Excess polymer material separation and recovery apparatus, excess polymer material separation and recovery jig, and excess polymer material separation and recovery method

Abstract

To provide an excess polymer material separation and recovery apparatus capable of easily removing foreign matter when recovering an excess polymer material which is an unused polymer material adhering to a shaped article shaped by a three dimensional lamination shaping method.SOLUTION: The surplus polymer material separation and recovery device includes a separation force applying mechanism capable of applying a separation force for separating the surplus polymer material B adhering to the modeled object 10 to the surplus polymer material B, a first intermediate layer 230 capable of passing the surplus polymer material B separated from the modeled object 10 by providing a plurality of first hole portions 233, a second intermediate layer 240 capable of capturing foreign matter C contained in the surplus polymer material B while passing the surplus polymer material B by providing a plurality of second hole portions 243 having a size smaller than that of the plurality of first hole portions 233, and a storage portion 250 capable of receiving and storing the surplus polymer material B.SELECTED DRAWING: Figure 13

Description

[Technical Field]

[0001] The present disclosure relates to an excess polymer material separation and recovery device (hereinafter also simply referred to as a "separation and recovery device") and an excess polymer material separation and recovery method (hereinafter also simply referred to as a "separation and recovery method") that separate and recover excess polymer material, which is unused polymer material attached to an object formed by three-dimensional additive manufacturing, from the object, and also to an excess polymer material separation and recovery tool (hereinafter also simply referred to as a "separation and recovery tool") that is suitable for use in the separation and recovery device and separation and recovery method. [Background technology]

[0002] For example, International Publication No. 2023 / 214319 (Patent Document 1) discloses a method for separating and recovering unused polymer material attached to an object fabricated by a three-dimensional additive manufacturing method, as well as an apparatus for implementing the method. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2023 / 214319 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in general, a molded object immediately after being molded by a three-dimensional additive manufacturing method may contain not only unused polymer material but also foreign matter. Examples of such foreign matter include a solid polymer composition or a highly viscous liquid polymer composition that is formed when polymer material located around already bonded polymer material is affected by heat or light that promotes bonding during molding, causing the bonding to proceed unintentionally.

[0005] Therefore, in order to reuse the recovered unused polymer material, it is necessary to separate and remove this foreign matter separately, but this removal process is not easy and is a major obstacle to the reuse of polymer materials.

[0006] Therefore, an object of the present disclosure is to provide an apparatus for separating and recovering surplus polymer material, a tool for separating and recovering surplus polymer material, and a method for separating and recovering surplus polymer material that can easily remove foreign matter when recovering surplus polymer material, which is unused polymer material attached to an object formed by three-dimensional additive manufacturing. [Means for solving the problem]

[0007] An apparatus for separating and recovering excess polymer material according to one aspect of the present disclosure is an apparatus for separating and recovering unused excess polymer material attached to a modeled object fabricated by a three-dimensional additive manufacturing (3D AM) method, from the modeled object. The apparatus includes a detachment force application mechanism, a first intermediate layer, a second intermediate layer, and a reservoir. The detachment force application mechanism is capable of applying a detachment force to the excess polymer material to detach the excess polymer material from the modeled object in a predetermined detachment direction. The first intermediate layer has a first main surface intersecting the detachment direction and a second main surface located opposite the first main surface. The first intermediate layer can restrict movement of the modeled object in the detachment direction by contacting the first main surface with the modeled object to which the excess polymer material is attached. The first intermediate layer is provided with a plurality of first holes. This allows the excess polymer material detached from the modeled object to pass through the first intermediate layer. The second intermediate layer is located at a distance from the first intermediate layer in the removal direction, and has a third main surface facing the second main surface and intersecting the removal direction, and a fourth main surface located on the opposite side of the third main surface. The second intermediate layer is provided with a plurality of second holes smaller than the plurality of first holes. This allows the second intermediate layer to pass the excess polymer material that has passed through the first intermediate layer while capturing foreign matter contained in the excess polymer material. The storage section is located at a distance from the second intermediate layer in the removal direction and is arranged to face the fourth main surface. This allows the storage section to receive and store the excess polymer material that has passed through the second intermediate layer.

[0008] A jig for separating and recovering surplus polymer material according to one embodiment of the present disclosure is used to separate and recover unused surplus polymer material adhering to a model manufactured by three-dimensional additive manufacturing (3D AM), from the model. The jig includes a first intermediate layer, a second intermediate layer, and a reservoir. The first intermediate layer has a first main surface and a second main surface opposite the first main surface. The first intermediate layer is provided with a plurality of first holes, allowing the surplus polymer material detached from the model to pass through. The second intermediate layer is located at a distance from the first intermediate layer and has a third main surface facing the second main surface and a fourth main surface opposite the third main surface. The second intermediate layer is provided with a plurality of second holes smaller in size than the plurality of first holes. The second intermediate layer is capable of allowing the surplus polymer material that has passed through the first intermediate layer to pass through while capturing foreign matter contained in the surplus polymer material. The reservoir is positioned at a distance from the second intermediate layer and faces the fourth major surface, thereby allowing the reservoir to receive and store the excess polymer material that has passed through the second intermediate layer.

[0009] A method for separating and recovering surplus polymer material according to one embodiment of the present disclosure is a method for separating and recovering unused surplus polymer material attached to a modeled object fabricated by a three-dimensional additive manufacturing (3D AM) process, from the modeled object. The method includes a detachment force application mechanism, a first intermediate layer, a second intermediate layer, and a reservoir. The detachment force application mechanism is capable of applying a detachment force to the surplus polymer material to detach the surplus polymer material from the modeled object in a predetermined detachment direction. The first intermediate layer has a first main surface intersecting the detachment direction and a second main surface located opposite the first main surface, and the first intermediate layer has a plurality of first holes. The second intermediate layer is located at a distance from the first intermediate layer in the detachment direction, and has a third main surface facing the second main surface and intersecting the detachment direction, and a fourth main surface located opposite the third main surface. The second intermediate layer is provided with a plurality of second holes smaller than the plurality of first holes. The reservoir is positioned at a distance from the second intermediate layer in the detachment direction and is disposed to face the fourth main surface. In the method for separating and recovering surplus polymer material according to one aspect of the present disclosure, the detachment force is applied to the surplus polymer material in the detachment direction by the detachment force application mechanism while the shaped object to which the surplus polymer material is attached is in contact with the first main surface. As a result, the surplus polymer material passes through the plurality of first holes, then the plurality of second holes, and is then received by the reservoir. Here, as the surplus polymer material passes through the plurality of second holes, foreign matter contained in the surplus polymer material is captured by the second intermediate layer.

[0010] Note that unused polymer material adhering to a model manufactured by 3D additive manufacturing refers to the polymer material supplied to the processing chamber (processing tank, processing room, etc.) of the 3D additive manufacturing device during manufacturing, which does not become part of the model and remains, resulting in the polymer material adhering to the model. For example, when a liquid vat photopolymerization method is used as the 3D additive manufacturing method, the unused polymer material corresponds to the polymer material that was not exposed to light during manufacturing (i.e., the polymer material that did not undergo a chemical change), and when a powder bed fusion method is used as the 3D additive manufacturing method, the unused polymer material corresponds to the polymer material that was not melted during manufacturing (i.e., the polymer material that did not undergo a state change). [Effects of the Invention]

[0011] According to the present disclosure, it is possible to provide an apparatus for separating and recovering surplus polymer material, a tool for separating and recovering surplus polymer material, and a method for separating and recovering surplus polymer material that can easily remove foreign matter when recovering surplus polymer material, which is unused polymer material attached to an object formed by three-dimensional additive manufacturing. [Brief explanation of the drawings]

[0012] [Figure 1] 1A and 1B are schematic diagrams illustrating the specification of an insole as an example of an object manufactured by three-dimensional additive manufacturing. [Figure 2] FIG. 2 is a perspective view of the insole shown in FIG. [Figure 3] FIG. 2 is a flow diagram for explaining a method for manufacturing an insole to which the method for separating and recovering excess polymer material according to the first embodiment is applied. [Figure 4] FIG. 10 is a schematic diagram for explaining three-dimensional additive manufacturing of an insole. [Figure 5] FIG. 10 is a schematic diagram for explaining three-dimensional additive manufacturing of an insole. [Figure 6] FIG. 10 is a schematic diagram for explaining three-dimensional additive manufacturing of an insole. [Figure 7]FIG. 10 is a schematic diagram for explaining another example of three-dimensional additive manufacturing of an insole. [Figure 8] 1 is a perspective view of a jig for separating and recovering excess polymer material according to a first embodiment. FIG. [Figure 9] FIG. 9 is an exploded perspective view of the jig for separating and recovering excess polymer material shown in FIG. [Figure 10] FIG. 9 is a schematic cross-sectional view of the jig for separating and recovering excess polymer material shown in FIG. [Figure 11] FIG. 5 is a schematic cross-sectional view showing a state in which a shaped object immediately after being shaped by three-dimensional additive manufacturing is set in the jig for separating and recovering excess polymer material shown in FIG. 4 in the method for separating and recovering excess polymer material according to the first embodiment. [Figure 12] FIG. 2 is a schematic diagram for explaining centrifugal separation in the method for separating and recovering an excess polymer material according to the first embodiment. [Figure 13] FIG. 10 is a schematic cross-sectional view showing how excess polymer material is separated from the shaped object during centrifugation. [Figure 14] 10 is a schematic cross-sectional view illustrating the collection process in the insole manufacturing method. FIG. [Figure 15] 10A and 10B are schematic cross-sectional views illustrating a cleaning process in the insole manufacturing method. [Figure 16] FIG. 10 is a flow chart for explaining a method for manufacturing an insole to which a method for separating and recovering excess polymer material according to a second embodiment is applied. [Figure 17] FIG. 10 is a schematic diagram for explaining separation by gas blowing in the method for separating and recovering an excess polymer material according to the second embodiment. [Figure 18] FIG. 10 is a schematic diagram for explaining separation by gas blowing in the method for separating and recovering an excess polymer material according to the third embodiment. [Figure 19] FIG. 10 is a schematic diagram for explaining separation by gas blowing in the method for separating and recovering an excess polymer material according to the fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, embodiments will be described in detail with reference to the drawings. In the embodiments shown below, an insole is exemplified as an example of a shaped object formed by a three-dimensional lamination molding method, and the case where the present invention is applied to a surplus polymer material separation and recovery device, a jig for separating and recovering a surplus polymer material, and a method for separating and recovering a surplus polymer material used in the production of the insole will be exemplified and described. In the embodiments shown below, the same or common parts are denoted by the same reference numerals in the drawings, and the description thereof will not be repeated.

[0014] (Embodiment 1) <A. Configuration of Insole> FIG. 1 is a schematic diagram for explaining the specification aspect of an insole as an example of a shaped object formed by a three-dimensional lamination molding method, and FIG. 2 is a perspective view of the insole shown in FIG. 1. First, prior to explaining the surplus polymer material separation and recovery device, the jig for separating and recovering the surplus polymer material, and the method for separating and recovering the surplus polymer material according to the present embodiment, the insole 5 as a shaped object will be described with reference to FIGS. 1 and 2.

[0015] As shown in FIG. 1, the insole 5 is used by being mounted on, for example, shoes 1 as footwear. The shoes 1 include a sole 2 and an upper 3, and in use, the insole 5 is inserted into the shoe 1 through an opening 4 provided in the upper 3. As a result, the insole 5 is placed on the inner bottom surface of the shoe 1 so that its lower surface faces the inner bottom surface of the shoe 1, and thereby the insole 5 is mounted on the shoe 1.

[0016] When the user wears the shoes 1, the sole of the user's foot is placed on the upper surface of the insole 5. Therefore, the insole 5 is sandwiched between the sole 2 of the shoe 1 and the sole of the user's foot, and thereby the insole 5 supports the user's foot.

[0017] As shown in Figure 2, the insole 5 has a flat shape, and its outline in plan view roughly matches the outline of the inner bottom surface of the shoe 1. The insole 5 is made of a single member, and is made of a shaped object 10 produced by a three-dimensional additive manufacturing method, which will be described later. Here, the specific structure of the insole 5 is not particularly limited, but the insole 5 shown in the figure includes a base layer 6 and an upper layer 7, each of which is configured to form layers.

[0018] The base layer 6 has an upper surface, a lower surface, and a peripheral surface, and constitutes the lower portion of the insole 5. The upper layer 7 has an upper surface, a lower surface, and a peripheral surface, and constitutes the upper portion of the insole 5 by covering the upper surface of the base layer 6. In other words, the insole 5 has a two-layer structure consisting of the base layer 6 and the upper layer 7.

[0019] As described above, since the insole 5 is made of a single member, the upper surface of the base layer 6 and the lower surface of the upper layer 7 are configured to be continuous with each other. In other words, the upper surface of the base layer 6 and the lower surface of the upper layer 7 refer to the boundary surface where the structural differences between the base layer 6 and the upper layer 7, which will be described later, occur.

[0020] The base layer 6 is configured as a three-dimensional mesh structure in which a unit structure, a three-dimensional lattice structure, is repeatedly arranged in a plurality of units. Here, the three-dimensional lattice structure is formed by interconnecting a plurality of pillars extending in a predetermined direction. In the insole 5 shown in the figure, a plurality of the unit structures are repeatedly and continuously arranged in three orthogonal axial directions, namely, the front-rear direction, the left-right direction, and the up-down direction. As a result, a large number of holes are formed inside the base layer 6 and on its outer surface.

[0021] The upper layer 7 is made of a sheet-like structure, and the upper layer 7 made of the sheet-like structure has a plurality of through-holes that penetrate the upper layer 7 in its thickness direction (i.e., the vertical direction of the insole 5).

[0022] The insole 5 is made of a polymer material, and can be made of, for example, resin or rubber. More specifically, if the insole 5 is made of resin, it can be made of, for example, polyolefin resin, ethylene-vinyl acetate copolymer (EVA), polyamide-based thermoplastic elastomer (TPA, TPAE), thermoplastic polyurethane (TPU), or polyester-based thermoplastic elastomer (TPEE). On the other hand, if the insole 5 is made of rubber, it can be made of, for example, butadiene rubber (BR).

[0023] When the insole 5 is made of a polymer composition, examples of the polymer contained in the polymer composition include olefin polymers such as olefin elastomers and olefin resins. Examples of olefin polymers include polyethylene (e.g., linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE)), polypropylene, ethylene-propylene copolymers, propylene-1-hexene copolymers, propylene-4-methyl-1-pentene copolymers, propylene-1-butene copolymers, ethylene-1-hexene copolymers, ethylene-4-methyl-pentene copolymers, ethylene-1-butene copolymers, 1-butene-1-hexene copolymers, 1-butene-4-methyl-pentene, ethylene-methacrylic acid copolymers, ethylene-methyl methacrylate copolymers, ethylene- Examples of polyolefins include ethyl methacrylate copolymer, ethylene-butyl methacrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-ethyl acrylate copolymer, ethylene-butyl acrylate copolymer, propylene-methacrylic acid copolymer, propylene-methyl methacrylate copolymer, propylene-ethyl methacrylate copolymer, propylene-butyl methacrylate copolymer, propylene-methyl acrylate copolymer, propylene-ethyl acrylate copolymer, propylene-butyl acrylate copolymer, ethylene-vinyl acetate copolymer, and propylene-vinyl acetate copolymer.

[0024] The polymer may also be an amide polymer such as an amide elastomer or an amide resin, etc. Examples of the amide polymer include polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 610, and polyether block amide (PEBA).

[0025] The polymer may also be an ester-based polymer such as an ester-based elastomer or an ester-based resin, etc. Examples of the ester-based polymer include polyethylene terephthalate and polybutylene terephthalate.

[0026] The polymer may be a urethane polymer such as a urethane elastomer or a urethane resin, etc. Examples of the urethane polymer include polyester polyurethane and polyether polyurethane.

[0027] The polymer may also be a styrene-based polymer such as a styrene-based elastomer or a styrene-based resin. Examples of styrene-based elastomers include styrene-ethylene-butylene copolymer (SEB), styrene-butadiene-styrene copolymer (SBS), hydrogenated SBS (styrene-ethylene-butylene-styrene copolymer (SEBS)), styrene-isoprene-styrene copolymer (SIS), hydrogenated SIS (styrene-ethylene-propylene-styrene copolymer (SEPS)), styrene-isobutylene-styrene copolymer (SIBS), styrene-butadiene-styrene-butadiene (SBSB), and styrene-butadiene-styrene-butadiene-styrene (SBSBS). Examples of styrene-based resins include polystyrene, acrylonitrile-styrene resin (AS), and acrylonitrile-butadiene-styrene resin (ABS).

[0028] Furthermore, the polymer may be, for example, an acrylic polymer such as polymethyl methacrylate, a urethane-based acrylic polymer, a polyester-based acrylic polymer, a polyether-based acrylic polymer, a polycarbonate-based acrylic polymer, an epoxy-based acrylic polymer, a conjugated diene polymer-based acrylic polymer and hydrogenated products thereof, a urethane-based methacrylic polymer, a polyester-based methacrylic polymer, a polyether-based methacrylic polymer, a polycarbonate-based methacrylic polymer, a polyester-based urethane acrylate, a polycarbonate-based urethane acrylate, a polyether-based urethane acrylate, an epoxy-based methacrylic polymer, a conjugated diene polymer-based methacrylic polymer and hydrogenated products thereof, a polyvinyl chloride resin, a silicone-based elastomer, butadiene rubber, isoprene rubber (IR), chloroprene rubber (CR), natural rubber (NR), styrene-butadiene rubber (SBR), acrylonitrile-butadiene rubber (NBR), butyl rubber (IIR), or the like.

[0029] Since the insole 5 is preferably made of a flexible material, it is particularly preferable that it be made of urethane acrylate among the above-mentioned materials. When the insole 5 is made of urethane acrylate, not only does it have excellent durability and elongation, but it also has sufficient elasticity. As mentioned above, the insole 5 is manufactured by three-dimensional additive manufacturing (more specifically, three-dimensional additive manufacturing using a liquid vat photopolymerization method), and therefore the insole 5 contains a photopolymerization initiator and the like as a secondary component.

[0030] In this way, the insole 5 is constructed from a two-layer structure 10 having a base layer 6 made of a three-dimensional mesh structure and an upper layer 7 made of a sheet-like structure with a plurality of through holes, and by forming the insole 5 from a flexible polymer material, it is possible to create an insole that has excellent cushioning properties, breathability, and durability, and also provides a good wearing comfort.

[0031] Here, as the unit structure of the three-dimensional lattice structure of the base layer portion 6 composed of a three-dimensional mesh structure, various structures can be used. For example, a rectangular parallelepiped lattice, a diamond lattice, an octahedron lattice, a double pyramid lattice, or a structure in which various columnar supports are added to these lattices can be used.

[0032] Alternatively, instead of the three-dimensional lattice structure described above, the base layer portion 6 may be configured by a three-dimensional mesh structure in which a plurality of unit structures each having a three-dimensional wall structure are repeatedly arranged. The three-dimensional wall structure is formed by a wall whose outer shape is defined by a pair of parallel curved surfaces or flat surfaces. As the unit structure of the three-dimensional wall structure of the base layer portion 6 composed of a three-dimensional mesh structure, various structures can be used. For example, a Schwarz P structure, a gyroid structure, a Schwarz D structure, an octet structure, a cubic structure, etc. can be used.

[0033] Note that it is not always necessary to configure the lining 5 with the shaped object 10 having the two-layer structure as described above, and it may be configured with a shaped object having another structure. For example, the lining 5 may be configured with only a three-dimensional mesh structure or a shaped object, or the lining 5 may be configured with only a sheet-like structure or a shaped object.

[0034] <B. Manufacturing method of the lining> FIG. 3 is a flowchart for explaining a manufacturing method of a lining to which the surplus polymer material separation and recovery method according to the present embodiment is applied. Next, the manufacturing method of the lining 5 will be described with reference to FIG. 3.

[0035] As shown in FIG. 3, when manufacturing the lining 5 described above, first, in step ST1, three-dimensional laminated shaping of the lining 5 is performed. In the present embodiment, the three-dimensional laminated shaping of the lining 5 is performed by a three-dimensional laminated shaping method of a liquid tank photopolymerization method, and the details thereof will be described in detail later.

[0036] Next, in step ST2, centrifugation is performed to separate the excess polymer material from the cushioning material 5 to which the excess polymer material has adhered. Then, in step ST3, the excess polymer material separated from the cushioning material 5 is recovered. Among these, step ST2 in particular corresponds to the method for separating and recovering the excess polymer material according to the present embodiment, and the details thereof will be described later.

[0037] Next, in step ST4, the cushioning material 5 from which the excess polymer material has been removed is washed. Subsequently, in step ST5, the washed cushioning material 5 is dewatered and dried. Further, in step ST6, the cushioning material 5 after dewatering and drying is irradiated with ultraviolet rays. Then, in step ST7, heat treatment of the cushioning material 5 after being irradiated with ultraviolet rays is performed.

[0038] By going through the above steps, the production of the above-described cushioning material 5 is completed. Note that the irradiation of the cushioning material 5 with ultraviolet rays performed in step ST6 is carried out to promote the curing of the polymer material that has not yet been completely cured by the ultraviolet ray irradiation performed in step ST1, which will be described in detail later.

[0039] <C. Three-dimensional laminated molding of the cushioning material> FIGS. 4 to 6 are schematic diagrams for explaining the three-dimensional laminated molding of the cushioning material, showing the state at the start of the molding, the state at an intermediate stage, and the state at the end, respectively. FIG. 7 is a schematic diagram for explaining another example of the three-dimensional laminated molding of the cushioning material. Next, referring to FIGS. 4 to 7, the three-dimensional laminated molding of the cushioning material 5 in step ST1 described above will be described in detail.

[0040] A three-dimensional additive manufacturing apparatus 400 such as that shown in FIGS. 4 to 6 is used for the three-dimensional additive manufacturing of the insole 5. The liquid vat photopolymerization three-dimensional additive manufacturing method is a modeling method that uses a photocurable liquid polymer material that hardens when exposed to light of a specific wavelength as the main raw material, and produces a desired shape by sequentially layering hardened portions of the material by irradiating the material with light of the specific wavelength. For example, ultraviolet light is used as the light of the specific wavelength, and in this case, an ultraviolet-curable polymer is used as the main raw material. Note that the liquid polymer material described above as the main raw material is not limited to a one-component material, and may be a two-component material, etc.

[0041] 4 to 6, the three-dimensional additive manufacturing apparatus 400 includes a light source (not shown), a raw material tank 401, a platform 402, and an elevating mechanism 403. The raw material tank 401 is a portion for storing liquid polymer material A as a raw material, and the platform 402 is for holding and moving the model 10. The elevating mechanism 403 is for moving the platform 402 in the vertical direction.

[0042] 4, in the three-dimensional additive manufacturing apparatus 400, first, the platform 402 is moved by the lifting mechanism 403, so that the lower surface of the platform 402 is positioned near the inner bottom surface of the reservoir tank 401. In this state, the light source emits light of a specific wavelength, which is irradiated so as to draw a predetermined pattern on the liquid polymer material A located between the lower surface of the platform 402 and the inner bottom surface of the reservoir tank 401, thereby exposing the liquid polymer material A located between the lower surface of the platform 402 and the inner bottom surface of the reservoir tank 401. As a result, the liquid polymer material A located between the lower surface of the platform 402 and the inner bottom surface of the reservoir tank 401 hardens in a layer while adhering to the inner bottom surface of the reservoir tank 401 and the lower surface of the platform 402, and a first hardened layer is formed.

[0043] Next, platform 402 is moved upward (i.e., in the direction of arrow DR1 in the figure) by a predetermined distance by lifting mechanism 403, thereby peeling the first cured layer from the inner bottom surface of reservoir 401, and in this state, light of a specific wavelength emitted from the light source is irradiated so as to draw a predetermined pattern on liquid polymer material A located between the lower surface of platform 402 and the inner bottom surface of reservoir 401, thereby exposing it. As a result, liquid polymer material A located between the lower surface of the first cured layer and the inner bottom surface of reservoir 401 is cured in a layer while adhering to the lower surface of the first cured layer and the lower surface of platform 402, and a second cured layer is formed.

[0044] By repeating steps similar to those for forming the second cured layer (i.e., the step of moving the platform 402 and the step of exposing the liquid polymer material A), multiple cured layers are sequentially stacked downward (i.e., in the direction of the arrow DR2 shown in the figure) as shown in Figure 5, thereby progressing the formation of the insole 5. During this process of formation, the base layer 6 and the upper layer 7 are simultaneously and sequentially additively manufactured.

[0045] Then, as shown in Figure 6, after all parts of the insole 5 have been formed, the platform 402 is lifted further upward by the lifting mechanism 403, and the insole 5 is separated from the liquid polymer material A stored in the raw material tank 401 and removed from the three-dimensional additive manufacturing device 400.

[0046] 4 to 6, the insole 5 is configured so that its fabrication progresses from the rear end to the front end. This makes it possible to fabricate multiple insoles 5 simultaneously, as shown in the figures, thereby improving manufacturing efficiency.

[0047] In addition, when configured in this way, due to the relationship between the shape of the mat 5 to be shaped and the posture (i.e., orientation) of the mat 5 during shaping, it is necessary to form the support portion 11 as shown in FIGS. 5 and 6 separately from the mat 5 so that the shape of the still relatively soft mat 5 is maintained during shaping. This support portion 11 is removed by being separated from the mat 5 after the shaping of the mat 5.

[0048] On the other hand, in another example of the three-dimensional laminated shaping of the mat 5 shown in FIG. 7, the mat 5 is configured such that its shaping progresses from the lower end side toward the upper end side. In this way, since the footprint required for shaping the mat 5 on the platform 402 becomes relatively large, it becomes difficult to shape a plurality of mats 5 simultaneously.

[0049] However, on the contrary, when configured in this way, due to the relationship between the shape of the mat 5 to be shaped and the posture (i.e., orientation) of the mat 5 during shaping, the support portion 11 as shown in FIGS. 5 and 6 becomes unnecessary and the time required for shaping is shortened. Therefore, in this regard, it is possible to shorten the tact time, and no problem such as waste material (i.e., the support portion 11 after being separated from the mat 5) being generated occurs, and in this sense, the manufacturing cost can be reduced.

[0050] After the three-dimensional laminated shaping of the mat 5 described above is completed, the mat 5 is in a state where surplus polymer material, which is an unused liquid polymer material, adheres to it. In particular, in the shaped article 10 having a large number of holes formed on its surface and inside, such as the mat 5 described above, a large amount of surplus polymer material adheres due to surface tension. In particular, since the viscosity of the liquid polymer material is relatively high, it does not easily detach from the shaped article 10 and remains attached to the surface and inside of the shaped article 10.

[0051] <D. Fixture for Separating and Recovering Surplus Polymer Material> FIG. 8 is a perspective view of a jig for separating and recovering surplus polymer material according to this embodiment. FIG. 9 is an exploded perspective view of the jig for separating and recovering surplus polymer material, and FIG. 10 is a schematic cross-sectional view taken along line XX in FIG. 8. Next, with reference to FIGS. 8 to 10, a jig 200A for separating and recovering surplus polymer material according to this embodiment will be described. Here, the jig 200A for separating and recovering surplus polymer material is used in the centrifugation in step ST2 and the recovery operation in step ST3 described above, and a portion of the jig 200A for separating and recovering surplus polymer material is also used in the cleaning process in step ST4 described above. Hereinafter, the three-dimensionally additively manufactured insole 5 will be referred to solely as the shaped object 10.

[0052] As shown in Figures 8 to 10, the separation and recovery jig 200A mainly comprises a box body 210, a lid body 220, a first intermediate layer 230, and a second intermediate layer 240, and when these components are combined with each other, the overall appearance is that of a box with a lid.

[0053] Box 210 includes a first container 2110 and a second container 2120, and is configured in the shape of a stacked box. Specifically, the lower end portion of first container 2110 can be inserted into the upper end portion of second container 2120, and thus, when first container 2110 is stacked on second container 2120, first container 2110 and second container 2120 form one box 210.

[0054] 9 and 10, the first container 2110 has a first bottom wall 2111 and a first peripheral wall 2112 extending from the periphery of the first bottom wall 2111. A first flange 2113 extending outward is provided at the upper edge of the first peripheral wall 2112, and a first upper opening 2114 is located inside the first peripheral wall 2112 at the portion where the first flange 2113 is provided. A lower opening 2115 is provided in a portion of the first bottom wall 2111 excluding the periphery. The first peripheral wall 2112 has an inclined shape such that the width and depth of the first container 2110 narrow downward, and a first step 2116 is provided at a predetermined position in the height direction of the first peripheral wall 2112 (i.e., the depth direction of the first container 2110).

[0055] The second container 2120 has a second bottom wall portion 2121 and a second peripheral wall portion 2122 standing upright from the peripheral edge of the second bottom wall portion 2121. A second flange portion 2123 extending outward is provided on the upper edge of the second peripheral wall portion 2122, and a second upper opening portion 2124 is located inside the second peripheral wall portion 2122 at the portion where the second flange portion 2123 is provided. The second peripheral wall portion 2122 has an inclined shape such that the width and depth of the second container 2120 narrow downward, and a second step portion 2126 is provided at a predetermined position in the height direction of the second peripheral wall portion 2122 (i.e., the depth direction of the second container 2120).

[0056] As such, the first container 2110 and the second container 2120 basically have the same shape, but the difference is that the first bottom wall portion 2111 of the first container 2110 has a lower opening 2115, while the second bottom wall portion 2121 of the second container 2120 does not have such an opening.

[0057] The first container 2110 and the second container 2120 configured in this manner are stacked together by inserting the lower end portion of the first container 2110 into the upper end portion of the second container 2120 as described above, and function as a single box 210. When the first container 2110 is stacked on the second container 2120, the first step portion 2116 of the first container 2110 abuts against the second flange portion 2123 of the second container 2120, and the portion of the first peripheral wall portion 2112 of the first container 2110 that is lower than the first step portion 2116 fits into the portion of the second peripheral wall portion 2122 of the second container 2120 that is lower than the second step portion 2126, so that the first container 2110 is stably held by the second container 2120.

[0058] 10 , in a box 210 formed by stacking a first container 2110 on a second container 2120, the bottom wall 211 of the box 210 is formed by a second bottom wall 2121 of the second container 2120, and the peripheral wall 212 of the box 210 is formed by a first peripheral wall 2112 of the first container 2110 and a second peripheral wall 2122 of the second container 2120. In addition, an opening 214 provided on the top surface of the box 210 is formed by a first upper opening 2114 provided in the first container 2110.

[0059] As described above, the first bottom wall 2111 of the first container 2110 has the lower opening 2115, and therefore the first bottom wall 2111 has a substantially frame-like shape in plan view. The first bottom wall 2111 having the frame-like shape in plan view is disposed at a predetermined position in the depth direction of the box 210, thereby functioning as a shelf provided inside the box 210.

[0060] 8 to 10, the lid 220 is capable of closing the opening 214 of the box body 210 (i.e., the first upper opening 2114 of the first container 2110). The lid 220 prevents the shaped object 10 and the excess polymer material B separated from the shaped object 10 (see FIGS. 11 to 13, etc.) from flying out of the separation and recovery jig 200A when the separation and recovery jig 200A is handled before and after centrifugation, which will be described later, and also prevents the shaped object 10 from falling over during the centrifugation.

[0061] The box body 210 and the lid body 220 may be made of any material, but from the viewpoint of preventing unintended hardening of the model 10 due to the incidence of ultraviolet rays from outside, it is preferable to use a container that can block ultraviolet rays, such as a black container.

[0062] 9 and 10, the first intermediate layer 230 and the second intermediate layer 240 are both made of a mesh member. The first intermediate layer 230 and the second intermediate layer 240 are both housed inside the box body 210.

[0063] First intermediate layer 230 is made of a flat mesh member having a first main surface 231 and a second main surface 232 located opposite first main surface 231, and is provided with a pair of legs 234 at its side ends. First intermediate layer 230 is provided with a plurality of first holes 233 so as to reach both first main surface 231 and second main surface 232. Here, in the present embodiment, first intermediate layer 230 is made of a wire mesh, and therefore each of the plurality of first holes 233 is formed in a generally rectangular shape in plan view.

[0064] The second intermediate layer 240 is made of a flat mesh member having a third main surface 241 and a fourth main surface 242 located opposite the third main surface 241. The second intermediate layer 240 is provided with a plurality of second holes 243 so as to reach both the third main surface 241 and the fourth main surface 242. In this embodiment, the second intermediate layer 240 is also made of a wire mesh, and each of the plurality of second holes 243 is therefore configured to have a generally rectangular shape in plan view.

[0065] The second intermediate layer 240 has an edge 245 supported by the first bottom wall 2111 of the first container 2110, which functions as a shelf provided inside the box 210. As a result, the lower opening 2115 provided in the first bottom wall 2111 of the first container 2110 is covered by the second intermediate layer 240. The second intermediate layer 240 is disposed inside the box 210 so that its third main surface 241 faces upward and its fourth main surface 242 faces downward.

[0066] The first intermediate layer 230 is also supported by the first bottom wall 2111 of the first container 2110, which functions as a shelf provided inside the box 210. More specifically, the first intermediate layer 230 is arranged so that its legs 234 are supported by the first bottom wall 2111 of the first container 2110. As a result, the portion of the first intermediate layer 230 excluding the legs 234 is positioned at a distance from the second intermediate layer 240, and the lower opening 2115 provided in the first bottom wall 2111 of the first container 2110 is also covered by this first intermediate layer 230. The first intermediate layer 230 is arranged inside the box 210 so that its first main surface 231 faces upward and its second main surface 232 faces downward.

[0067] Here, the above-mentioned leg portion 234 is provided on the first intermediate layer 230 in order to maintain the distance between the first intermediate layer 230 and the second intermediate layer 240. Therefore, if the distance between the first intermediate layer 230 and the second intermediate layer 240 is maintained by another method, it is not necessary to provide the leg portion 234 on the first intermediate layer 230.

[0068] By configuring the separation and recovery jig 200A in this manner, when the components that make it up are combined with each other, the separation and recovery jig 200A has a first intermediate layer 230 which has a first main surface 231 and a second main surface 232 located opposite the first main surface 231, and which has a plurality of first hole portions 233 formed therein, and a second intermediate layer 240 which is located at a distance from the first intermediate layer 230, has a third main surface 241 facing the second main surface 232 of the first intermediate layer 230, and a fourth main surface 242 located opposite the third main surface 241, and which has a plurality of second hole portions 243 formed therein, and the first intermediate layer 230 and second intermediate layer 240 divide the interior space of the box body 210 into three spaces in the vertical direction.

[0069] More specifically, as shown in FIG. 10, the internal space of the box body 210 is divided into three spaces: a first space SP1 located between the opening 214 (i.e., the first upper opening 2114 of the first container 2110) on the top surface of the box body 210 and the first main surface 231 of the first intermediate layer 230; a second space SP2 located between the second main surface 232 of the first intermediate layer 230 and the third main surface 241 of the second intermediate layer 240; and a third space SP3 located between the fourth main surface 242 of the second intermediate layer 240 and the bottom wall portion 211 of the box body 210 (i.e., the second bottom wall portion 2121 of the second container 2120).

[0070] The first space SP1 is a space in which the model 10 is placed during centrifugation, as will be described later, and the third space SP3 functions as a storage section 250 in which excess polymer material separated from the model 10 by the centrifugation is stored. That is, the storage section 250 is formed by the bottom wall section 211 of the box body 210 and a peripheral wall section 212 that defines the above-mentioned third space SP3 (i.e., the lower end portion of the second peripheral wall section 2122 of the second container 2120).

[0071] Here, as described above, the first intermediate layer 230 and the second intermediate layer 240 are each provided with a plurality of first holes 233 and a plurality of second holes 243. Among these, the sizes of the plurality of second holes 243 are configured to be smaller than the sizes of the plurality of first holes 233. The reason for such a configuration will be described in detail later.

[0072] As described above, in the present embodiment, both the first intermediate layer 230 and the second intermediate layer 240 are each constituted by a wire mesh as a mesh member. However, the first intermediate layer 230 and the second intermediate layer 240 do not necessarily have to be wire meshes, and they may be constituted by a mesh material made of a material other than metal (for example, resin, etc.). Further, the first intermediate layer 230 and the second intermediate layer 240 do not necessarily have to be constituted by a mesh material, and for example, they may be constituted by a plate material provided with a plurality of holes.

[0073] Also, the shape of each of the plurality of first holes 233 provided in the first intermediate layer 230 and the plurality of second holes 243 provided in the second intermediate layer 240 is not limited to the substantially rectangular shape in plan view described above, and may be any shape such as a circular shape in plan view or a hexagonal shape in plan view. Further, the first intermediate layer 230 may be constituted by, for example, beam materials arranged parallel to each other.

[0074] <E. Centrifugal Separation> FIG. 11 is a schematic cross-sectional view showing a state in which an object formed immediately by a three-dimensional laminating shaping method is set in the surplus polymer material separation and recovery jig described above in the surplus polymer material separation and recovery method according to the present embodiment. Further, FIG. 12 is a schematic diagram for explaining centrifugal separation in the surplus polymer material separation and recovery method according to the present embodiment, and FIG. 13 is a schematic cross-sectional view showing a state in which the surplus polymer material is separated from the object by the centrifugal separation. Next, referring to FIGS. 11 to 13, the surplus polymer material separation and recovery apparatus 100A and the surplus polymer material separation and recovery method according to the present embodiment will be described.

[0075] 11, the object 10 immediately after being manufactured by the three-dimensional additive manufacturing method is set in the separation and recovery jig 200A with unused surplus polymer material still attached thereto. Specifically, the object 10 is placed on the first main surface 231 of the first intermediate layer 230 located inside the separation and recovery jig 200A, and thereby housed inside the separation and recovery jig 200A.

[0076] 12, the separation and recovery apparatus 100A includes a centrifuge 110. The centrifuge 110 has a chamber 111, a rotating basket 112 disposed within the chamber 111, and a drive motor 113 that rotates the rotating basket 112. The rotating basket 112 is rotatably supported by a bearing or the like (not shown) so that it can rotate within the chamber, and is rotated by the drive motor 113, thereby rotating at high speed within the chamber 111 in the direction of arrow DR3 shown in the figure.

[0077] The separation and recovery jig 200A containing the object 10 immediately after being fabricated by the above-described three-dimensional additive manufacturing method is set in the rotating basket 112 of the centrifuge 110. At this time, it is preferable to set a plurality of separation and recovery jigs 200A in the rotating basket 112 from the viewpoint of shortening the takt time.

[0078] Here, the separation and recovery jig 200A is arranged so that the bottom wall 211 of its box body 210 is located radially outside the centrifuge 110 and its lid body 220 is located radially inside the centrifuge 110. As a result, the first intermediate layer 230, the second intermediate layer 240, and the storage section 250 of the separation and recovery jig 200A are all located radially outside the shaped object 10 of the centrifuge 110.

[0079] By operating the centrifuge 110 in this state, the separating and recovering jig 200A rotates at high speed together with the rotating basket 112, and centrifugal force acts on the separating and recovering jig 200A and the model 10 housed therein in the direction of arrow DR4 shown in the figure. This centrifugal force serves as a detachment force for detaching the excess polymer material from the model 10 to which the excess polymer material has adhered, and the direction in which this centrifugal force acts (i.e., the direction of arrow DR4 shown in the figure) serves as the detachment direction for detaching the excess polymer material from the model 10. Therefore, the centrifuge 110 corresponds to a detachment force application mechanism that applies a detachment force to the excess polymer material to detach it from the model 10.

[0080] 13, when centrifugal force is applied to the model 10 in the direction of the arrow DR4 in the figure, the model 10 comes into contact with the first main surface 231 of the first intermediate layer 230, and movement in the direction of the arrow DR4 in the figure (i.e., the detachment direction) is restricted. In contrast, the excess polymer material adhering to the model 10 is subjected to the centrifugal force in the direction of the arrow DR4 in the figure (i.e., the detachment force) and moves in that direction (i.e., the detachment direction).

[0081] The excess polymer material B that has detached from the model 10 passes through the multiple first holes 233 provided in the first intermediate layer 230, and thereby moves from the first space SP1 to the second space SP2. At this time, the foreign matter C that has adhered to the model 10 also detaches from the model 10 together with the excess polymer material B, passes through the multiple first holes 233 provided in the first intermediate layer 230, and reaches the second space SP2 from the first space SP1.

[0082] At this time, the multiple first holes 233 provided in the first intermediate layer 230 are configured to be relatively large, so that the excess polymer material B and foreign matter C that have detached from the model 10 can move smoothly into the second space SP2. Here, the size of the multiple first holes 233 is preferably configured to be sufficiently larger than the size of the unit structures of the three-dimensional mesh structure contained in the model 10 so that the foreign matter C can smoothly reach the second space SP2, and it is preferable to make the size even larger as long as the movement of the model 10 in the direction of the arrow DR4 in the figure is restricted.

[0083] The excess polymer material B and foreign matter C that reach the second space SP2 by passing through the multiple first hole portions 233 provided in the first intermediate layer 230 continue to be subjected to centrifugal force (i.e., separation force) in the direction of arrow DR4 in the figure, and move in that direction (i.e., the separation direction), and then reach the second intermediate layer 240.

[0084] At this time, since the multiple second hole portions 243 provided in the second intermediate layer 240 are configured to be relatively small in size, the excess polymer material B and foreign matter C that have detached from the model 10 basically adhere to the second intermediate layer 240 without passing through the multiple second hole portions 243 of the second intermediate layer 240 as they are.

[0085] Here, by appropriately adjusting the size of the multiple second hole portions 243, it becomes possible to selectively move only the liquid excess polymer material B, which has a relatively low viscosity, from the excess polymer material B and foreign matter C adhering to the second intermediate layer 240 through the multiple second hole portions 243 to the third space SP3.

[0086] More specifically, among foreign matter C made of a solid polymer composition or a high-viscosity liquid polymer composition, foreign matter C made of a solid polymer composition that is larger in size than the plurality of second holes 243 can be captured by the second intermediate layer 240. Furthermore, foreign matter C made of a high-viscosity liquid polymer composition can be captured by the second intermediate layer 240 by adjusting the magnitude and application time of the separation force applied thereto and the size of the plurality of second holes 243 in accordance with the viscosity of the high-viscosity liquid polymer composition as the foreign matter C to be captured, based on Darcy's equation, which defines the relationship between the porosity of a member having holes and the area of ​​the holes, the viscosity and flow rate of the liquid passing through the holes, and the pressure loss of the liquid when passing through the holes.

[0087] Therefore, by adjusting these, foreign matter C consisting of a solid polymer composition or a high-viscosity liquid polymer composition can be captured by the second intermediate layer 240, and only the relatively low-viscosity liquid excess polymer material B can be selectively moved to the third space SP3 through the plurality of second holes 243. In other words, by adjusting these, foreign matter C consisting of a solid polymer composition or a high-viscosity liquid polymer composition can be captured by the second intermediate layer 240, and therefore the foreign matter C can be effectively separated from the excess polymer material B.

[0088] As described above, the size of the multiple second holes 243 is determined based on Darcy's equation and on the viscosity of the high-viscosity liquid polymer composition serving as the foreign matter C to be captured. However, if the size is configured to be smaller than the size of the unit structure of the three-dimensional mesh structure contained in the model 10, it will be possible to effectively capture foreign matter C, particularly that consisting of a solid polymer composition.

[0089] Then, the excess polymer material B that has reached the third space SP3 by passing through the plurality of second holes 243 provided in the second intermediate layer 240 continues to receive centrifugal force (i.e., separation force) in the direction of arrow DR4 in the figure, and moves in that direction (i.e., the separation direction), thereby adhering to the bottom wall 211 of the box 210 that defines the storage section 250 (i.e., the second bottom wall 2121 of the second container 2120). This allows the excess polymer material B, from which the foreign matter C has been removed, to be stored in the storage section 250.

[0090] After the above-described centrifugation has been carried out for a predetermined time, the operation of the centrifugal separator 110 is stopped, and the separation and recovery jig 200A is removed from the centrifugal separator 110.

[0091] The separation and recovery device 100A and separation and recovery method according to the present embodiment described above mainly use the centrifuge 110 as the above-mentioned separation force application mechanism, and the first intermediate layer 230, second intermediate layer 240, and storage section 250 provided in the above-mentioned separation and recovery jig 200A. The centrifuge 110 applies a separation force to the excess polymer material B while the shaped object 10 to which the excess polymer material B is attached is in contact with the first main surface 231 of the first intermediate layer 230. This causes the excess polymer material B to pass through the first holes 233 provided in the first intermediate layer 230, then through the second holes 243 provided in the second intermediate layer 240, and then be received by the storage section 250. Furthermore, as the excess polymer material B passes through the second holes 243 provided in the second intermediate layer 240, foreign matter C contained in the excess polymer material B is captured by the second intermediate layer 240.

[0092] Therefore, by using the separation and recovery device 100A, the separation and recovery jig 200A, and the separation and recovery method according to the present embodiment, not only can the surplus polymer material B be separated from the shaped object 10 to which the surplus polymer material B adheres by a single process of centrifugation using the centrifuge 110, but also foreign matter C contained in the surplus polymer material B can be separated from the surplus polymer material B. Therefore, according to the present embodiment, when recovering the surplus polymer material B adhering to the shaped object 10, an effect that the foreign matter C can be easily removed can be obtained.

[0093] <F. Recovery and Cleaning> FIG. 14 is a schematic cross-sectional view for explaining the recovery operation in the manufacturing method of the insole. FIG. 15 is a schematic cross-sectional view for explaining the cleaning process in the manufacturing method of the insole. Next, referring to FIGS. 14 and 15, the recovery operation and the cleaning process in the manufacturing method of the above-described insole 5 will be described.

[0094] As shown in FIGS. 14 and 15, the separation and recovery jig 200A according to the above-described present embodiment is also used for the recovery operation in step ST3 and the cleaning process in step ST4 following the centrifugation in step ST2 described above.

[0095] As shown in FIG. 14, in the recovery operation in step ST3, the first container 2110 is removed from the second container 2120. As a result, the first container 2110 contains the second intermediate layer 240 to which the shaped object 10 and the foreign matter C adhere, and the second container 2120 contains the surplus polymer material B substantially free of the foreign matter C. Therefore, by a simple operation of removing the first container 2110 from the second container 2120, the surplus polymer material B substantially free of the foreign matter C can be recovered. The recovered surplus polymer material B can be reused as a raw material for three-dimensional laminated modeling.

[0096] 15 , in the cleaning process in step ST4, the model 10 is immersed together with the first container 2110 in a cleaning tank 300 that stores a cleaning liquid 301. Here, since the first bottom wall portion 2111 of the first container 2110 is provided with the above-mentioned lower opening 2115, the cleaning liquid 301 flows into the first container 2110 through the lower opening 2115.

[0097] As described above, the separation and recovery tool 200A according to this embodiment can be used not only for the centrifugation in step ST2 described above, but also for the recovery work in step ST3 and the cleaning treatment in step ST4, which facilitates the handling of the shaped object 10 and the excess polymer material B separated from the shaped object 10 in each step. This makes it possible to simplify the manufacturing process, which contributes to reducing manufacturing costs.

[0098] (Embodiment 2) Fig. 16 is a flow diagram illustrating a method for manufacturing an insole to which the method for separating and recovering excess polymer material according to embodiment 2 is applied. Fig. 17 is a schematic diagram illustrating separation by gas blowing in the method for separating and recovering excess polymer material according to this embodiment. Hereinafter, the apparatus 100B for separating and recovering excess polymer material and the method for separating and recovering excess polymer material according to this embodiment will be described with reference to Figs. 16 and 17.

[0099] 16, the manufacturing method of insole 5 to which the method for separating and recovering excess polymer material according to this embodiment is applied differs from the manufacturing method of insole 5 to which the method for separating and recovering excess polymer material according to the above-mentioned embodiment 1 is applied only in the step of separating the excess polymer material from insole 5 to which the excess polymer material has adhered. That is, in the above-mentioned embodiment 1, this step is achieved by centrifugation in step ST2, but in this embodiment, this step is achieved by separation by blowing gas in step ST2A.

[0100] 17, separation and recovery apparatus 100B includes a blower 120, a first intermediate layer 130, a second intermediate layer 140, and a storage section 150. Blower 120 is capable of blowing gas 1000 such as air or an inert gas. First intermediate layer 130 and second intermediate layer 140 are essentially the same as first intermediate layer 230 and second intermediate layer 240, respectively, included in separation and recovery tool 200A described in the first embodiment, and storage section 150 is also essentially the same as storage section 250 included in separation and recovery tool 200A described in the first embodiment.

[0101] The blower 120 is installed at the top of the separation and recovery device 100B and blows the gas 1000 downward. The first intermediate layer 130 is installed below the blower 120. The second intermediate layer 140 is installed below the first intermediate layer 130. The storage section 150 is installed below the second intermediate layer 140.

[0102] The first intermediate layer 130 is made of a flat mesh member having a first main surface 131 and a second main surface 132 located on the opposite side to the first main surface 131. A plurality of first holes 133 are provided in the first intermediate layer 130 so as to reach both the first main surface 131 and the second main surface 132. The first main surface 131 faces upward, and the second main surface 132 faces downward.

[0103] The second intermediate layer 140 is made of a flat mesh member having a third main surface 141 and a fourth main surface 142 located on the opposite side to the third main surface 141. The second intermediate layer 140 has a plurality of second holes 143 formed therein so as to reach both the third main surface 141 and the fourth main surface 142. The third main surface 141 faces upward, and the fourth main surface 142 faces downward. The third main surface 141 is located opposite the second main surface 132 of the first intermediate layer 130 at a predetermined distance.

[0104] The reservoir 150 has a container-like shape and is disposed so as to face the fourth main surface 142 of the second intermediate layer 140.

[0105] The object 10 immediately after being manufactured by the three-dimensional additive manufacturing method is placed on the first main surface 131 of the first intermediate layer 130 with the unused polymer material (surplus polymer material) still attached thereto.

[0106] By operating the blower 120 in this state, gas 1000 is blown toward the model 10, and wind pressure acts on the model 10 in the direction of arrow DR5 shown in the figure. This wind pressure serves as a detachment force for detaching the excess polymer material from the model 10 to which the excess polymer material has adhered, and the direction in which this wind pressure acts (i.e., the direction of arrow DR5 shown in the figure) is the detachment direction for detaching the excess polymer material from the model 10. Therefore, the blower 120 corresponds to a detachment force application mechanism that applies a detachment force to the excess polymer material to detach it from the model 10.

[0107] Here, in the separation and recovery apparatus 100B and separation and recovery method of this embodiment, the above-mentioned blower 120 as the separation force application mechanism, the first intermediate layer 130, the second intermediate layer 140, and the storage section 150 are mainly used, and while the shaped object 10 to which the excess polymer material B is attached is brought into contact with the first main surface 131 of the first intermediate layer 130, a separation force is applied to the excess polymer material B by the blower 120, so that the excess polymer material B passes through the multiple first hole portions 133 provided in the first intermediate layer 130, then passes through the multiple second hole portions 143 provided in the second intermediate layer 140, and then is received by the storage section 150, and further, when the excess polymer material B passes through the multiple second hole portions 143 provided in the second intermediate layer 140, foreign matter C contained in the excess polymer material B is captured by the second intermediate layer 140.

[0108] Therefore, by using the separation and recovery device 100B and separation and recovery method according to this embodiment, not only can the excess polymer material B be separated from the shaped object 10 to which the excess polymer material B has adhered, but also the foreign matter C contained in the excess polymer material B can be separated from the excess polymer material B, through a single process of performing separation by blowing gas 1000 using the blower 120. Therefore, according to this embodiment, it is possible to obtain the effect that the foreign matter C can be easily removed when recovering the excess polymer material B adhered to the shaped object 10.

[0109] (Embodiment 3) Fig. 18 is a schematic diagram for explaining separation by gas blowing in the method for separating and recovering surplus polymer material according to embodiment 3. Hereinafter, the apparatus 100C for separating and recovering surplus polymer material and the method for separating and recovering surplus polymer material according to this embodiment will be explained with reference to Fig. 18. The method for separating and recovering surplus polymer material according to this embodiment is basically the same as the method for separating and recovering surplus polymer material according to embodiment 2 described above, except for the specific mode of separation by gas blowing in step ST2A described above.

[0110] 18, the separation and recovery apparatus 100C includes a blower 120, a stage 160, a second intermediate layer 140, and a storage section 150. The blower 120, the second intermediate layer 140, and the storage section 150 are similar to those included in the separation and recovery apparatus 100B according to the above-described embodiment 2. On the other hand, the stage 160 is made of a shelf-shaped member provided with a window section 161, and is arranged between the blower 120 and the second intermediate layer 140.

[0111] Here, in the separation and recovery method according to the present embodiment, a separation and recovery tool 200B is used which has a different configuration from the separation and recovery tool 200A according to the above-described first embodiment. Specifically, the separation and recovery tool 200B includes a box body 210 formed of a single container, and a first intermediate layer 230. Of these, the first intermediate layer 230 is basically similar to the first intermediate layer 230 provided in the separation and recovery tool 200A described in the above-described first embodiment, but is different in configuration in that it does not have leg portions 234 (see FIG. 9, etc.).

[0112] The box 210 has a bottom wall 211 and a peripheral wall 212 standing upright from the periphery of the bottom wall 211, with an opening 214 provided at the upper end of the peripheral wall 212. A lower opening 215 is provided in the portion of the bottom wall 211 excluding the periphery, so that the bottom wall 211 has a substantially frame-like shape in plan view. The bottom wall 211 having this frame-like shape in plan view functions as a shelf.

[0113] The first intermediate layer 230 has an edge 235 supported by the bottom wall 211, which functions as a shelf provided on the box 210. As a result, the lower opening 215 provided in the bottom wall 211 is covered by the first intermediate layer 230. The first intermediate layer 230 is disposed inside the box 210 so that its first main surface 231 faces upward and its second main surface 232 faces downward.

[0114] The object 10 immediately after being manufactured by the three-dimensional additive manufacturing method is housed inside the separation and recovery jig 200B with unused surplus polymer material still attached thereto, and more specifically, is placed on the first main surface 231 of the first intermediate layer 230. The separation and recovery jig 200B housing the object 10 is set on the stage 160 of the separation and recovery apparatus 100C. At this time, the separation and recovery jig 200B is placed on the stage 160 so that the lower opening 215 provided in the bottom wall portion 211 of the box body 210 of the separation and recovery jig 200B overlaps with the window portion 161 provided in the stage 160. As a result, the first intermediate layer 230 also overlaps with the window portion 161 provided in the stage 160.

[0115] By operating the blower 120 in this state, gas 1000 is blown toward the model 10, and wind pressure acts on the model 10 in the direction of the arrow DR5 shown in the figure. This wind pressure acts as a detachment force for detaching the excess polymer material from the model 10 to which it has adhered, and the direction in which this wind pressure acts (i.e., the direction of the arrow DR5 shown in the figure) is the detachment direction for detaching the excess polymer material from the model 10.

[0116] Here, the separation and recovery device 100C and separation and recovery method according to this embodiment mainly use the blower 120 as the above-described separation force application mechanism, and the first intermediate layer 230, the second intermediate layer 140, and the storage section 150 provided in the above-described separation and recovery jig 200B, so that the blower 120 applies a separation force to the excess polymer material B while the shaped object 10 to which the excess polymer material B has adhered is in contact with the first main surface 231 of the first intermediate layer 230. As a result, excess polymer material B passes through the multiple first holes 233 provided in the first intermediate layer 230, then passes through the multiple second holes 143 provided in the second intermediate layer 140, and is then received by the storage section 150; and as the excess polymer material B passes through the multiple second holes 143 provided in the second intermediate layer 140, foreign matter C contained in the excess polymer material B is captured by the second intermediate layer 140.

[0117] Therefore, by using the separation and recovery device 100C and separation and recovery method according to this embodiment, not only can the excess polymer material B be separated from the shaped object 10 to which the excess polymer material B has adhered, but also the foreign matter C contained in the excess polymer material B can be separated from the excess polymer material B, through a single process of performing separation by blowing gas 1000 using the blower 120. Therefore, according to this embodiment, it is possible to obtain the effect that the foreign matter C can be easily removed when recovering the excess polymer material B adhered to the shaped object 10.

[0118] Furthermore, in the separation and recovery method according to this embodiment, the separation and recovery tool 200B used for separation by spraying gas in the above-described step ST2A can also be used for the subsequent cleaning treatment in the above-described step ST4, making it easier to handle the shaped object 10 in each step, which makes it possible to simplify the manufacturing process and contributes to reducing manufacturing costs.

[0119] (Fourth embodiment) Fig. 19 is a schematic diagram for explaining separation by gas blowing in the method for separating and recovering surplus polymer material according to embodiment 4. Hereinafter, the method for separating and recovering surplus polymer material according to this embodiment will be explained with reference to Fig. 19. Note that the method for separating and recovering surplus polymer material according to this embodiment is basically the same as the method for separating and recovering surplus polymer material according to embodiment 2 described above, but compared to this, the specific mode of separation by gas blowing in the above-mentioned step ST2A is different.

[0120] 19, in the separation and recovery method according to the present embodiment, a spray gun 170 is used as a separation force application mechanism that applies a separation force to the excess polymer material to separate the excess polymer material from the shaped object 10. In addition, in the separation and recovery method according to the present embodiment, the separation and recovery tool 200A according to the first embodiment described above is used.

[0121] Specifically, in the separation by gas spraying in step ST2A described above, first, the model 10 immediately after being modeled by the three-dimensional additive manufacturing method is set in the separation and recovery jig 200A with the unused surplus polymer material still attached to it. In this state, the spray gun 170 is used to spray the gas 1000 onto the model 10 placed in the separation and recovery jig 200A.

[0122] As a result, gas 1000 is blown toward the model 10, and wind pressure acts on the model 10 in the direction of arrow DR5 shown in the figure. This wind pressure acts as a detachment force for detaching the excess polymer material from the model 10 to which it has adhered, and the direction in which this wind pressure acts (i.e., the direction of arrow DR5 shown in the figure) is the detachment direction in which the excess polymer material is detached from the model 10.

[0123] Here, in the separation and recovery method of this embodiment, the spray gun 170 as the above-mentioned separation force application mechanism, and the first intermediate layer 230, second intermediate layer 240, and storage section 250 provided in the above-mentioned separation and recovery jig 200A are mainly used, and while the shaped object 10 to which the excess polymer material B is attached is brought into contact with the first main surface 231 of the first intermediate layer 230, a separation force is applied to the excess polymer material B by the spray gun 170, so that the excess polymer material B passes through the multiple first hole sections 233 provided in the first intermediate layer 230, then passes through the multiple second hole sections 243 provided in the second intermediate layer 240, and then is received by the storage section 250, and further, when the excess polymer material B passes through the multiple second hole sections 243 provided in the second intermediate layer 240, foreign matter C contained in the excess polymer material B is captured by the second intermediate layer 240.

[0124] Therefore, by using the separation and recovery method according to this embodiment, it is possible to perform a single process of performing separation by spraying gas 1000 using spray gun 170, not only to separate excess polymer material B from model 10 to which excess polymer material B has adhered, but also to separate foreign matter C contained in excess polymer material B from excess polymer material B. Therefore, according to this embodiment, it is possible to obtain the effect that foreign matter C can be easily removed when recovering excess polymer material B that has adhered to model 10.

[0125] Furthermore, in the separation and recovery method according to this embodiment, the separation and recovery jig 200A used in the separation by gas spraying in the above-mentioned step ST2A can be used as is for the recovery work in the above-mentioned subsequent step ST3 and the cleaning treatment in the above-mentioned step ST4, which makes it easier to handle the shaped object 10 and the excess polymer material B separated from the shaped object 10 in each step. This makes it possible to simplify the manufacturing process and contributes to reducing manufacturing costs.

[0126] (Summary of the Disclosure in the Embodiments) The characteristic configurations disclosed in the above-described embodiments can be summarized as follows.

[0127] [Appendix 1] An apparatus for separating and recovering surplus polymer material, which is unused polymer material attached to a model formed by a three-dimensional additive manufacturing method, is provided, the apparatus comprising: a separation force application mechanism that applies a separation force to the excess polymer material so as to separate the excess polymer material in a predetermined separation direction from the shaped object to which the excess polymer material is attached; a first intermediate layer having a first main surface that intersects with the releasing direction and a second main surface that is located on the opposite side to the first main surface, the first main surface coming into contact with the object to which the excess polymer material has adhered, thereby restricting movement of the object in the releasing direction, and having a plurality of first holes that allow the excess polymer material that has been released from the object to pass through; a second intermediate layer positioned at a distance from the first intermediate layer in the removal direction, having a third main surface facing the second main surface and intersecting the removal direction, and a fourth main surface positioned on the opposite side to the third main surface, and having a plurality of second hole portions smaller in size than the plurality of first hole portions, thereby allowing the excess polymer material that has passed through the first intermediate layer to pass through while capturing foreign matter contained in the excess polymer material; An excess polymer material separation and recovery device comprising: a storage section positioned at a distance from the second intermediate layer in the separation direction and arranged opposite the fourth main surface, thereby being capable of receiving and storing the excess polymer material that has passed through the second intermediate layer.

[0128] By adopting the configuration described in Supplementary Note 1, when recovering surplus polymer material, which is unused polymer material attached to an object fabricated by three-dimensional additive manufacturing, it is possible to capture foreign matter contained in the surplus polymer material separated from the object by the second intermediate layer. Therefore, it is possible to recover the surplus polymer material from which the foreign matter has been removed in a single process, thereby providing an surplus polymer material separation and recovery device that can easily remove foreign matter from the surplus polymer material.

[0129] [Appendix 2] An excess polymer material separation and recovery device as described in Appendix 1, wherein the separation force application mechanism comprises a centrifuge that applies centrifugal force as the separation force to the excess polymer material in order to centrifuge the excess polymer material from the object to which the excess polymer material is attached.

[0130] By adopting the configuration described in Appendix 2 above, it becomes possible to recover excess polymer material from which foreign matter has been removed by a single process of centrifugation, thereby providing an excess polymer material separation and recovery device with a simple configuration that can easily remove foreign matter from excess polymer material.

[0131] [Appendix 3] An excess polymer material separation and recovery device as described in Appendix 1, wherein the separation force application mechanism comprises a blower that blows gas onto the modeled object to which the excess polymer material is attached, thereby blowing the excess polymer material away from the modeled object.

[0132] By adopting the configuration described in Appendix 3 above, it becomes possible to recover excess polymer material from which foreign matter has been removed by a single process of separation by blowing gas, thereby providing an excess polymer material separation and recovery device with a simple configuration that can easily remove foreign matter from excess polymer material.

[0133] [Appendix 4] A jig for separating and recovering surplus polymer material, which is used to separate and recover unused surplus polymer material attached to a model manufactured by a three-dimensional additive manufacturing method, from the model, comprising: a first intermediate layer having a first main surface and a second main surface located opposite to the first main surface, the first intermediate layer having a plurality of first holes formed therein to allow the excess polymer material separated from the shaped object to pass through; a second intermediate layer positioned at a distance from the first intermediate layer, having a third main surface facing the second main surface and a fourth main surface positioned on the opposite side to the third main surface, and having a plurality of second hole portions smaller in size than the plurality of first hole portions, thereby allowing the excess polymer material that has passed through the first intermediate layer to pass through while capturing foreign matter contained in the excess polymer material; A jig for separating and recovering excess polymer material, comprising: a storage section positioned at a distance from the second intermediate layer and arranged opposite the fourth main surface, thereby being capable of receiving and storing the excess polymer material that has passed through the second intermediate layer.

[0134] By employing the configuration described in Supplementary Note 4, when recovering surplus polymer material, which is unused polymer material adhering to an object fabricated by three-dimensional additive manufacturing, it becomes possible to capture foreign matter contained in the surplus polymer material separated from the object by the second intermediate layer. Therefore, the surplus polymer material from which the foreign matter has been removed can be recovered in a single process, making it possible to provide a jig for separating and recovering surplus polymer material that can easily remove foreign matter from the surplus polymer material.

[0135] [Appendix 5] The device further includes a box having a bottom wall and a peripheral wall, and an opening on the top surface thereof, the first intermediate layer is disposed inside the box body at a distance from the opening in the depth direction of the box body, and the second intermediate layer is disposed inside the box body at a distance from the first intermediate layer in the depth direction of the box body, thereby dividing the space inside the box body into two spaces: a first space located between the opening and the first main surface, a second space located between the second main surface and the third main surface, and a third space located between the fourth main surface and the bottom wall portion; 5. The jig for separating and recovering excess polymer material according to claim 4, wherein the storage section is constituted by the bottom wall section and the peripheral wall section that defines the third space.

[0136] By adopting the configuration described in Appendix 5 above, it is possible to create a relatively simple jig for separating and recovering excess polymer material that is capable of capturing foreign matter contained in excess polymer material separated from a molded object using the second intermediate layer.

[0137] [Appendix 6] A jig for separating and recovering excess polymer material according to Appendix 5, wherein the portion of the box that constitutes the storage section is removable from the other portions of the box.

[0138] By employing the configuration described in Supplementary Note 6 above, it is possible to provide a jig for separating and recovering excess polymer material that is suitable for handling a shaped object and the excess polymer material separated from the shaped object.

[0139] [Appendix 7] 7. The jig for separating and recovering excess polymer material according to claim 5 or 6, further comprising a lid capable of closing the opening.

[0140] By employing the configuration described in Supplementary Note 7, it is possible to provide a jig for separating and recovering excess polymer material that is suitable for handling a shaped object and the excess polymer material separated from the shaped object.

[0141] [Appendix 8] 8. The jig for separating and recovering excess polymer material according to any one of claims 4 to 7, wherein the first intermediate layer and the second intermediate layer are both made of mesh members.

[0142] By adopting the configuration described in Appendix 8 above, it is possible to create a relatively simple jig for separating and recovering excess polymer material that is capable of capturing foreign matter contained in excess polymer material separated from a molded object using the second intermediate layer.

[0143] [Appendix 9] A method for separating and recovering surplus polymer material, which is unused polymer material attached to a model manufactured by a three-dimensional additive manufacturing method, from the model, comprising: a separation force application mechanism that applies a separation force to the excess polymer material so as to separate the excess polymer material in a predetermined separation direction from the shaped object to which the excess polymer material is attached; a first intermediate layer having a first main surface intersecting the removal direction and a second main surface located on the opposite side to the first main surface, the first intermediate layer having a plurality of first holes; a second intermediate layer positioned at a distance from the first intermediate layer in the removal direction, having a third main surface facing the second main surface and intersecting the removal direction, and a fourth main surface positioned on the opposite side to the third main surface, and having a plurality of second holes smaller than the plurality of first holes; a storage section positioned at a distance from the second intermediate layer in the removal direction and facing the fourth main surface, a separation and recovery method for surplus polymer material, the method comprising: holding the shaped object to which the surplus polymer material is attached in contact with the first main surface; applying the detachment force to the surplus polymer material in the detachment direction using the detachment force application mechanism; causing the surplus polymer material to pass through the plurality of first hole portions, then pass through the plurality of second hole portions, and then be received by the storage portion; and causing foreign matter contained in the surplus polymer material to be captured by the second intermediate layer as the surplus polymer material passes through the plurality of second hole portions.

[0144] By employing the method described in Supplementary Note 9, when recovering surplus polymer material, which is unused polymer material attached to an object fabricated by three-dimensional additive manufacturing, it becomes possible to capture foreign matter contained in the surplus polymer material separated from the object by the second intermediate layer. Therefore, the surplus polymer material from which the foreign matter has been removed can be recovered in a single process, providing a method for separating and recovering surplus polymer material that makes it possible to easily remove foreign matter from the surplus polymer material.

[0145] (Other forms, etc.) In the above-described embodiment, an insole is used as an example of an object manufactured by three-dimensional additive manufacturing, and the present invention is described as being applied to an apparatus for separating and recovering surplus polymer material, a jig for separating and recovering surplus polymer material, and a method for separating and recovering surplus polymer material used in manufacturing the insole. However, objects manufactured by three-dimensional additive manufacturing are not necessarily limited to insoles. In other words, the present invention is not limited by the type of object manufactured by three-dimensional additive manufacturing, and can be applied to an apparatus for separating and recovering surplus polymer material, a jig for separating and recovering surplus polymer material, and a method for separating and recovering surplus polymer material used in manufacturing any and all objects manufactured by three-dimensional additive manufacturing.

[0146] Furthermore, in the above-described embodiment, the present invention has been described as being applied to a liquid vat photopolymerization method as a 3D additive manufacturing method, but the application of the present invention is not limited to this. In other words, the present invention can be applied to any type of 3D additive manufacturing method that uses a polymer material as a raw material for manufacturing an object. As an example, the present invention can also be applied to a 3D additive manufacturing method that uses a powder bed fusion method, in which a powdered polymer material is used as a raw material for manufacturing an object.

[0147] Furthermore, the configurations of the excess polymer material separation and recovery device and the excess polymer material separation and recovery tool specifically exemplified in the above-described embodiments can be modified in various ways without departing from the spirit of the present disclosure.

[0148] Furthermore, the characteristic configurations shown in the above-described embodiments can be combined with each other without departing from the spirit of the present disclosure.

[0149] As such, the above-described embodiments disclosed herein are illustrative in all respects and are not restrictive. The technical scope of the present invention is defined by the claims, and includes all modifications within the meaning and scope of the claims. [Explanation of symbols]

[0150] REFERENCE SIGNS LIST 1 shoe, 2 sole, 3 upper, 4 shoe opening, 5 insole, 6 base layer, 7 upper layer, 10 molded object, 11 support part, 100A to 100C excess polymer material separation and recovery device, 110 centrifuge, 111 chamber, 112 rotating basket, 113 drive motor, 120 blower, 130 first intermediate layer, 131 first main surface, 132 second main surface, 133 first hole part, 140 second intermediate layer, 141 third main surface, 142 fourth main surface, 143 second hole part, 150 storage part, 160 stage, 161 window part, 170 spray gun, 200A, 200B excess polymer material separation and recovery jig, 210 box body, 211 bottom wall part, 212 peripheral wall part, 214 Opening, 215 Lower opening, 2110 First container, 2111 First bottom wall, 2112 First peripheral wall, 2113 First flange, 2114 First upper opening, 2115 Lower opening, 2116 First step, 2120 Second container, 2121 Second bottom wall, 2122 Second peripheral wall, 2123 Second flange, 2124 Second upper opening, 2126 Second step, 220 Lid, 230 First intermediate layer, 231 First main surface, 232 Second main surface, 233 First hole, 234 Leg, 235 Edge, 240 Second intermediate layer, 241 Third main surface, 242 Fourth main surface, 243 Second hole, 245 Edge, 250 Storage portion, 300 Cleaning tank, 301 Cleaning solution, 400 three-dimensional additive manufacturing device, 401 raw material tank, 402 platform, 403 lifting mechanism, 1000 gas, A polymer material, B excess polymer material, C foreign matter, SP1 first space, SP2 second space, SP3 third space.

Claims

1. An apparatus for separating and recovering surplus polymer material, which is unused polymer material attached to a model formed by a three-dimensional additive manufacturing method, is provided, the apparatus comprising: a separation force application mechanism that applies a separation force to the excess polymer material so as to separate the excess polymer material in a predetermined separation direction from the modeled object to which the excess polymer material is attached; a first intermediate layer having a first main surface that intersects with the releasing direction and a second main surface that is located on the opposite side to the first main surface, the first main surface coming into contact with the object to which the excess polymer material has adhered, thereby restricting movement of the object in the releasing direction, and having a plurality of first holes that allow the excess polymer material that has been released from the object to pass through; a second intermediate layer positioned at a distance from the first intermediate layer in the separation direction, having a third main surface facing the second main surface and intersecting the separation direction, and a fourth main surface positioned on the opposite side to the third main surface, and having a plurality of second hole portions smaller in size than the plurality of first hole portions, thereby allowing the surplus polymer material that has passed through the first intermediate layer to pass through while capturing foreign matter contained in the surplus polymer material; An excess polymer material separation and recovery device comprising: a storage section positioned at a distance from the second intermediate layer in the separation direction and arranged opposite the fourth main surface, thereby being capable of receiving and storing the excess polymer material that has passed through the second intermediate layer.

2. The excess polymer material separation and recovery device described in claim 1, wherein the separation force application mechanism comprises a centrifuge that applies centrifugal force as the separation force to the excess polymer material in order to centrifuge the excess polymer material from the object to which the excess polymer material is attached.

3. 2. The excess polymer material separation and recovery device according to claim 1, wherein the separation force application mechanism comprises a blower that blows gas onto the modeled object to which the excess polymer material is attached, thereby blowing the excess polymer material away from the modeled object.

4. A jig for separating and recovering surplus polymer material, which is used to separate and recover unused surplus polymer material attached to an object fabricated by a three-dimensional additive manufacturing method, from the object, comprising: a first intermediate layer having a first main surface and a second main surface located opposite to the first main surface, the first intermediate layer having a plurality of first holes formed therein to allow the excess polymer material separated from the shaped object to pass through; a second intermediate layer positioned at a distance from the first intermediate layer, having a third main surface facing the second main surface and a fourth main surface positioned opposite the third main surface, and having a plurality of second hole portions smaller in size than the plurality of first hole portions, thereby allowing the excess polymer material that has passed through the first intermediate layer to pass through while capturing foreign matter contained in the excess polymer material; A jig for separating and recovering excess polymer material, comprising: a storage section positioned at a distance from the second intermediate layer and arranged opposite the fourth main surface, thereby being capable of receiving and storing the excess polymer material that has passed through the second intermediate layer.

5. The device further includes a box having a bottom wall and a peripheral wall, and an opening on the top surface thereof, the first intermediate layer is disposed inside the box body at a distance from the opening in the depth direction of the box body, and the second intermediate layer is disposed inside the box body at a distance from the first intermediate layer in the depth direction of the box body, thereby dividing the space inside the box body into three spaces: a first space located between the opening and the first main surface, a second space located between the second main surface and the third main surface, and a third space located between the fourth main surface and the bottom wall portion; The jig for separating and recovering excess polymer material according to claim 4 , wherein the storage section is constituted by the bottom wall section and the peripheral wall section that defines the third space.

6. The jig for separating and recovering excess polymer material according to claim 5 , wherein a portion of the box body that constitutes the storage section is detachable from the other portion of the box body.

7. The jig for separating and recovering excess polymer material according to claim 5 , further comprising a lid capable of closing the opening.

8. The jig for separating and recovering excess polymer material according to claim 4 , wherein the first intermediate layer and the second intermediate layer are both made of mesh members.

9. A method for separating and recovering surplus polymer material, which is unused polymer material attached to a model manufactured by a three-dimensional additive manufacturing method, from the model, comprising: a separation force application mechanism that applies a separation force to the excess polymer material so as to separate the excess polymer material in a predetermined separation direction from the modeled object to which the excess polymer material is attached; a first intermediate layer having a first main surface intersecting the separation direction and a second main surface located on the opposite side to the first main surface, the first intermediate layer having a plurality of first holes; a second intermediate layer positioned at a distance from the first intermediate layer in the separation direction, having a third main surface facing the second main surface and intersecting the separation direction, and a fourth main surface positioned on the opposite side to the third main surface, and having a plurality of second holes smaller than the plurality of first holes; a storage portion positioned at a distance from the second intermediate layer in the removal direction and facing the fourth main surface, a separation and recovery method for surplus polymer material, the method comprising: holding the shaped object to which the surplus polymer material is attached in contact with the first main surface; applying the separation force to the surplus polymer material in the separation direction using the separation force application mechanism; causing the surplus polymer material to pass through the plurality of first hole portions, then pass through the plurality of second hole portions, and then be received by the storage portion; and causing foreign matter contained in the surplus polymer material to be captured by the second intermediate layer as the surplus polymer material passes through the plurality of second hole portions.

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