Boundary block manufacturing method and boundary block

Abstract

To provide a boundary block manufacturing method with which lightweight and strong boundary blocks can be properly manufactured.SOLUTION: A boundary block 1 has an outer shell part 11 formed of cement-based solidification material, and a reinforcing part 12 disposed inside the outer shell part 11. In the cross section of the boundary block 1, the reinforcing part 12 is composed of linear portions, and in making the boundary block 1, the reinforcing part 12 comes into shape by using a 3D printer to stack up a 3D printer modeling material.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a boundary block and a boundary block.

Background Art

[0002] In order to separate the roadway and the sidewalk, a roadway-sidewalk boundary block is provided at the boundary between the roadway and the sidewalk. In addition, a site boundary block is used as a separator for various spaces.

[0003] These boundary blocks are generally manufactured as precast members using cement-based solidifying materials such as concrete and mortar. Patent Documents 1 and 2 describe examples of such boundary blocks.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] Boundary blocks are heavy objects, and it is difficult to install them manually. Therefore, a crane is required for lifting, but crane work is dangerous. In addition, when the road length is long, the movement and installation work of the crane occur each time, so the installation work takes a long time.

[0006] The boundary blocks of Patent Documents 1 and 2 are hollow and lightweight. However, being hollow may be a disadvantage in terms of the strength and durability of the boundary blocks.

[0007] Furthermore, mass productivity for manufacturing a large number of boundary blocks of the same shape is also required for precast boundary blocks.

[0008] The present invention has been made in view of the above problems, and an object thereof is to provide a method for manufacturing a boundary block and the like that can suitably manufacture a lightweight and highly strong boundary block.

Means for Solving the Problems

[0009] A first invention for solving the above-described problems is a method for manufacturing a boundary block having an outer shell portion formed of a cementitious solidifying material and a reinforcing portion disposed inside the outer shell portion, wherein in a cross-section of the boundary block, the reinforcing portion is constituted by a linear portion, and the reinforcing portion is formed by laminating a modeling material of a 3D printer with the 3D printer. A second invention is a method for manufacturing a boundary block having an outer shell portion formed of a cementitious solidifying material and a reinforcing portion disposed inside the outer shell portion, wherein in a cross-section of the boundary block, the reinforcing portion is constituted by a linear portion, and after manufacturing the reinforcing portion separately from the outer shell portion, the outer shell portion is provided outside the reinforcing portion.

[0010] The boundary block of the present invention has an outer shell portion and a reinforcing portion, and the outer shell portion having a hollow interior is reinforced by the reinforcing portion provided inside the outer shell portion. Further, since the reinforcing portion is constituted by a linear portion in the cross-section of the boundary block, the boundary block is lightweight and excellent in strength. In addition, if one attempts to optimize the area of the reinforcing portion (the area in the cross-section of the boundary block) and the reinforcing effect of the outer shell portion, the shape of the reinforcing portion often becomes complex rather than simple. When manufacturing a boundary block having an outer shell portion and a reinforcing portion by filling concrete or the like into a formwork as in the prior art, problems occur in terms of mass productivity and the like. However, in the first invention, the reinforcing portion is manufactured by a 3D printer, and in the second invention, the reinforcing portion is manufactured separately from the outer shell portion, so that not only when the shape of the reinforcing portion is simple, but also when the reinforcing portion has a complex shape, it can be easily formed, and it is excellent in mass productivity and the like.

[0011] It is desirable that the reinforcing portion is inclined with respect to the vertical direction and has a portion where the end reaches the inner surface of the outer shell portion. If an attempt is made to increase the reinforcing effect of the outer shell portion with a small-area reinforcing portion, typically, in the cross-section of the boundary block, a linear portion that is inclined with respect to the vertical direction and whose end reaches the inner surface of the outer shell portion often appears in the reinforcing portion. Such a portion can bear loads in both the vertical and horizontal directions and transmit the load to the outer shell portion.

[0012] It is desirable that the reinforcing portion has a pair of straight portions in the cross-section of the boundary block. The straight portions are inclined with respect to the vertical direction, the pair of straight portions intersect in an X shape, and both ends of the pair of straight portions reach the inner surface of the outer shell portion. Also, it is desirable that the reinforcing portion has a pair of bent portions in the cross-section of the boundary block, and the pair of bent portions are arranged along the upper and lower inner surfaces of the outer shell portion, respectively, and connect the upper ends and the lower ends of the pair of straight portions. A truss-like reinforcing structure can be realized by a pair of X-shaped straight portions, and the reinforcing effect of the outer shell portion can be increased with a small-area reinforcing portion. Also, by providing the above-mentioned bent portions above and below these straight portions, further reinforcement of the outer shell portion becomes possible.

[0013] It is also desirable that the reinforcing portion is provided with a convex portion for forming a pocket through which a wire rod passes in the cross-section of the boundary block, and the pocket is formed between the reinforcing portion and the outer shell portion or within the reinforcing portion. Thereby, when passing a wire rod such as an optical fiber cable through the inside of the boundary block, the position of the wire rod can be held by the pocket.

[0014] A third invention is a boundary block having an outer shell portion formed of a cementitious solidifying material and a reinforcing portion disposed inside the outer shell portion. In the cross-section of the boundary block, the reinforcing portion is constituted by a linear portion, and the reinforcing portion is formed by laminating a modeling material of a 3D printer. The third invention is a boundary block manufactured by the manufacturing method of the first invention. [Effect of the Invention]

[0015] According to the present invention, it is possible to provide a method for manufacturing a boundary block and the like that can suitably manufacture a boundary block that is lightweight and excellent in strength. [Brief Description of the Drawings]

[0016]

Figure 1

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Figure 10

[0017] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0018] (1. Boundary Block 1) FIG. 1 is a diagram showing a cross-section and a side view of a boundary block 1 according to an embodiment of the present invention. This boundary block 1 is a sidewalk-road boundary block provided at the boundary between a roadway and a sidewalk. As shown in FIG. 2, a plurality of them are arranged side by side along the boundary between the roadway 2 and the sidewalk 3 and protrude upward from the road surfaces of the roadway 2 and the sidewalk 3.

[0019] The cross-section of the boundary block 1 in FIG. 1 is a cross-section orthogonal to the extending direction of the boundary block 1, and the side view of the boundary block 1 is a view of the boundary block 1 seen from a direction orthogonal to the extending direction in a plan view.

[0020] As shown in FIG. 1, the boundary block 1 has an outer shell portion 11 and a reinforcing portion 12.

[0021] The outer shell portion 11 is a cylindrical member that forms the outer peripheral portion of the cross-section of the boundary block 1. The cross-section of the outer shell portion 11 in this embodiment is trapezoidal, and has a bottom plate portion 111, side wall portions 112, and a top plate portion 113.

[0022] The bottom plate portion 111 and the top plate portion 113 are horizontal portions arranged parallel to each other above and below the outer shell portion 11. The side wall portions 112 rise from both ends in the width direction of the bottom plate portion 111, and the upper ends of both side wall portions 112 are connected to both ends in the width direction of the top plate portion 113. Note that the width direction is a direction orthogonal to the extending direction of the boundary block 1 in a plan view.

[0023] The width of the top plate portion 113 is smaller than the width of the bottom plate portion 111, and both side wall portions 112 are inclined at the same inclination angle (inner angle) α so as to incline inward as they go upward, and the distance between the side wall portions 112 narrows as it approaches the top plate portion 113. The outer surface of the connection portion between the top plate portion 113 and the side wall portions 112 has an arcuate roundness R.

[0024] The reinforcing portion 12 is provided in the hollow portion inside the outer shell portion 11 and reinforces the outer shell portion 11 from the inside. In this embodiment, in the cross-section of the boundary block 1, the reinforcing portion 12 is composed of linear portions.

[0025] In the cross-section of the boundary block 1, the reinforcing portion 12 is substantially in the shape of an 8, and has a pair of straight portions 121 and bent portions 122 disposed above and below the straight portions 121. The straight portions 121 are inclined with respect to the vertical direction, and the pair of straight portions 121 intersect in an X shape. Both ends of these straight portions 121 reach the inner surface of the outer shell portion 11. The upper bent portion 122 bends along the inner surface of the upper portion of the outer shell portion 11 and connects the upper end portions of the pair of straight portions 121. The lower bent portion 122 bends along the inner surface of the lower portion of the outer shell portion 11 and connects the lower end portions of the pair of straight portions 121.

[0026] In this embodiment, as shown in FIG. 3, the boundary block 1 is manufactured by a 3D printer 20. The 3D printer 20 is of a stacked robot arm type, and by stacking a cement-based solidifying material 10 such as non-shrinking mortar discharged as a modeling material from a nozzle at the tip of the arm, the outer shell portion 11 and the reinforcing portion 12 of the boundary block 1 are formed.

[0027] The dashed lines in FIGS. 4(a) and 4(b) are examples of the nozzle strokes when forming the reinforcing portion 12. FIG. 4(a) forms the straight portions 121 intersecting in an X shape in such a manner that the vertices of the U-shaped portions are in contact with each other, and FIG. 4(b) forms the straight portions 121 intersecting in an X shape by stacking the straight portions 121 vertically. However, in either case, the reinforcing portion 12 can be formed in one stroke. However, the reinforcing portion 12 can also be formed in a plurality of parts.

[0028] As the cement-based solidifying material 10, for example, those that absorb carbon dioxide (hereinafter referred to as CO 2 can be used. SUICOM is a concrete containing γC 2 S, which is a calcium material that reacts with CO 2 as a admixture. γC 2 S reacts with CO 2 to carbonize, thereby absorbing and fixing CO 2 . Note that the cement-based solidifying material 10 is not limited to SUICOM, and quicklime, steelmaking slag, etc. that absorb CO 2It suffices to contain a calcium material that carbonates by reaction with [substance not specified].

[0029] (2. Manufacturing method of boundary block 1) FIG. 5 is a flowchart showing the manufacturing method of boundary block 1. In the present embodiment, first, three-dimensional shape data of boundary block 1 is created, and from the three-dimensional shape data, slice data for manufacturing boundary block 1 by 3D printer 20 is created (S1).

[0030] Although various methods can be considered for creating the three-dimensional shape data, as an example, known topology optimization technology (see, for example, Japanese Unexamined Patent Application Publication No. 2021-182201) can be applied to create the three-dimensional shape data of reinforcement part 12. In topology optimization, for example, the structural performance required for boundary block 1 is input as mechanical conditions such as load, and the shape of reinforcement part 12 that can obtain the structural performance is determined so that it can be realized with the minimum area (area in the cross-section of boundary block 1).

[0031] Note that the shape of outer shell part 11 is determined by the specifications of boundary block 1 and the like, but it is not limited thereto. In some cases, it is also possible to determine the shape of outer shell part 11 by the above-described topology optimization. In addition to topology optimization, it is also possible to apply an analysis technique that optimizes (maximizes) the surface area of boundary block 1 without changing the structural performance of boundary block 1. Furthermore, in order to obtain the target CO 2 absorption amount during forced carbonation curing described later, the volume of boundary block 1 is optimized, and it may be set to a volume corresponding to the target CO 2 absorption amount.

[0032] Slice data is data obtained by slicing the above three-dimensional shape data and dividing it into upper and lower layers, and is used when manufacturing boundary block 1 by 3D printer 20. Since the method for creating slice data is known, the description thereof is omitted.

[0033] In this embodiment, based on the slice data created in S1, as shown in FIG. 3, a cement-based solidifying material 10, which is a modeling material of the 3D printer 20, is laminated by the 3D printer 20 to produce a boundary block 1 (S2).

[0034] In this embodiment, thereafter, forced carbonation curing of the cement-based solidifying material 10 is performed (S3). The forced carbonation curing is performed, for example, as shown in FIG. 6, by accommodating the boundary block 1 made of the cement-based solidifying material 10 in a curing tank 4 and supplying CO 2 to the curing tank 4. The curing tank 4 has an injection part 41 for supplying CO 2 gas into the tank and a discharge part 42 for discharging CO 2 gas. In the example of FIG. 6, the injection part 41 is provided below the discharge part 42. However, the vertical positions of the injection part 41 and the discharge part 42 may be reversed.

[0035] The boundary block 1 produced by the 3D printer 20 has irregularities on its surface as shown in FIG. 3 and the like, so its surface area is large. As a result, the absorption efficiency of CO 2 is improved and the curing can be shortened. Also, in this embodiment, in the cross section of the boundary block 1, since the outer shell part 11 and the reinforcing part 12 are composed of linear parts with a narrow width, CO 2 is easily absorbed to the inside, which greatly contributes to shortening the curing time. In the example of FIG. 6, the boundary block 1 is placed vertically (the cross section of the boundary block 1 in FIG. 1 faces upward), but the boundary block 1 may be placed horizontally (the cross section of the boundary block 1 in FIG. 1 faces horizontally), and in that case, it is easier for CO 2 to flow inside the boundary block 1. However, even when the boundary block 1 is placed vertically, if the boundary block 1 is lifted from the floor and placed on a base such as expanded metal, the flow of CO 2 can be ensured, and the arrangement of the boundary block 1 during curing is not particularly limited.

[0036] As described above, the boundary block 1 of the present embodiment has an outer shell portion 11 and a reinforcing portion 12, and the outer shell portion 11 with a hollow interior is reinforced by the linear reinforcing portion 12 provided inside the outer shell portion 11. Moreover, since the reinforcing portion 12 is composed of a linear portion in the cross-section of the boundary block 1, the boundary block 1 is lightweight and excellent in strength. For example, a conventional boundary block is a solid member formed by assembling a formwork and filling concrete or the like inside it. However, by adopting the above configuration, the boundary block 1 of the present embodiment can reduce the cross-sectional area, that is, the weight, to 50% or less compared with a solid member having the same outer shape. Further, since there are cavities in the portion of the outer shell portion 11 other than the reinforcing portion 12, the boundary block 1 can be carried and installed by one worker by accessing the cavities. Therefore, the dangerous crane work during the installation of the boundary block 1 can be omitted. Furthermore, since the movement and installation work of the crane are eliminated, the construction cycle is also improved.

[0037] Also, if we want to optimize the area of the reinforcing portion 12 in the cross-section of the boundary block 1 and the reinforcing effect of the outer shell portion 11, the shape of the reinforcing portion 12 often becomes complex rather than simple. When manufacturing the boundary block 1 having the outer shell portion 11 and the reinforcing portion 12 by filling concrete or the like into a formwork as in the prior art, problems arise in terms of mass productivity and the like. However, in the present embodiment, by manufacturing the reinforcing portion 12 by the 3D printer 20, even when the shape of the reinforcing portion 12 is simple, it can be easily formed, and even when the reinforcing portion 12 has a complex shape, it can be easily formed, and it is excellent in mass productivity and the like.

[0038] Also, if we want to increase the reinforcing effect of the outer shell portion 11 with a small-area reinforcing portion 12, typically, in the cross-section of the boundary block 1, a linear portion that is inclined with respect to the vertical direction and whose end reaches the inner surface of the outer shell portion 11 appears in the reinforcing portion 12, like the above-mentioned straight portion 121. Such a portion can bear the loads in both the vertical and horizontal directions and transmit the loads to the outer shell portion 11.

[0039] In particular, in the reinforcing portion 12 of the present embodiment, a truss-like reinforcing structure can be realized by a pair of X-shaped straight portions 121, and the reinforcing effect of the outer shell portion 11 can be enhanced with a small-area reinforcing portion 12. Further, by providing the bent portions 122 described above above and below these straight portions 121, further reinforcement of the outer shell portion 11 becomes possible.

[0040] However, the present invention is not limited to the above-described embodiment. For example, although the boundary block 1 of the present embodiment is a sidewalk-road boundary block provided at the boundary between a sidewalk and a roadway, it may be a ground boundary block or the like arranged at other boundary portions. The shape of the outer shell portion 11 varies according to the installation location and purpose of the boundary block 1, and is not limited to the trapezoidal shape as described above.

[0041] Further, the outer shell portion 11 of the present embodiment forms a closed cross-section by a bottom plate portion 111, a side wall portion 112, and a top plate portion 113, but is not limited thereto. For example, the bottom surface may be open.

[0042] Also, when forming the outer shell portion 11 by the 3D printer 20, by arranging a temporary outer formwork 30 outside the outer shell portion 11 as shown in FIG. 7(a), the outer surface of the outer shell portion 11 (the side surface of the boundary block 1) can be smoothed as shown in FIG. 7(b), and it is excellent in terms of design surface and the like.

[0043] Also, as shown in FIG. 8(a), after forming the reinforcing portion 12 by the 3D printer 20, as shown in FIG. 8(b), the above-described outer formwork 30 and a temporary inner formwork 31 connecting the upper and lower bent portions 122 of the reinforcing portion 12 are arranged, and a cement-based solidifying material 10 such as non-shrink mortar is filled between the outer formwork 30, the reinforcing portion 12 inside thereof, and the inner formwork 31, so that the outer shell portion 11 may be provided outside the reinforcing portion 12 as shown in FIG. 8(c). In this way, it is also possible to separately manufacture the outer shell portion 11 and the reinforcing portion 12.

[0044] Alternatively, the outer shell part 11 and the reinforcing part 12 may be manufactured separately, and the reinforcing part 12 may be inserted inside the outer shell part 11 so that the outer shell part 11 is provided outside the reinforcing part 12, and the reinforcing part 12 may be fixed to the outer shell part 11 with an adhesive or the like. When the outer shell part 11 and the reinforcing part 12 are manufactured separately, the reinforcing part 12 is not necessarily limited to being manufactured by the 3D printer 20, and it may be manufactured by another method such as arranging a formwork and filling it with the cementitious solidifying material 10. Also by this method, the reinforcing part 12 having a complex shape can be easily manufactured, and the mass productivity of the boundary block 1 is excellent.

[0045] Also, the shape of the reinforcing part 12 is not limited to a substantially figure-eight shape. As shown in the reinforcing part 12a of FIG. 9(a), the bent portion 122 may be omitted from the above-mentioned reinforcing part 12, and the straight portions 121 may intersect in an X shape. Also, as shown in the reinforcing part 12b of FIG. 9(b), it may be substantially X-shaped with the arcuate bent portions 123 inclined with respect to the vertical direction contacting back to back. These bent portions 123 are arranged such that both ends thereof reach the inner surface of the outer shell part 11. In addition, as shown in the reinforcing part 12c of FIG. 9(c), it may be linear in the vertical direction, or as shown in the reinforcing part 12d of FIG. 9(d), it may be cross-shaped with a vertical portion 124 and a horizontal portion 125.

[0046] In addition, as shown in the reinforcing part 120 of FIG. 10(a), a pair of straight portions 121 and upper and lower bent portions 122 are arranged in a substantially figure-eight shape, and further, a convex portion 126 protruding upward is provided on the lower bent portion 122, and a pocket (hole) 127 may be formed between the convex portion 126 and the outer shell part 11. Thereby, when passing a wire such as an optical fiber cable through the inside of the boundary block 1, the wire can be passed through the pocket 127 to hold its position.

[0047] In the above example, the pocket 127 is provided between the reinforcing part 120 and the outer shell part 11. However, as shown in FIG. 10(b), the pocket 127 may be provided inside the reinforcing part 120a. FIG. 10(b) shows a structure in which a convex portion 126 protruding upward is provided at the intersection of the straight portions 121 intersecting in an X shape, and a pocket 127 is formed between the convex portion 126 and the straight portion 121.

[0048] Also, in this embodiment, forced carbonation curing of the cementitious solidifying material 10 was performed during the production of the boundary block 1, but the forced carbonation curing can also be omitted. In this case, as the cementitious solidifying material 10, one that does not contain a calcium material that carbonates by reaction with CO 2 can also be used. Also, when producing the reinforcing part 12, a shaping material other than the cementitious solidifying material can be used.

[0049] As described above, the preferred embodiments of the present invention have been described with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious that those skilled in the art can come up with various modification examples or correction examples within the scope of the technical idea disclosed in this application, and it is naturally understood that those also belong to the technical scope of the present invention.

Explanation of Reference Numerals

[0050] 1: Boundary block 10: Cementitious solidifying material 11: Outer shell part 12, 12a, 12b, 12c, 12d, 120, 120a: Reinforcing part 20: 3D printer 121: Straight part 122, 123: Bent part 124: Vertical part 125: Horizontal part 126: Convex part 127: Pocket

Claims

1. An outer shell portion formed of a cementitious solidifying material, A reinforcing portion disposed inside the outer shell portion, A method for manufacturing a boundary block having, In the cross section of the boundary block, the reinforcing portion is composed of linear portions, The method for manufacturing a boundary block, characterized in that the reinforcing portion is formed by laminating a modeling material of a 3D printer with the 3D printer.

2. An outer shell portion formed of a cementitious solidifying material, A reinforcing portion disposed inside the outer shell portion, A method for manufacturing a boundary block having, In the cross section of the boundary block, the reinforcing portion is composed of linear portions, The method for manufacturing a boundary block, characterized in that the reinforcing portion is manufactured separately from the outer shell portion, and then the outer shell portion is provided outside the reinforcing portion.

3. The method for manufacturing a boundary block according to claim 1 or claim 2, characterized in that the reinforcing portion is inclined with respect to the vertical direction and has a portion where the end reaches the inner surface of the outer shell portion.

4. In the cross section of the boundary block, the reinforcing portion has a pair of linear portions, The linear portions are inclined with respect to the vertical direction, The pair of linear portions intersect in an X shape, The method for manufacturing a boundary block according to claim 3, characterized in that both ends of the pair of linear portions reach the inner surface of the outer shell portion.

5. In the cross section of the boundary block, the reinforcing portion has a pair of bent portions, The pair of bent portions are respectively arranged along the upper and lower inner surfaces of the outer shell portion, and connect the upper ends and the lower ends of the pair of linear portions. The method for manufacturing a boundary block according to claim 4.

6. The reinforcing portion is provided with a convex portion for forming a pocket through which a wire is passed in the cross section of the boundary block, The method for manufacturing a boundary block according to claim 1 or claim 2, characterized in that the pocket is formed between the reinforcing portion and the outer shell portion or inside the reinforcing portion.

7. A boundary block having an outer shell portion formed of a cementitious solidifying material, A reinforcing portion disposed inside the outer shell portion, In the cross section of the boundary block, the reinforcing portion is composed of linear portions, The boundary block, characterized in that the reinforcing portion is formed by laminating a modeling material of a 3D printer. ​

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