JP7532997B2 - Building material and manufacturing method thereof - Google Patents

Description

The present invention relates to building materials.

Carbon Fiber Reinforced Plastics (CFRP), a composite material of carbon fiber and matrix resin, is strong, rigid, and lightweight, and is widely used in aircraft, automobiles, sporting goods, construction, and other fields. However, CFRP has low heat resistance, and when temperatures exceed 100°C, the resin (organic matter) begins to soften and structural strength decreases. For this reason, when used in fire-resistant buildings, fire-resistant coating materials (such as mortar) and finishing materials (such as fire-resistant paint) are placed around the CFRP to prevent heat from being transferred to the CFRP in the event of a fire (see, for example, Patent Document 1).

Japanese Patent Application Publication No. 9-72105

When constructing a structure using CFRP, applying fireproof coating or finishing materials around the CFRP as mentioned above could result in the finished dimensions being significantly larger than the size required for the structure.

The present invention was made in light of these circumstances, and its purpose is to reduce the finished dimensions.

In order to achieve this objective, the building component of the present invention has a dense core, an air layer portion (excluding foamed nonwoven fabric) that is continuous with the core and has a plurality of hollow portions, and a dense surface layer portion that is continuous with the air layer portion, and is characterized in that at least the core portion is formed from carbon fiber reinforced plastic.

With this type of building material, an air layer with low thermal conductivity is provided between the core (CFRP) and the surface layer, which increases the insulating effect and makes it difficult for heat to be transmitted during a fire. This makes fire-resistant covering materials and finishing materials unnecessary, and allows for the finished dimensions to be reduced.

In addition, in order to achieve this objective, the building component of the present invention has a solid core, an air layer portion that is continuous with the core and has a plurality of hollow portions, and a solid surface layer portion that is continuous with the air layer portion, and is characterized in that the core, the air layer portion and the surface layer are all made of carbon fiber reinforced plastic without changing the material .

Such building components can all be constructed from the same material (CFRP). Also, by forming the surface layer from CFRP, it is possible to improve the design.

In such a building component, it is desirable that the thickness of the air layer portion is greater than the thickness of the surface layer portion.

This type of building material allows for improved fire resistance while reducing the finished dimensions.

In such a building component, it is desirable that the air layer portion and the surface layer portion are provided in pairs on both sides of the core portion in the thickness direction.

This type of building material can improve fire resistance on both sides of the thickness direction.

In such a building component, it is desirable that the air layer and the surface layer are provided on all four sides covering the core.

With this type of building component, the core is surrounded by an air layer and a surface layer, which can further improve fire resistance.

In order to achieve this objective, the manufacturing method for a building component of the present invention includes the steps of forming a solid core portion from carbon fiber reinforced plastic using a 3D printer, forming an air layer portion with multiple cavities using the 3D printer, and forming a solid surface layer portion using the 3D printer, and is characterized in that the core portion, the air layer portion, and the surface layer portion are formed continuously.

This method of manufacturing building components allows for easy production of building components with high fire resistance. This eliminates the need for fire-resistant covering materials and finishing materials, allowing for reduced finished dimensions.

The present invention makes it possible to reduce the finished dimensions.

FIG. 2 is a schematic explanatory diagram of a construction member according to the present embodiment. FIG. 1 is a diagram showing an example of a building component formed by a 3D printer. FIG. 1 is a schematic explanatory diagram showing the process of modeling using a 3D printer. FIG. 3 is a flow diagram showing a method for manufacturing the building component shown in FIG. 2 .

One embodiment of the present invention will be described below with reference to the drawings.

====Embodiment===
<About the composition of building materials>
FIG. 1 is a schematic explanatory diagram of a building member according to the present embodiment.

The building component shown in FIG. 1 comprises a core 10, an air layer 20, and a surface layer 30. The core 10, the air layer 20, and the surface layer 30 are all made of carbon fiber reinforced plastic (hereafter referred to as CFRP).

CFRP is a composite material made of carbon fiber and matrix resin. Organic fibers such as polyacrylonitrile (PAN) fibers and pitch-based fibers (fibers made from petroleum-based raw materials such as coal tar) are used as carbon fibers. Thermosetting resins (unsaturated polyester, epoxy, vinyl ester, etc.) and thermoplastic resins (nylon, polypropylene, etc.) are used as resins. Such CFRP is a lightweight, high-strength material that has excellent mechanical properties and a high specific strength, while having a lower density than metal materials such as iron and aluminum.

However, CFRP has low heat resistance, and when temperatures exceed roughly 100°C, the resin (organic matter) begins to soften, reducing its structural strength. Therefore, unless its fire resistance is improved, it cannot be used as a building material. Conventionally, in order to improve fire resistance, fire-resistant coating materials (such as mortar) and finishing materials (such as fire-resistant paint) have been applied around the periphery of CFRP. This has led to the risk of the finished dimensions being larger than the size required for the structure.

In this embodiment, a three-dimensional (3D) printer is used to continuously form the core 10, air layer 20, and surface layer 30 out of CFRP, creating a building component with high fire resistance and reducing the finished dimensions.

The core 10 is a part required for structural strength (the center of the structure) and is made of dense CFRP.

The air layer section 20 is formed of CFRP and is continuous with the core section 10, and has a number of independent cavities 20a. The cavities 20a are three-dimensionally distributed in the air layer section 20, and may have any shape, such as a 3D honeycomb shape or a 3D bubble shape. The size (diameter) of the cavities 20a is preferably 1 mm to 10 mm.

The surface layer 30 is a portion that covers the outer periphery of the building component, and is formed in a dense shape from CFRP, continuing from the air layer 20. CFRP also has excellent designability, and in this embodiment, by forming the surface layer 30 from CFRP, the designability of the surface can be improved.

In this way, the building component of this embodiment has the core 10, air layer 20, and surface layer 30 all made of CFRP, and the air layer 20 with multiple cavities 20a is provided between the core 10 and the surface layer 30. The air (gas) contained in the cavity 20a of the air layer 20 has the property of being less likely to transmit heat than solids or liquids, so providing the air layer 20 reduces the thermal conductivity from the surface layer 30 side to the core 10 (obtaining a heat insulating effect). In other words, the fire resistance of the building component using CFRP can be improved. This makes it unnecessary to use fire-resistant coating materials (e.g., mortar) or finishing materials (e.g., fire-resistant paint), and therefore allows the finished dimensions to be reduced.

When heat is transferred in the air layer portion 20, heat convection occurs in the cavities 20a, so the smaller the size of the cavities 20a (the more cavities 20a there are), the smaller the thermal conductivity (the more difficult it is to transfer heat). Therefore, it is more preferable to disperse many tiny cavities 20a in the air layer portion 20. In this case, the integrity of the surface layer portion 30 and the core portion 10 can be further improved.

Figure 2 shows an example of a building component formed by a 3D printer. The manufacturing method using a 3D printer will be described later.

In this example, a pair of air layers 20 and surface layers 30 are provided on both sides of the thickness of the core 10. This improves the fire resistance of the core 10 on both sides of the thickness. Such building components can be used for, for example, stairs, floors, walls, and ceilings.

In addition, generally, the air layer 20, which has a low thermal conductivity, is less likely to transmit heat if its thickness is large. It is desirable that the thickness of the air layer 20 is greater than that of the surface layer 30. In this embodiment, as shown in the figure, when the thickness of the core 10 is d1, the thickness of the air layer 20 is d2, and the thickness of the surface layer d3 is d3, d2>d1>d3. By increasing the thickness d2, it is possible to slow down the transfer of heat to the core 10 in the event of a fire. In addition, by reducing the thickness d3, it is possible to reduce the dimensions. This allows the finished dimensions to be reduced while improving the fire resistance. However, this is not limited to this, and for example, d1>d2>d3 may also be acceptable. This allows for improved design.

<About the manufacturing method of building materials>
In this embodiment, a building component is manufactured using a 3D printer. The 3D printer is a printer that creates a three-dimensional object based on three-dimensional data (CAD data) created by a computer, for example.

Figure 3 is a schematic diagram showing the process of modeling using a 3D printer. The 3D printer used in this embodiment is a fused deposition modeling (FDM) printer. Because it is an FDM printer, a thermoplastic resin is used as the matrix resin for the CFRP of this embodiment. In other words, it can be made fluid by heating and melting it, and can be solidified by cooling.

The plate 100 is a base (modeling base) fixed inside the 3D printer, and the model is formed on the plate 100.

The nozzle 200 faces the upper surface of the plate 100 and is configured to be movable in a horizontal direction (horizontal movement) relative to the plate 100. The nozzle 200 extrudes the modeling material (filament 300) toward the plate 100 while moving horizontally.

In this embodiment, the filament 300 is CFRP, and continuous carbon fiber and thermoplastic resin are integrated and supplied to the nozzle 200. The thermoplastic resin is arranged around the continuous carbon fiber and also functions as an adhesive (binder). In this embodiment, polyether ether ketone (PEEK) resin is used as the thermoplastic resin fiber. PEEK resin has high heat resistance and is superior in performance to general-purpose polyethylene (PE) and ABS resin. As described above, since the 3D printer is an FDM type, the filament 300 is extruded from the nozzle 200 in a state (molten state) heated by a heater (not shown) or the like.

Then, the filaments 300 extruded from the moving nozzle 200 are piled up on the plate 100 as shown in FIG. 3, forming a three-dimensional object (a 3D object: in this embodiment, a building component).

In the above-mentioned 3D printer, the position of the plate 100 is fixed and the nozzle 200 moves horizontally, but this is not limited to the above. For example, the nozzle 200 may be configured to have multiple axes of movement, allowing it to move in directions other than the horizontal direction, so that material (filament 300) can be layered at any angle. Alternatively, the inclination of the plate 100 relative to the horizontal plane may be made changeable at will. Also, as the plate 100 moves downward, material extruded from the moving nozzle 200 may be piled up to form a model.

Figure 4 is a flow diagram showing the manufacturing method of the building component shown in Figure 2. Note that in each process shown in Figure 4, the above-mentioned 3D printer (see Figure 3) is used to model the filament 300 (CFRP) extruded from the moving nozzle 200 (description will be omitted below).

First, the surface layer 30 (the lower of the two surface layers 30 in FIG. 2) is formed in a dense shape on the plate 100 (S10).

Next, an air layer section 20 (the lower of the two air layer sections 20 in FIG. 2) is formed on the surface layer section 30 formed in step S10 (S20). At this time, a plurality of cavities 20a are formed three-dimensionally and independently. As a result, an air layer section 20 with a plurality of cavities 20a is provided continuously on the surface layer section 30.

Next, the core 10 is formed in a solid shape on the air layer 20 formed in step S20 (S30). This results in the solid core 10 being provided continuously with the air layer 20.

Next, an air layer section 20 (the upper of the two air layer sections 20 in FIG. 2) is formed on the core section 10 formed in step S30 (S40). At this time, a plurality of cavities 20a are formed three-dimensionally and independently. As a result, an air layer section 20 with a plurality of cavities 20a is provided continuously on the core section 10.

Finally, the surface layer 30 (the upper of the two surface layers 30 in FIG. 2) is formed in a solid shape on the air layer 20 formed in step S40 (S50). This results in the solid surface layer 30 being provided continuously with the air layer 20.

The construction component shown in Figure 2 is manufactured through the above process. In this embodiment, each part (layer) of the construction component is formed using a 3D printer, so even complex shapes can be formed easily and with high precision. In particular, the hollow portion 20a of the air layer portion 20 can be formed with high precision regardless of its size or shape (three-dimensional shape).

The configuration (method) of the 3D printer is not limited to the above. For example, in this embodiment, a one-nozzle method using one nozzle (nozzle 200) is used, but a two-nozzle method using a CFRP nozzle and a resin nozzle may also be used.

===Other embodiments===
The above-mentioned embodiment is for facilitating understanding of the present invention, and is not intended to limit the present invention. The present invention may be modified or improved without departing from the spirit of the present invention, and it goes without saying that the present invention includes equivalents. In particular, the following embodiment is also included in the present invention.

In the above-mentioned embodiment, the core portion 10, the air layer portion 20, and the surface layer portion 30 are all made of CFRP, but it is sufficient that at least the core portion 10 is made of CFRP. In other words, the air layer portion 20 and the surface layer portion 30 may be made of a material other than CFRP. For example, it is possible to use the above-mentioned 3D printer to form them in the same way by changing the material.

In addition, in FIG. 2, the air layer portion 20 and the surface layer portion 30 are provided in pairs on both sides of the core portion 10 in the thickness direction, but it is preferable that they are also provided on both sides of the core portion 10 (i.e., provided on the four sides covering the core portion 10). This allows the periphery of the core portion 10 to be covered with the air layer portion 20 and the surface layer portion 30, thereby further improving the fire resistance.

For example, when only one side of the core 10 needs to be fireproof, or when a separate fireproof structure is provided on one side, the air layer 20 and the surface layer 30 may be provided on only one side of the core 10.

10 Core portion 20 Air layer portion 20a Cavity portion 30 Surface layer portion 100 Plate 200 Nozzle 300 Filament

Claims (6)

A dense core and
An air layer portion (excluding foamed nonwoven fabric) provided continuously with the core portion and having a plurality of cavities;
A solid surface layer portion provided continuously with the air layer portion;
At least the core portion is formed of carbon fiber reinforced plastic.
A building component characterized by: A dense core and
An air layer portion provided continuously with the core portion and having a plurality of cavities;
A solid surface layer portion provided continuously with the air layer portion;
having
The core portion, the air layer portion, and the surface layer portion are all made of carbon fiber reinforced plastic without changing the material .
A building component characterized by: The building member according to claim 1 or 2,
The thickness of the air layer portion is greater than the thickness of the surface layer portion.
A building component characterized by: The building member according to any one of claims 1 to 3,
In the thickness direction, the air layer portion and the surface layer portion are provided in pairs on both sides of the core portion,
A building component characterized by: The building member according to any one of claims 1 to 4,
The air layer portion and the surface layer portion are provided around the four periphery of the core portion.
A building component characterized by: A process of forming a solid core part from carbon fiber reinforced plastic using a 3D printer;
Forming an air layer portion having a plurality of cavities using the 3D printer;
A step of forming a dense surface layer portion using the 3D printer;
The core portion, the air layer portion, and the surface layer portion are continuously formed.
A method for manufacturing a building component comprising the steps of:

Images