Formwork making device and method to make finishing material

Abstract

To provide a formwork making device and a method to make a finishing material, which can easily make a finishing material of a particular shape.SOLUTION: There are an additive making device 2 for making a formwork 12, and a control part 3 that controls the additive making apparatus 2; the control part 3 has a measurement part 4 that measures the shape of an existing stone member 11 (existing member) in three dimensions, an inverted surface data generation part 5 that generates 3D data of an inverted surface by inverting the surface shape of the existing stone member 11 based on the results of measurements by the measurement part 4, a formwork shape data generation part 6 that generates shape data of a form 12 for forming a finishing material that has a shape similar to that of an existing stone member 11 based on the data of the inverted surface generated by the inverted surface data generating part 5, and a formwork shape data transmission part 7 that transmits the shape data of the formwork 12 generated by the formwork shape data generation part 6 to the additive making device 2.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a formwork manufacturing device and a method for manufacturing a finishing material. [Background technology]

[0002] In recent years, with the development of 3D printing technology, for example, the construction of structural materials using additive manufacturing equipment has been proposed (see, for example, Patent Document 1). This makes it possible to freely shape structural materials, and also streamlines construction by improving workability and shortening construction time. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-137992 Summary of the Invention [Problem to be solved by the invention]

[0004] Finishing materials are sometimes attached to the surface of structural materials to improve their appearance. For this reason, it is desirable to use 3D printing technology to manufacture finishing materials in the desired shape easily and accurately.

[0005] SUMMARY OF THE PRESENT EMBODIMENT An object of the present invention is to provide a formwork manufacturing device and a method for manufacturing a finishing material that can easily manufacture finishing materials of a predetermined shape. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the formwork production apparatus of the present invention comprises an additive manufacturing apparatus that produces a formwork, and a control unit that controls the additive manufacturing apparatus, and the control unit comprises a measurement unit that measures the shape of an existing component in three dimensions, an inverted surface data generation unit that generates 3D data of an inverted surface that inverts the surface shape of the existing component based on the results measured by the measurement unit, a formwork shape data generation unit that generates shape data of a formwork for forming a finishing material having a similar shape to the existing component based on the data of the inverted surface generated by the inverted surface data generation unit, and a formwork shape data transmission unit that transmits the shape data of the formwork generated by the formwork shape data generation unit to the additive manufacturing apparatus.

[0007] In order to achieve the above object, the manufacturing method of the finishing material according to the present invention includes a measuring step of three-dimensionally measuring the shape of an existing component, an inverted surface data generating step of generating 3D data of an inverted surface obtained by inverting the surface shape of the existing component based on the results of the measurement in the measuring step, a formwork shape data generating step of generating shape data of a formwork for forming a finishing material having a similar shape to the existing component based on the data of the inverted surface generated in the inverted surface data generating step, a formwork shape data transmitting step of transmitting the shape data of the formwork generated in the formwork shape data generating step to an additive manufacturing device, a formwork manufacturing step of receiving the shape data of the formwork transmitted in the formwork shape data transmitting step and manufacturing the formwork with an additive manufacturing device based on the shape data of the formwork, a hydraulic mixture filling step of filling the formwork manufactured in the formwork manufacturing step with a hydraulic mixture and hardening it, a demolding step of removing the hardened hydraulic mixture from the formwork, and a coloring step of coloring the surface of the hydraulic mixture removed from the formwork.

[0008] In the present invention, a formwork is produced using an additive manufacturing device such as a 3D printer based on data from the inverted surface of the surface shape of an existing part measured in three dimensions, making it possible to easily and accurately produce a finishing material with a surface shape similar to that of the existing part. Furthermore, by coloring the surface of the finishing material produced in this manner, a finishing member of a desired color or pattern can be easily produced. For example, by coloring the surface of the finishing material in the same color or pattern as the existing member, a finishing material with a surface shape similar to that of the existing member can be easily produced. By coloring the surface of the finishing material in a color or pattern different from that of the existing member, a finishing material with a similar shape to the existing member but a different color or pattern from that of the existing member can be easily produced.

[0009] In order to achieve the above-mentioned object, the formwork production apparatus of the present invention comprises an additive manufacturing apparatus that produces a formwork, and a control unit that controls the additive manufacturing apparatus, and the control unit comprises a 3D data generation unit that converts the shape of a designed finishing material into three-dimensional data, an adjusted inverted surface data generation unit that generates 3D data of an adjusted inverted surface by adjusting the uneven dimensions of the inverted surface that inverts the surface shape of the finishing material based on the data generated by the 3D data generation unit, a formwork shape data generation unit that generates shape data of a formwork for forming the finishing material based on the data of the adjusted inverted surface generated by the adjusted inverted surface data generation unit, and a formwork shape data transmission unit that transmits the shape data of the formwork generated by the formwork shape data generation unit to the additive manufacturing apparatus.

[0010] In order to achieve the above object, the manufacturing method of the finishing material according to the present invention includes a 3D data generation process for three-dimensionally digitizing the shape of the designed finishing material, an adjusted inverted surface data generation process for generating 3D data of an adjusted inverted surface by adjusting the unevenness dimensions of the inverted surface obtained by inverting the surface shape of the finishing material based on the data generated in the 3D data generation process, a formwork shape data generation process for generating shape data of a formwork for forming the finishing material based on the data of the adjusted inverted surface generated in the adjusted inverted surface data generation process, a formwork shape data transmission process for transmitting the formwork shape data generated in the formwork shape data generation process to an additive manufacturing device, a formwork manufacturing process for receiving the formwork shape data transmitted in the formwork shape data transmission process and manufacturing the formwork with an additive manufacturing device based on the formwork shape data, a hydraulic mixture filling process for filling the formwork manufactured in the formwork manufacturing process with a hydraulic mixture and hardening it, a demolding process for removing the hardened hydraulic mixture from the formwork, and a coloring process for coloring the surface of the hydraulic mixture removed from the formwork.

[0011] In the present invention, a formwork is produced using an additive manufacturing device such as a 3D printer based on data from an adjusted inverted surface, in which the concave-convex dimensions of the inverted surface are adjusted by inverting the surface shape of the designed finishing material, so that a finishing material with the desired designed surface shape can be produced easily and accurately. Furthermore, by coloring the surface of the finishing material produced in this manner, finishing members of desired colors and patterns can be easily produced.

[0012] In the method for producing a finishing material according to the present invention, the coloring step may involve coloring the surface of the hydraulic mixture removed from the formwork using a UV printer.

[0013] With this configuration, finishing materials of desired colors and patterns can be produced easily and accurately. Effect of the Invention

[0014] According to the present invention, finishing materials of a predetermined shape can be easily manufactured, and it is possible to streamline finishing work by improving workability and shortening construction time. [Brief description of the drawings]

[0015] [Figure 1] FIG. 2 is a diagram showing an example of a formwork manufacturing device according to the first embodiment. [Diagram 2] 1 is a flowchart of a method for producing a finishing material according to a first embodiment. [Diagram 3] FIG. 11 is a diagram showing an example of a formwork manufacturing device according to a second embodiment. [Figure 4] 11 is a flowchart of a method for producing a finishing material according to a second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] (First embodiment) Hereinafter, a formwork manufacturing device and a method for manufacturing a finishing material according to a first embodiment of the present invention will be described with reference to Figs. 1 and 2. The formwork producing device 1 according to the first embodiment shown in Fig. 1 is a device for producing forms for finishing materials such as interior and exterior materials, flooring materials, etc. The method for producing finishing materials according to this embodiment is a method for producing finishing materials such as interior and exterior materials, flooring materials, etc. The finishing material to be produced is in the form of a plate. The finished surface of the finishing material to be produced has the same shape, color and pattern as the existing stone material 11 (existing member). The surface of the existing stone material 11 has projections and recesses. The finishing material is produced by filling a formwork 12 with a hydraulic mixture such as mortar, concrete, or silica foam cement.

[0017] The method for producing a finishing material according to the first embodiment is performed as follows: Figure 2 shows a flowchart of the method for producing a finishing material according to the first embodiment. The shape of the existing stone 11 is measured three-dimensionally (measurement step S-1). Based on the measurement results, 3D data of an inverted surface that inverts the surface shape of the existing stone 11 is generated (inverted surface data generation step S-2). Based on the data of the inverted surface generated in the inverted surface data generating step, shape data of the form 12 for forming a finishing material having a shape similar to that of the existing stone material 11 is generated (form shape data generating step S-3). The shape data of the form 12 generated in the form shape data generating step is transmitted to the additive manufacturing device 2 of the form manufacturing device 1 (form shape data transmitting step S-4). The shape data of the form 12 transmitted in the form shape data transmission process is received, and the form 12 is manufactured by the additive manufacturing device 2 based on the shape data of the form 12 (form manufacturing process S-5). The formwork 12 produced in the formwork production step is filled with a hydraulic mixture and hardened (hydraulic mixture filling step S-6). The hardened hydraulic mixture is removed from the formwork 12 (demolding step S-7). The surface of the hydraulic mixture removed from the formwork 12 is colored (coloring step S-8).

[0018] The measurement step S-1, the inverted surface data generation step S-2, the formwork shape data generation step S-3, the formwork shape data transmission step S-4 and the formwork production step S-5 are performed using a formwork production device 1 shown in FIG. The formwork production device 1 has an additive manufacturing device 2 such as a 3D printer, and a control unit 3 that controls the additive manufacturing device 2. The control unit 3 has a measurement unit 4, an inverted surface data generation unit 5, a form shape data generation unit 6, and a form shape data transmission unit .

[0019] The measuring unit 4 three-dimensionally measures the surface shape of the existing stone 11. The measuring unit 4 is, for example, a 3D scanner. The measuring step S-1 is performed by the measuring unit 4. The inverted surface data generating unit 5 generates 3D data of an inverted surface obtained by inverting the surface shape of the existing stone 11 based on the result of measurement by the measuring unit 4. The inverted surface data generating step S-2 is performed by the inverted surface data generating unit 5. The formwork shape data generating unit 6 generates shape data of the formwork 12 for forming a finishing material having a shape similar to that of the existing stone material 11, based on the data of the inverted surface generated by the inverted surface data generating unit 5. The formwork shape data generating step S-3 is performed by the formwork shape data generating unit 6. The form shape data transmission unit 7 transmits to the additive manufacturing apparatus the shape data of the form 12 generated by the form shape data generation unit 6. The form shape data transmission step S-4 is performed by the form shape data transmission unit 7.

[0020] The additive manufacturing device 2 produces the form 12 for forming a finishing material having a shape similar to that of the existing stone material 11, based on the shape data of the form 12 received from the form shape data transmission unit 7. In the formwork production process S-5, first, a finishing surface formwork 121 corresponding to the portion that will become the finishing surface of the finishing material is produced using the additive manufacturing device 2. Next, the produced finishing surface formwork 121 is used as a bottom plate, and side plates 122 are provided around the finishing surface formwork 121 to produce the formwork 12 for the finishing material.

[0021] The form shape data generating unit 6 generates shape data of the form 12 so as to correspond to the additive manufacturing device 2. The form shape data generating unit 6 may generate shape data of the form 12 so that the finishing surface of the finishing material has a desired shape different from the surface shape of the existing stone material 11.

[0022] In the hydraulic mixture filling step S-6, a super-water-repellent solvent is applied to the finishing surface formwork 121, and the hydraulic mixture is filled into the formwork 12. A glass plate is placed on the formwork 12 filled with the hydraulic mixture, sealed, and cured at a predetermined temperature for a predetermined period of time.

[0023] In the demolding step S-7, the demolded hydraulic mixture (hereinafter referred to as the base material) is appropriately dried.

[0024] In the coloring step S-8, the surface of the base material is polished, and an epoxy-based base material is applied to the polished surface of the base material as a base treatment. After the surface preparation is completed, a color and a pattern are printed on the surface of the base material by a UV printer. In this embodiment, the color and pattern on the surface of the existing stone 11 are scanned, and the scanned image data is used to print the same color and pattern as the surface of the existing stone 11 on the surface of the base material. Once printing is complete, a fluorine-based topcoat is applied to the surface of the printed substrate, using a material that is compatible with the UV ink used for printing.

[0025] Next, the operation and effect of the formwork producing device and the finishing material producing method according to the present embodiment will be described. In the formwork production apparatus and finishing material production method of this embodiment, the additive manufacturing apparatus 2 produces the formwork 12 based on data of the inverted surface obtained by inverting the surface shape of an existing stone 11 measured in three dimensions, so that a finishing material with a surface shape similar to that of the existing stone 11 can be easily and accurately produced. Moreover, by coloring the surface of the finishing material produced in this manner, finishing members of a desired color and pattern can be easily produced. In this embodiment, the surface of the finishing material is colored in the same color and pattern as the existing stone material 11, so that a finishing material of the same shape, color, and pattern as the existing stone material 11 can be easily produced. In addition, if the surface of the finishing material is colored in a different color or pattern from the existing stone material 11, it is possible to easily produce a finishing material whose surface shape is the same as that of the existing stone material 11 but whose color or pattern is different from that of the existing stone material 11. By being able to easily produce finishing materials in the desired form in this way, it is possible to streamline the finishing work by improving workability and shortening the construction period.

[0026] Furthermore, in the coloring process, a UV printer is used to color the surface of the hydraulic mixture removed from the formwork 12, making it possible to easily and accurately produce a finishing material with a desired color and pattern.

[0027] Second embodiment Next, a second embodiment will be described. The same or similar members and parts as those in the first embodiment described above are denoted by the same reference numerals, and the description will be omitted. Only the configurations different from the first embodiment will be described. The formwork producing device 1B according to the second embodiment shown in Fig. 3 is a device that produces a finishing material in a desired designed shape, rather than the shape of an existing stone material 11. The finishing material producing method according to the second embodiment shown in the flowchart of Fig. 4 is a method that produces a finishing material in a desired designed shape, color and pattern, rather than the shape and color of an existing stone material 11. In the method for producing a finishing material according to the second embodiment, instead of the measurement step S-1 in the first embodiment, a 3D data generation step S-21 is performed to convert the shape of the designed finishing material into three-dimensional data. In an adjusted inverted surface data generation step S-22 of the method for producing a finishing material according to the second embodiment, 3D data is generated for an adjusted inverted surface by adjusting the uneven dimensions of the inverted surface obtained by inverting the surface shape of the finishing material, based on the data generated in the 3D data generation step S-21.

[0028] In the adjusted inverted surface data generation step S-22, for example, the unevenness dimensions of the designed finishing material or the 3D data of its inverted surface are evaluated and adjusted. The unevenness dimensions are evaluated by the creator who produces the finishing material by visually inspecting the image data (3D data) of the designed finishing material or its inverted surface. For example, if the creator feels that the unevenness of the inverted surface is poor, the unevenness dimensions may be adjusted to be increased overall. The unevenness dimensions of the inverted surface may be adjusted so as to fall within a preset range of the dimensions of the inverted surface that protrude or recess from a reference surface. For example, if the unevenness dimensions of the inverted surface exceed the unevenness dimensions that can be produced by the additive manufacturing device 2 that produces the mold 12 in the subsequent mold production step S-25, the unevenness dimensions may be adjusted to dimensions that can be produced. The unevenness dimensions of the inverted surface may be adjusted by the manufacturer to any unevenness dimensions, or a numerical range of the unevenness dimensions may be set in advance and adjusted to be within that numerical range. In addition, when setting the numerical range of the unevenness dimensions, the manufacturer may set it after visually inspecting the image data (3D data) of the designed finishing material or its inverted surface.

[0029] In the formwork shape data generating step S-23, formwork shape data for forming the finishing material is generated based on the adjusted inverted surface data generated in the adjusted inverted surface data generating step S-22. The formwork shape data transmitting step S-24, formwork fabricating step S-25, hydraulic mixture filling step S-26, and demolding step S-27 subsequent to the formwork shape data generating step S-23 are the same as the formwork shape data transmitting step S-4, formwork fabricating step S-5, hydraulic mixture filling step S-6, and demolding step S-7 in the first embodiment.

[0030] In the coloring step S-28 of the method for producing a finishing material according to the second embodiment, similar to the coloring step S-8 of the first embodiment, the substrate is subjected to a surface treatment, and the designed color and pattern are printed on the surface of the substrate using a UV printer. After the printing is completed, a fluorine-based topcoat material is applied to the surface of the substrate on which the printing has been performed, similar to the coloring step S-8 of the first embodiment.

[0031] The control unit 3B of the formwork production device 1B according to the second embodiment is provided with a 3D data generation unit 8, an adjusted inverted surface data generation unit 5B, and a formwork shape data generation unit 6B, instead of the measurement unit 4, the inverted surface data generation unit 5, and the formwork shape data generation unit 6 of the control unit 3 of the formwork production device 1 according to the first embodiment. The 3D data generation unit 8 three-dimensionally digitizes the shape of the designed finishing material. The adjusted inverted surface data generation unit 5B generates 3D data of an adjusted inverted surface in which the unevenness dimensions of an inverted surface in which the surface shape of the finishing material is inverted are adjusted based on the data generated by the 3D data generation unit 8. The adjustment of the unevenness dimensions of the inverted surface in the adjusted inverted surface data generation unit 5B may be performed, for example, by setting a range of the protruding dimension or the recessed dimension of the inverted surface from the reference surface in advance, and adjusting the unevenness dimensions of the inverted surface to fall within that range. The adjustment of the unevenness dimensions of the inverted surface in the adjusted inverted surface data generation unit 5B may also be performed by the manufacturer inputting any unevenness dimensions. The formwork shape data generating unit 6B generates shape data of a formwork for forming a finishing material based on the adjusted inverted surface data generated in the adjusted inverted surface data generating unit 5B. The additive manufacturing device 2 of the form production apparatus 1B according to the second embodiment is similar to the additive manufacturing device 2 of the form production apparatus 1 according to the first embodiment.

[0032] In the formwork production apparatus 1B and finishing material production method according to the above-mentioned second embodiment, the additive manufacturing apparatus 2 produces the formwork 12 based on data of an adjusted inverted surface in which the concave-convex dimensions of the inverted surface obtained by inverting the surface shape of the designed finishing material are adjusted, so that a finishing material having the desired designed surface shape can be produced easily and accurately. Furthermore, by coloring the surface of the finishing material produced in this manner, finishing members of desired colors and patterns can be easily produced.

[0033] The above describes an embodiment of the formwork manufacturing device and finishing material manufacturing method according to the present invention, but the present invention is not limited to the above embodiment and can be modified as appropriate without departing from the spirit of the present invention. For example, in the above embodiment, the finishing material to be produced is in a plate shape, and one surface to be the finished surface has the same shape, color, and pattern as the surface of the existing stone material 11 (existing member). The finishing material to be produced does not have to be in a plate shape. The material used as the existing member may be a member other than stone. In the measuring unit 4 of the formwork manufacturing device 1 and the measuring step S-1 of the manufacturing method of the finishing material of the first embodiment, only the surface of the existing member to be used for the finishing surface of the finishing member may be measured three-dimensionally. In the 3D data generating unit 8 of the formwork manufacturing device 1B and the 3D data generating step of the manufacturing method of the finishing material of the second embodiment, only the surface to be the finishing surface of the designed finishing material may be converted into three-dimensional data.

[0034] In the coloring steps S-8 and S-28 of the above embodiment, the color and pattern are printed on the surface of the base material by a UV printer, but printing may be performed using a printer other than a UV printer. Also, coloring may be performed by a method other than printing. In the coloring process S-8 of the first embodiment described above, the color and pattern of the surface of the existing stone 11 is scanned, and the scanned image data is used to print a color and pattern similar to that of the surface of the existing stone 11 on the surface of the base material, but the existing stone 11 may also be colored a color or pattern different from that of the existing stone 11.

[0035] The Sustainable Development Goals (SDGs) are among the 17 international goals adopted at the United Nations Summit in September 2015. The formwork production device and finishing material production method according to this embodiment can contribute to achieving the 17 SDGs goals, such as goal 9. "Create infrastructural foundations for industry and innovation." [Explanation of symbols]

[0036] 1,1B Formwork production device 2 Additive manufacturing equipment 3,3B control section 4. Measurement section 5. Inversion surface data generation section 5B Adjustment inversion surface data generation section 6,6B Formwork shape data generation section 7 Formwork shape data transmission section 8. 3D Data Generation Section 11 Existing stone materials (existing components) 12 Formwork S-1 Measurement process S-21 3D data generation process S-2 Reversed surface data generation process S-3, S-23 Formwork shape data generation process S-4, S-24 Formwork shape data transmission process S-5, S-25 Formwork production process S-6,S-26 Hydraulic mixture filling process S-7,S-27 Demolding process S-8,S-28 Coloring process S-22 Adjustment inversion surface data generation process

Claims

1. An additive manufacturing device that produces the formwork; A control unit for controlling the additive manufacturing device, The control unit is A measuring unit that measures the shape of an existing member in three dimensions; an inverted surface data generation unit that generates 3D data of an inverted surface obtained by inverting a surface shape of the existing component based on a result of measurement by the measurement unit; a formwork shape data generating unit that generates shape data of a formwork for forming a finishing material having a similar shape to that of the existing member based on the data of the inverted surface generated by the inverted surface data generating unit; A form manufacturing device comprising: a form shape data transmission unit that transmits the form shape data generated by the form shape data generation unit to the additive manufacturing device.

2. An additive manufacturing device that produces the formwork; A control unit for controlling the additive manufacturing device, The control unit is a 3D data generating unit that converts the shape of the designed finishing material into three-dimensional data; an adjusted inverted surface data generating unit that generates 3D data of an adjusted inverted surface by adjusting the unevenness dimensions of an inverted surface obtained by inverting the surface shape of the finishing material based on the data generated by the 3D data generating unit; a formwork shape data generating unit that generates shape data of a formwork for forming the finishing material based on the adjusted inverted surface data generated by the adjusted inverted surface data generating unit; A form manufacturing device comprising: a form shape data transmission unit that transmits the form shape data generated by the form shape data generation unit to the additive manufacturing device.

3. a measuring step of measuring the shape of an existing component in three dimensions; an inverted surface data generation step of generating 3D data of an inverted surface obtained by inverting a surface shape of the existing member based on the results of the measurement in the measurement step; a formwork shape data generating step of generating shape data of a formwork for forming a finishing material having a shape similar to that of the existing member based on the data of the inverted surface generated in the inverted surface data generating step; a form shape data transmission process for transmitting the form shape data generated in the form shape data generation process to an additive manufacturing device; a form manufacturing process of receiving the shape data of the form transmitted in the form shape data transmission process and manufacturing the form using an additive manufacturing device based on the shape data of the form; A hydraulic mixture filling step of filling the form produced in the form production step with a hydraulic mixture and hardening the mixture; a demolding step of removing the hardened hydraulic mixture from the formwork; A coloring step of coloring the surface of the hydraulic mixture removed from the formwork.

4. A 3D data generation process for converting the shape of the designed finishing material into three-dimensional data; an adjusted inverted surface data generation step for generating 3D data of an adjusted inverted surface by adjusting the unevenness dimensions of an inverted surface obtained by inverting the surface shape of the finishing material based on the data generated in the 3D data generation step; a formwork shape data generating step of generating shape data of a formwork for forming the finishing material based on the adjusted inverted surface data generated in the adjusted inverted surface data generating step; a form shape data transmission process for transmitting the form shape data generated in the form shape data generation process to an additive manufacturing device; a form manufacturing process of receiving the shape data of the form transmitted in the form shape data transmission process and manufacturing the form using an additive manufacturing device based on the shape data of the form; A hydraulic mixture filling step of filling the form produced by the form production step with a hydraulic mixture and hardening the mixture; a demolding step of removing the hardened hydraulic mixture from the formwork; A coloring step of coloring the surface of the hydraulic mixture removed from the formwork.

5. 5. The method for producing a finishing material according to claim 3 or 4, wherein the coloring step uses a UV printer to color the surface of the hydraulic mixture removed from the formwork.

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