图；
图5为实施例中的打印编织流程图；
图6为实施例中的打印编织实施示意图。
具体实施方式
下面结合附图和实施例对本发明作进一步的说明：
如图1所示，本发明提供的3D打印编织一体化成型建筑的建造方法，包括以下步骤：
(1)选取基本结构构件，空间建模后采用有限元分析，结合应力云图设定判别域值，进行结构空间优化，得到结构构件骨架；
(2)对结构构件骨架进行计算分析，确定结构受力薄弱面和线材布设关键部位，在关键部位设置编织定位点，进行线材编织设计，确定编织 范围和编织数量；并确定打印流程和编织流程；
(3)配制3D打印材料；
(4)根据步骤(2)中的打印流程和编织流程进行3D打印基体，将线材编入，逐层建造后叠加、硬化后一次性成型，形成3D打印编织一体化建筑；或分段打印后通过预设榫接构造段连接得到3D打印编织一体化成型建筑。
实施例
设计空间造型门式拱架模型作为桥梁结构建造参考。
1、根据结构功能要求确定结构形式和空间造型。桥梁通常选取梁式或者拱式结构作为其主要受力构件，3D打印水泥基材料通常抗压强度高、抗拉强度低，选择拱形造型作为桥梁结构的主要受力构件可以充分利用材料的抗压性能而避免结构拉伸断裂失效。
拱结构的空间造型和结构受力采用结构拓扑优化进行选型，为避免错失全局最优解，可以采用桁架离散结构和连续体拓扑两种方式或者二者组合的方式进行。优化后的结构形式经规则化后如图2所示，包括a方案和b方案，3D打印桥梁时可以作为结构的初步选择。
2、图2所示门式拱架中的第二种方案(即b方案)力的传递路径更为明确，选择其作为桥梁结构的基本形式进行受力分析。根据使用荷载水平下结构的应力及应力均匀分布系数作为结构优化依据，确定连续体/桁架 组合结构的空间布设方案。
基于有限元分析求得的结构的应力分布如图3和图4所示，其中拱圈中间部位、拱架端部区域的应力较大，是需要局部加强的区域。
3、根据上述计算结果和结构受力阈值确定编织范围。具体以应力/强度比值确定安全系数作为高强线材布设依据；并在编织范围内根据打印路径设置定位点为编织线材定位；通过设置加密编织与普通编织的阈值，从而确定区域编织密度；根据桥梁的空间结构型式以及编织范围和编织密度确定打印流程和编织流程，打印编织一体化的工序流程如图5所示。
4、打印编织的实施如图6所示，3D打印基体到预设厚度后开始打印编织，平行打印方向可以直接一体化编入绳材，编织定位点喷射螺钉定位以保证编织到位且绳材编入时适度张紧，有益于打印编织结构成型后整体受力。垂直打印方向可以借助喷射螺钉定位后逐层编入，高强绳材和3D打印基体整体固化成型，在内部形成空间网格受力骨架，提升结构抗裂性能，变形性能和抗震性能。
具体的，在本实施例中，根据设定的阀值和计算的安全系数，在图6中，a图为打印方向示意图，其中A`为打印起始点，箭头方向为打印方向；b图为编织方向示意图，箭头方向为编织方向，A点为编织起始点，AB、BC、LK、KJ、FG、GH、HI、JK、KL和MA段为加密编织区域，CD、DL、JE、EF、IJ和LM段为普通编织区域；A-M点为在编织定位点喷射的用于定位的螺钉。
5、按打印编织流程和预先设计的结构造型逐层打印编织建造，一体化成型，制造形成拱架。构件整体养护后，可现场进行吊装，组合，形成整体结构。
在本实施例中，3D打印材料为水泥基材料，线材为钢绞线。
上述实施例仅用于解释说明本发明的发明构思，而非对本发明权利保护的限定，凡是依据本发明的技术和方法实质对以上实施例所做的任何简单修改、等同变化与修饰，均仍属于本发明的技术和方法方案的范围内。

Claims (7)

  1. 一种3D打印编织一体化成型建筑的建造方法，包括以下步骤：
    (1)选取基本建筑结构构件，空间建模后采用有限元分析，结合应力云图，设定判别域值，进行结构空间优化，得到结构构件骨架；
    (2)对结构构件骨架进行计算分析，根据结构受力薄弱区域和大小确定线材的编织范围和编织密度，再根据结构构件骨架以及线材的编织范围和编织密度确定打印流程和编织流程；
    (3)配制3D打印材料；
    (4)根据步骤(2)中的打印流程和编织流程进行3D打印基体并将线材编入，逐层建造、叠筑、硬化后一次性成型，形成3D打印编织一体化建筑；或分段打印后通过预设榫接构造段连接得到3D打印编织一体化成型建筑；所述线材的编入方法为：在平行打印方向上，3D打印基体并一体化编入线材，在编织定位点喷射螺钉定位，将编入的线材缠绕在喷射的螺钉上；在垂直打印方向上，3D打印基体后，在编织定位点喷射螺钉定位，在打印材料初凝前编入线材，编入的线材缠绕在喷射的螺钉上形成空间网格。
  2. 根据权利要求1所述的3D打印编织一体化成型建筑的建造方法，其特征在于，在步骤(2)中，根据结构受力薄弱区域和大小确定线材的编织范围和编织密度的方法为：
    (2-1)根据应力/强度比值确定的安全系数确定编织范围；
    (2-2)根据安全系数与阀值的大小，确定加密编织和普通编织范围，所述阀值根据实际取值确定。
  3. 根据权利要求1或2所述的3D打印编织一体化成型建筑的建造方法，其特征在于，所述的步骤(2)还包括在线材的编织范围设置定位点，用于为编织线材定位。
  4. 根据权利要求1所述的3D打印编织一体化成型建筑的建造方法，其特征在于，在步骤(3)中，所述的3D打印材料选自水泥基材料、石膏材料或尼龙材料中一种或至少两种的组合。
  5. 根据权利要求1所述的3D打印编织一体化成型建筑的建造方法，其特征在于，在步骤(3)中，所述的3D打印材料还包括增强组分，所述增强组分选自纤维及其聚合物、膨化微珠或中空微粒、纳米材料中的一种或至少两种的组合。
  6. 根据权利要求1所述的3D打印编织一体化成型建筑的建造方法，其特征在于，在步骤(4)中，所述的线材选自钢绞线、纤维复合线材或纳米线材中的一种或者或至少两种的组合。
  7. 根据权利要求1所述的3D打印编织一体化成型建筑的建造方法，其特征在于，在步骤(4)中，所述的分段打印的方法为：3D打印基体和线材按照结构构件的构造要求分段打印预制，然后通过后浇/后张法打印编织榫接结构连接。
PCT/CN2019/104274 2018-09-06 2019-09-04 一种3d打印编织一体化成型建筑的建造方法 Ceased WO2020048468A1 (zh)

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