JP7805644B2 - How the structure was built - Google Patents

Description

The present invention relates to a method for constructing a structure, and in particular to a method for constructing a structure that combines economy and livability through a hybrid structure that combines a vertical structure using 3D printing construction technology with a horizontal structure using precast floor panels.

In recent years, 3D printing construction technology has been developed to build large structures such as houses using 3D printing technology. 3D printing construction technology involves installing a large layer printing device and constructing a structure using a hardening base material such as concrete or mortar.
3D printing construction technology can be broadly divided into two methods: one in which a large 3D printing device is installed and a structure is layered directly on the site, and the other in which the structural components are manufactured using 3D printing technology and then assembled on-site to build the structure. In recent years, however, the method of layering the structure directly on the site has been attracting particular attention due to its ease of construction.

JP 2018-069661 A

The conventional technology has the following problems.
<1> With 3D printing technology, vertical surfaces are constructed by stacking upper substrates on lower substrates, so it is not possible to construct horizontal structures in mid-air. As a result, creating window or doorway openings in walls requires additional processes, such as installing support materials in the upper frame, which places design restrictions on where the openings can be placed.
<2> Because it is not possible to construct a horizontal ceiling surface, the base material must be arranged by gradually shifting it from the bottom to the top toward the interior, resulting in a roughly circular dome-shaped structure. This results in a unique, rounded shape that lacks design appeal and is difficult to harmonize with existing structures.
<3> A circular dome-shaped structure tends to create dead space inside the room, and the sloped ceiling creates a feeling of oppression. Furthermore, because the planar shape of the structure is roughly circular, the living space tends to be small relative to the site area. For these reasons, the living environment is extremely poor.

The method for constructing a structure of the present invention comprises the following steps: a foundation step in which a foundation is installed on a site using 3D printing construction technology; a lamination step in which strips of hardenable base material are arranged on the foundation using a lamination printing device and stacked to construct vertical structural parts that form the walls of the structure; and a loading step in which ceiling slabs are placed on the vertical structural parts to construct horizontal structural parts that form the ceiling of the structure. In the lamination step, the strips of hardenable base material are partially interrupted and stacked, and the upper part of the interruption is defined by the ceiling slab, thereby creating an opening that connects the vertical structural parts.

In the method for constructing a structure of the present invention, after the loading process, the vertical structural section may be considered as the foundation section, and the stacking process and loading process may be repeated to construct upper floors.

The method for constructing a structure of the present invention may also be a multi-layer structure in which the vertical structural portion has a hollow layer inside.

In the method for constructing a structure of the present invention, the laminate printing device includes a device main body, a nozzle unit provided on the device main body, a running unit provided on the device main body, and a guide unit provided on the device main body, and in the lamination process, the guide unit guides the curable substrate placed on the lower tier, and the running unit moves along the curable substrate while ejecting the curable substrate from the nozzle unit to place the curable substrate on the upper tier.

In the method for constructing a structure of the present invention, the layered printing device may further include a receiving unit provided in the device body and a control unit electrically connected to the travel unit and the receiving unit, wherein the receiving unit receives coordinate information from the coordinate information transmission means and identifies the current position of the layered printing device based on the coordinate information, and the control unit controls the travel of the travel unit based on the current position.

In the method for constructing a structure of the present invention, the coordinate information transmission means may be beacons installed in three or more locations, and the receiving unit may identify the current position of the layered printing device using a multi-point positioning method based on the coordinate information.

The method for constructing a structure of the present invention has at least one of the following advantages due to the above configuration.
<1> By combining 3D printing construction technology with precast construction methods, structures can be constructed in a short period of time and at low cost.
<2> By defining the upper part of the wall with a ceiling slab, openings such as windows and doorways can be freely designed without the need to install support materials.
<3> Because the ceiling surface is constructed with a horizontal ceiling slab, it is possible to build a roughly rectangular parallelepiped structure with vertical walls and a horizontal ceiling. This allows for excellent design and makes it easy to blend in with existing structures.
<4> Because an approximately rectangular parallelepiped space can be secured inside the room, the accommodation capacity is high and the ceiling does not feel oppressive. This makes it very comfortable to live in. In addition, because the planar shape can be made rectangular, the site can be used effectively.
<5> Compared to conventional construction methods, it reduces waste material generation and noise, contributing to the global and local environment.

Flowchart of the construction method of the structure Structure diagram Explanatory diagram of a lamination printing device Basic process diagram Stacking process diagram (1) Stacking process diagram (2) Stacking process diagram (3) Illustration of the loading process Explanatory diagram of Example 2

The method for constructing the structure of the present invention is described in detail below.

[Structure construction method]
<1> Overall configuration (Figure 1)
The structure construction method S of the present invention is a construction method for constructing a structure 1 using 3D printing construction technology.
The method S for constructing a structure includes at least a foundation step S1, a stacking step S2, and a loading step S3.
The construction method S for a structure of the present invention has one feature in that it is a hybrid construction method that combines a vertical structural section 20 made using 3D printing construction technology with a horizontal structural section 30 made using a precast construction method, allowing openings 22 such as windows and doorways to be installed as desired.

<1.1> Structure (Figure 2)
The structure 1 is a building that includes at least a foundation 10 that is installed on a site, a vertical structural part 20 that is installed on the foundation 10, and a horizontal structural part 30 that is installed on the vertical structural part 20. The structure 1 may be used for any purpose, such as a residence or a business office.
In this example, the structure 1 is two stories high, but it may be one story.
In this example, a mat foundation is used as the foundation 10, which includes a concrete floor slab 11, a rising portion 12 that rises linearly from the floor slab 11, and a floor panel 13 that is placed on the rising portion 12. However, the structure of the foundation 10 is not limited to this, and for example, the rising portion 12 may not be provided, or a strip footing may be used instead of a mat foundation.
The vertical structure 20 includes at least a wall portion 21 and an opening 22 .
In this example, a multi-layer structure is adopted for the wall surface portion 21, in which a hollow layer 21c is defined between an inner wall 21a and an outer wall 21b. The hollow layer 21c can be used as a space for arranging heat insulating materials, electrical equipment, and piping.
The horizontal structural part 30 comprises at least a ceiling slab 31 .
In this example, a precast concrete slab with reinforcing bars inside is used as the ceiling slab 31. The ceiling slab 31 can be used as a roof slab or can also be used as a floor slab for the second floor. When using it as a floor slab, openings are provided to allow stairs to pass between the upper and lower floors.

<1.2> Laminated printing device (Figure 3)
The layered printing device A is a device that builds a structure 1 using 3D printing construction technology.
In this example, the laminate printing device A is a self-propelled laminate printing device that includes a device main body A1, a nozzle section A2 provided in the device main body, a substrate supply section A3 that supplies a curable substrate B to the nozzle section A2, a running section A4 that moves the device main body A1, a guide section A5 that guides the movement of the device main body A1, and a control section A7 that controls the running section A4 based on design data.
The nozzle portion A2 protrudes downward from the rear of the apparatus main body A1.
The base material supply section A3 includes a mortar pressure-feeding device installed outside the site, for example, and communicates with the nozzle section A2 via a pressure-feeding pipe connected to the front of the device main body A1.
The running part A4 is, for example, a crawler provided on the bottom surface of the device main body A1, and runs on the floor panel 13 and the hardenable substrate B arranged on the lower level.
The guide section A5 consists of, for example, two guide rollers protruding downward from both sides of the device main body A1 below the running section A4, and the two guide rollers clamp the sides of the curable substrate B placed on the lower level to guide its running.
However, the laminate printing apparatus A is not limited to the above configuration, and for example, the running unit A4 may be a tire instead of a crawler.Furthermore, instead of being a self-propelled type, the laminate printing apparatus A may be a robot arm type or a portal frame type that does not have a running unit A4.

<2> Basic process (Figure 4)
The foundation step S1 is a step of installing the foundation portion 10. In detail, the foundation step S1 is performed in the following order (1) to (11), for example.
(1) Root cutting on the site, (2) laying and compacting crushed stone, (3) laying waterproof sheets, (4) pouring concrete, (5) reinforcing steel bars, (6) installing formwork, (7) pouring concrete for the floor slab, (8) installing anchor bolts, (9) pouring concrete for the rising section, (10) curing, and (11) installing floor panels.
When providing the rising portion 12, it is desirable to provide it at least directly below the wall portion 21 of the vertical structural portion 20 in order to support the weight of the vertical structural portion 20 and the load placed on the horizontal structural portion 30.
The anchor bolt is not a base but a bolt for fixing the floor panel 13. In detail, the floor panel 13 is placed on the rising portion 12, and the anchor bolt is inserted into a communication hole provided in the floor panel 13, and a nut is screwed onto the head of the anchor bolt, thereby fixing the floor panel 13 to the rising portion 12.

<3> Lamination process (FIGS. 5A to 5C)
The lamination step S2 is a step of constructing the vertical structural portion 20. In the lamination step S2, a lamination printing device A and a paste-like hardening base material B are used.
In this example, fiber reinforced mortar is used as the hardenable substrate B.
The design data of the structure 1 is input to the control unit A7 of the lamination printing device A, and the curable substrate B is arranged in a strip shape on the floor panel 13 in accordance with the design data.
The design data is data in which 3D data of a structure to be constructed is expanded into 2D data for each layer.
In detail, first, the surface of the base 10 is surveyed, and the travel start point of the layered printing device A is made to correspond to each coordinate on the design data.
Next, while traveling on the floor panel 13 by the traveling part A4, the paste-like hardenable base material B is discharged from the nozzle part A2 and arranged in a band shape with a uniform thickness and width. When arranging the bottommost hardenable base material B, the guide part A5 is removed because it gets in the way of traveling.
After placing the bottom-most curable substrate B, the lamination printing device A is placed on top of the cured bottom-most curable substrate B, and runs while guiding the side of the curable substrate B with the guide section A5, laminating the upper-level curable substrate B on top of the lower-level curable substrate B (Figure 5A).
The same process is repeated from the bottom to the top in accordance with the design data, and the curable base material B is layered to build the wall portion 21 (FIG. 5B).
At the designed window or doorway portions, the discharge of the curable substrate B is stopped to provide openings 22 that are continuous in the height direction (FIG. 5C).

<4> Loading process (Fig. 6)
The loading step S3 is a step of constructing the horizontal structure portion 30. In detail, the loading step S3 is performed as follows, for example.
After the vertical structural portion 20 has hardened, a ceiling slab 31 is lowered onto the top of the vertical structural portion 20 on the first floor using heavy machinery such as a crane.
In this example, the horizontal structural part 30 is made up of a combination of two ceiling slabs 31, and after the two ceiling slabs 31 are hung, they are connected to each other with bolts, joints, etc.
A guide protrusion 32 may be provided in advance on the bottom surface of the ceiling slab 31 for positioning the ceiling slab 31 on the upper edge of the wall portion 21 when hanging it down.
By installing the ceiling slab 31, the horizontal structural portion 30 is constructed, the upper edge of the unconstructed portion of the wall portion 21 is defined, and openings 22 for windows and doorways are constructed.

<5> Construction of the Second Floor The second floor floor panels 13 are fixed to the top of the first floor ceiling slab 31, and the vertical structural section 20 is constructed on the floor panels 13 using the lamination printing device A (lamination process S2).
Once the vertical structural portion 20 of the second floor is completed, a ceiling slab 31 is placed on the vertical structural portion 20 to construct the horizontal structural portion 30 that will serve as the roof (loading step S3).
The above completes the skeleton of the structure 1.
After the structure 1 is completed, fitting work such as installing window frames and doors, interior work such as ceilings, flooring, and wallpapering, electrical work, piping work, and equipment work are carried out in sequence. These steps are not the gist of the present invention, so a description thereof will be omitted.

[Example of controlling the travel of the lamination printing device based on current position information] (Fig. 7)
In this example, the lamination printing apparatus A further includes a receiving unit A6.
The receiving section A6 is a mechanism for identifying the current position of the lamination printing apparatus A based on the coordinate information transmitted by the coordinate information transmitting means C.
In this example, beacons C1 installed at three locations within the premises are used as the coordinate information transmission means C. The beacons C1 are devices that transmit wireless signals at predetermined time intervals, and for example, Bluetooth (registered trademark) Low Energy (BLE) that transmits wireless signals within a 30 m radius several times per second can be used as the beacons C1.
Three beacons C1 are placed around the construction site of the structure 1 and are fixed to the top of poles about 5 m high to avoid shielding of wireless signals. The installation locations of each beacon C1 within the site are identified in advance.
The receiving unit A6 can measure the distance to the beacon C1 from the strength of the radio signal (received radio wave intensity (RSSI)) received from the beacon C1, and by measuring the distance from three beacons C1 located in different positions, the current position of the laminate printing device A can be identified in three dimensions (three-point positioning method).
In this example, in the stacking step S2, the control unit A7 controls the travel of the travel unit A4 based on the current position information of the laminate printing device A. In detail, the design data of the structure 1 is collated with the current position information of the laminate printing device A, and the wall surface portion 21 is constructed while correcting the current position of the laminate printing device A as needed. This makes it possible to prevent construction defects caused by deviation of the travel path of the laminate printing device A due to shaking or the like during travel.
The coordinate information transmitting means C is not limited to the beacon C1, and may be, for example, a GPS satellite as long as the accuracy of the position information can be ensured. Furthermore, even when the beacon C1 is used, the current position may be determined by an angle measurement method that uses the phase difference of radio waves instead of the three-point positioning method.

REFERENCE SIGNS LIST 1 structure 10 foundation 11 floor slab 12 rising part 13 floor panel 20 vertical structural part 21 wall surface 21a inner wall 21b outer wall 21c hollow layer 22 opening 30 horizontal structural part
31 Ceiling slab 32 Guide protrusion A Lamination printing device A1 Device body A2 Nozzle section A3 Substrate supply section A4 Travel section A5 Guide section A6 Receiving section A7 Control section B Hardening substrate C Coordinate information transmitting means C1 Beacon S1 Foundation process S2 Lamination process S3 Loading process

Claims (6)

A method for building a structure using 3D printing building technology, comprising:
The foundation process involves installing the foundation on the site.
a lamination process in which a curable substrate is placed in a strip shape on the foundation using a lamination printing device and stacked to construct a vertical structural portion that forms the wall surface of the structure;
A loading step of loading a ceiling slab on the vertical structural portion to construct a horizontal structural portion that forms the ceiling of the structure,
In the lamination process, the strip-shaped arrangement of the curable base material is partially interrupted and laminated, and the interrupted upper part is defined by the ceiling slab, thereby providing an opening that communicates with the vertical structure.
How the structure is constructed. After the loading step, the foundation part is replaced with the horizontal structural part, and the stacking step and the loading step are repeated to construct the upper floor.
A method for constructing a structure according to claim 1. The vertical structure is a multi-layer structure having a hollow layer therein.
A method for constructing a structure according to claim 1. the laminate printing apparatus comprises an apparatus main body, a nozzle unit provided in the apparatus main body, a running unit provided in the apparatus main body, and a guide unit provided in the apparatus main body,
In the stacking step, the curable base material arranged in the lower stage is guided by the guide unit, and the curable base material is discharged from the nozzle unit while moving along the curable base material by the traveling unit, thereby arranging the curable base material in the upper stage.
A method for constructing a structure according to any one of claims 1 to 3. the laminate printing apparatus further comprises a receiving unit provided in the apparatus body, and a control unit electrically connected to the traveling unit and the receiving unit,
the receiving unit receives coordinate information from the coordinate information transmitting means, and identifies a current position of the layered printing device based on the coordinate information;
The control unit controls the travel of the traveling unit based on the current position.
A method for constructing a structure according to claim 4. The coordinate information transmitting means is a beacon installed in three or more locations,
The receiving unit identifies the current position of the layered printing device by a multi-point positioning method based on the coordinate information.
A method for constructing a structure according to claim 5.