Molding method and molded product

Abstract

This invention provides a molding method that reduces various costs, such as labor volume and expenses, when molding molded products for construction and civil engineering by filling them with a hardening material. [Solution] A molding method using a three-dimensional molding apparatus that creates a three-dimensional object by layering molten molding material, comprising: a mold molding step (step S1) in which a mold for the molded object is molded; a casting step (step S2) in which a hardening material is cast into the molded mold; a hardening step (step S3) in which the cast hardening material is hardened; and a demolding step (step S4) in which the hardened molded object is demolded from the mold. In the mold molding step (step S1), the molding material includes a first resin and a second resin having different properties from the first resin, and in the demolding step, the difference in properties is used to demold the object.

Description

Technical Field

[0001] This application discloses a molding method for molding a building and civil engineering molded product by filling a hardening material, and a molded product molded by such a molding method.

Background Art

[0002] In the molding of molded products such as construction members and structures by the precast concrete method, a method is performed in which concrete is filled into a mold, sufficiently hardened through curing, and then the mold is removed. As a mold used in such a precast concrete method, a steel mold is used. When molding a molded product with a complex design using such a steel mold, various costs such as time and cost increase, and there is a risk of reaching an unrealistic level. Therefore, Patent Document 1 discloses a method of forming a mold with a fiber-reinforced polymer composite material using a computer-controlled device and casting a highly designed building member.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the precast concrete method, various costs such as the work and cost of the process of removing the mold after casting become problems. In the method for casting a building member described in Patent Document 1, a method of melting the mold after casting is disclosed, but in order to melt the entire mold, a considerable amount of heating is required, resulting in an increase in cost.

[0005] This application has been made in view of such circumstances, and the main object is to disclose a molding method capable of reducing the cost of the process of removing the mold.

[0006] Furthermore, this application also aims to disclose molded articles formed by such molding methods. [Means for solving the problem]

[0007] To solve the above problems, the molding method disclosed in this application is a molding method for forming a molded product for construction and civil engineering by filling it with a hardening material, and uses a three-dimensional molding apparatus that builds a three-dimensional molded product by layering molten molding material, and performs a mold molding step of forming a mold for the molded product, a casting step of casting hardening material into the molded mold, a hardening step of hardening the cast hardening material, and a demolding step of demolding the hardened molded product from the mold, wherein the molding material comprises a first resin and a second resin having different properties from the first resin.

[0008] Furthermore, in the molding method described above, the first resin is a resin with a lower melting point or softening point than the second resin, and the demolding step is characterized by demolding by melting or softening the first resin contained in the mold by heating.

[0009] Furthermore, in the molding method described above, the first resin is characterized in that it is a resin mainly composed of polycaprolactone.

[0010] Furthermore, in the molding method described above, the mold forming step is characterized by forming a mold that combines a first structural part whose main component is a first resin and a second structural part whose main component is a second resin.

[0011] Furthermore, in the molding method, the mold has a plurality of columnar sections extending in the vertical direction and wall sections connecting the columnar sections, wherein the columnar sections include a first structural section and the wall sections include a second structural section.

[0012] Furthermore, in the molding method described above, the mold has a plurality of columnar sections extending in the vertical direction and wall sections connecting the columnar sections, wherein the columnar sections include a second structural section and the wall sections include a first structural section.

[0013] Furthermore, the molding method is characterized by performing a recovery step of selecting and recovering the second structural part after demolding, and a reuse step of reusing the second resin, which is the main component of the recovered second structural part, as a molding material.

[0014] Furthermore, the molded product for construction and civil engineering disclosed in this application is characterized by being molded by the molding method described above. [Effects of the Invention]

[0015] The molding method and molded product disclosed herein offer excellent advantages, such as reducing the cost of the demolding process, because by using a first resin and a second resin with different properties, the demolding process can be improved by utilizing the difference in properties, such as the difference in melting point or softening point. [Brief explanation of the drawing]

[0016] [Figure 1] This is an explanatory diagram showing an example of the appearance of a three-dimensional molding apparatus used in the molding method disclosed in this application. [Figure 2] This is a conceptual diagram illustrating an example of the general shape and function of a nozzle in a three-dimensional molding apparatus used in the molding method disclosed in this application. [Figure 3] This flowchart shows an example of each step performed in the molding method disclosed in this application. [Figure 4] This is a conceptual diagram illustrating an example of the mold fabrication process performed by the molding method disclosed in this application. [Figure 5] This is a conceptual diagram illustrating an example of a casting process performed by the molding method disclosed in this application. [Figure 6] This is a conceptual diagram illustrating an example of a curing process performed in the molding method disclosed in this application. [Figure 7] This is a conceptual diagram illustrating an example of a demolding step performed in the molding method disclosed in this application. [Figure 8] This is a conceptual diagram illustrating an example of a reuse process performed in the molding method disclosed in this application. [Modes for carrying out the invention]

[0017] <Examples of application> Hereinafter, the molding method disclosed in the present application will be described with reference to the drawings. The molding method disclosed in the present application is used, for example, for molding building and civil engineering molded products by a construction method such as the precast concrete method. The molded product for building and civil engineering in the present application refers to members and structures used for buildings or civil engineering, for example, members used for building walls, floors, ceilings, columns, stairs, etc., landscape materials, exterior members, or a part or all of civil engineering structures such as tunnels, roads, bridges, and revetments, but is not limited thereto. Hereinafter, the molding method disclosed in the present application will be described with reference to the drawings.

[0018] <Device to be used> FIG. 1 is an explanatory diagram showing an example of the appearance of a three-dimensional modeling device 1 used in the molding method disclosed in the present application. The molding method disclosed in the present application uses a three-dimensional modeling device 1 such as a 3D printer. The three-dimensional modeling device 1 is a device that laminates molten modeling material 2 to form a three-dimensional molded product. The three-dimensional modeling device 1 includes components such as a main body device 10 and a control device 11 that controls the main body device 10. The main body device 10 illustrated in FIG. 1 includes various components such as an arm 12 having two bending portions and a nozzle 13 formed at the tip of the arm 12. The main body device 10 is controlled by a control device 11 using a computer, and the control device 11 controls the operation of the arm 12 and the discharge of the modeling material 2 from the nozzle 13 with respect to the main body device 10.

[0019] The shaping material 2 is preferably a resin for a 3D printer in the form of a low-melting-point filamentous resin, pellet-shaped resin, etc. Also, as the shaping material 2, a resin with characteristics such as a water-soluble resin, biodegradable resin, photodegradable resin, etc. may be used. The above-described shaping material 2 is an example, and as the shaping material 2, various resins and further other materials are used according to applications and the like. In the molding method disclosed in the present application, the shaping material 2 uses a plurality of types of resins with different characteristics. In the present application, an example of an embodiment using a first resin 2a and a second resin 2b having different characteristics from the first resin 2a is disclosed. The first resin 2a is, for example, a resin having a lower melting point or softening point than the second resin 2b as a characteristic. As a specific example, the shaping material 2 mainly composed of low-melting-point polycaprolactone is used as the first resin 2a. The second resin 2b is a shaping material 2 mainly composed of a resin such as general-purpose polycarbonate or polypropylene having a higher melting point (or softening point) than the first resin 2a.

[0020] FIG. 2 is an explanatory diagram conceptually showing an example of the outline and function of a nozzle 13 provided in a three-dimensional shaping apparatus 1 used in the shaping method disclosed in the present application. Since the shaping method disclosed in the present application uses two types of melted resins, a dual-nozzle three-dimensional shaping apparatus 1 including a first nozzle 13a for supplying the first resin 2a and a second nozzle 13b for supplying the second resin 2b is used. FIG. 2(a) illustrates a nozzle 13 including the first nozzle 13a and the second nozzle 13b and having a single discharge hole. The nozzle 13 illustrated in FIG. 2(a) discharges the first resin 2a or the second resin 2b from a single discharge hole while switching between the discharge of the first resin 2a from the first nozzle 13a and the discharge of the second resin 2b from the second nozzle 13b. FIG. 2(b) illustrates a nozzle 13 including the first nozzle 13a and the second nozzle 13b and having different discharge holes. The nozzle 13 illustrated in FIG. 2(b) discharges the first resin 2a from the first nozzle 13a and the second resin 2b from the second nozzle 13b from their respective discharge holes.

[0021] <Steps of the shaping method> Next, the steps performed in the molding method disclosed in this application will be described. Figure 3 is a flowchart showing an example of each step performed in the molding method disclosed in this application. The molding method disclosed in this application performs a mold making step (step S1) in which a mold frame 3 for a molded product 5 is formed by extruding molten molding materials 2 such as a first resin 2a and a second resin 2b from a nozzle 13 and layering them using a three-dimensional molding apparatus 1.

[0022] Figure 4 is a conceptual diagram illustrating an example of a mold fabrication process performed by the molding method disclosed in this application. Figure 4 illustrates a mold fabrication process in which a three-dimensional molding apparatus 1 extrudes molding material 2 to fabricate a mold 3 for a molded object 5 (see Figure 7, etc.) as a three-dimensional object. The molded object 5 formed by the mold 3 is a component or structure used for building or civil engineering, and Figure 4 illustrates the fabrication of a mold 3 for forming a rectangular molded object 5. The mold 3 illustrated in Figure 4 is assembled in a rectangular shape in plan view and is formed in a frame shape with wall portions 31 on all four sides in order to form a rectangular molded object 5. The four vertices of the rectangular shape in plan view are four (or more) column portions 30 extending in the vertical direction, and the four sides of the rectangle are wall portions 31 connecting the column portions 30. The column section 30 is formed as a first structural section whose main component is the first resin 2a, and the wall section 31 is formed as a second structural section whose main component is the second resin 2b. The formwork 3 is formed by combining the first structural section and the second structural section.

[0023] Returning to the flowchart in Figure 3, the molding method disclosed in this application involves filling the molded formwork 3 with cement paste, mortar, and concrete. etc. The casting process is performed to cast (fill) the hardening material 4 (step S2).

[0024] Figure 5 is a conceptual diagram illustrating an example of a casting process performed by the molding method disclosed in this application. Figure 5 shows a casting process in which a hardening material 4 is poured into a formwork 3 that combines a column section 30, which is the first structural part, and a wall section 31, which is the second structural part.

[0025] Returning to the flowchart in Figure 3, the molding method disclosed herein involves performing a curing step to cure the cast hardened material 4 (step S3).

[0026] Figure 6 is a conceptual diagram illustrating an example of a curing process performed in the molding method disclosed in this application. Figure 6 shows the curing process in which the curing material 4 poured into the mold 3 is cured. The curing process is carried out by controlling the temperature and humidity through curing to prevent drying of the curing material 4 and to allow the hydration reaction to proceed. Various methods can be used for curing in the curing process, but the curing process illustrated in Figure 6 conceptually shows a form in which curing is performed using steam to control the temperature and humidity.

[0027] Returning to the flowchart in Figure 3, the molding method disclosed herein involves a demolding step (step S4) in which the cured molded product 5 is removed from the mold 3. The demolding step utilizes the difference in properties between the first resin 2a, which is the main component of the first structural part, and the second resin 2b, which is the main component of the second structural part. For example, demolding is performed by removing the first resin 2a.

[0028] Figure 7 is a conceptual diagram illustrating an example of a demolding process performed in the molding method disclosed herein. Figure 7 illustrates a form of demolding by melting the first structural part of the mold frame 3 and disassembling the mold frame 3 itself. When the first structural part is molded using a first resin 2a mainly composed of low-melting-point polycaprolactone, the demolding process involves heating at a temperature higher than the melting point of the first resin 2a and lower than the melting or softening point of the second resin 2b. Due to the heating, only the column part 30, which is the first structural part, melts, the wall part 31, which is the second structural part, detaches, and the mold frame 3 is demolded from the molded product 5.

[0029] The molding method disclosed herein involves molding the molded product 5 as described above.

[0030] The molding method disclosed herein involves reusing the molding material 2 after molding the molded product 5. Returning to the flowchart illustrated in Figure 3, the molding method disclosed herein performs a recovery step (step S5) in which the second structural part is selected and recovered after demolding. In the recovery step, the second structural part that has retained its original shape despite being removed from the mold 3 in the demolding step illustrated in Figure 7 is selected and recovered. Selective recovery in step S5 means that only the second structural part that is in a reusable state is selected and recovered, excluding the first structural part or the first resin 2a from which the first structural part has melted.

[0031] The molding method disclosed herein involves a reuse step (step S6) in which the second resin 2b, which is the main component of the recovered second structural part, is reused as the molding material 2.

[0032] Figure 8 is a conceptual diagram illustrating an example of a reuse process performed by the molding method disclosed in this application. Figure 8 conceptually illustrates a reuse process in which the recovered second structural part is fed into a reuse device 6 to regenerate the second resin 2b, which is a pelletized resin. The reuse device 6 heats and melts the fed-in second structural part, purifies it to remove impurities, solidifies and molds it into pellets, and then extrudes the molded second resin 2b. The extruded second resin 2b is reused as a molding material 2 for the three-dimensional molding device 1.

[0033] The molding method disclosed herein further involves a step of regenerating the molding material 2 after the molding of the molded product 5 as described above.

[0034] The molding method disclosed in this application, as described above, is a molding method for forming a molded product 5 using a formwork 3 such as a precast concrete construction method, and it is possible to remove the first structural part that constitutes a part of the formwork 3 by methods such as melting by heating. Therefore, the molding method disclosed in this application has excellent effects, such as being able to reduce various costs such as workability and cost in the process of removing a part of the formwork 3. Furthermore, since the molding method disclosed in this application uses a three-dimensional molding device 1 to form the formwork 3, it is possible to form a formwork 3 for forming a molded product 5 with a complex design, and even if the molded product 5 has a complex design, it is possible to easily remove the formwork 3, thus having excellent effects. Moreover, in the molding method disclosed in this application, by making a part of the formwork 3, rather than the entire formwork 3, a first structural part mainly composed of a first resin 2a, it is possible to reduce costs, such as by heating only the first structural part that is a part of the formwork 3, rather than heating the entire formwork 3.

[0035] The present invention is not limited to the embodiments described above and can be implemented in various other forms. Therefore, the embodiments described above are merely illustrative in all respects and should not be interpreted restrictively. The technical scope of the present invention is described by the claims and is not restricted in any way by the text of the specification. Furthermore, any modifications and changes falling within the equivalent scope of the claims are all within the scope of the present invention.

[0036] For example, in the above embodiment, a configuration in which the column portion 30 is the first structural portion and the wall portion 31 is the second structural portion is shown, but the molding method disclosed in this application is not limited to this and can be developed into various configurations. For example, the molding method disclosed in this application can be developed into various configurations, such as making the wall portion 31 the first structural portion and the column portion 30 the second structural portion, and melting the wall portion 31. Furthermore, the molding method disclosed in this application can also be developed into various configurations, such as providing the first structural portion near the midpoint of the column portions 30 at both ends of the wall portion 31, so that it can be divided near the center of a single wall portion 31.

[0037] Furthermore, although the above embodiment shows a method in which the first structural part is removed by heating, the molding method disclosed in this application is not limited to this, and can be expanded to various forms in which the first resin 2a is removed by utilizing the difference in properties between the first resin 2a and the second resin 2b. For example, in the molding method disclosed in this application, if a water-soluble resin is used as the first resin 2a, the first structural part can be removed and demolded by methods such as dissolution using water. Moreover, in the molding method disclosed in this application, if a photodegradable resin is used as the first resin 2a, the first structural part can be removed and demolded by methods such as decomposition by irradiation with light. [Explanation of Symbols]

[0038] 1 3D printing equipment 10 Main unit 11 Control device 12 arms 13 nozzles 13a First nozzle 13b Second nozzle 2. Modeling materials 2a 1st resin 2b 2nd resin 3. Formwork (for molded objects) 30 Pillar section (first structure section) 31 Wall section (second structure section) 4 Curing material 5 Molded object 6 Reuse equipment

Claims

1. A molding method for forming molded products for construction and civil engineering by filling them with a hardening material, Using a three-dimensional molding device that creates three-dimensional objects by layering molten molding material, the process involves creating a mold for the molded object, and The casting process involves pouring a hardening material into the molded formwork, The curing process involves curing the cast hardened material, The demolding process involves removing the hardened molded product from the mold. It is configured to execute, The molding material includes a first resin and a second resin having properties different from those of the first resin. A molding method characterized by the following:

2. The first resin is A resin with a lower melting point or softening point than the second resin mentioned above. The aforementioned demolding process is, The first resin contained in the mold is melted or softened by heating, thereby demolding. The molding method according to feature 1.

3. The first resin is It is a resin whose main component is polycaprolactone. The molding method according to feature 2.

4. The aforementioned formwork fabrication process is, A mold is formed by combining a first structural part whose main component is the first resin and a second structural part whose main component is the second resin. The molding method according to claim 1 or 2.

5. The aforementioned formwork is Multiple columnar sections extending in the vertical direction, A wall connecting the aforementioned column sections and It has, The column portion includes the first structural portion, The wall portion includes the second structural portion. The molding method according to feature 4.

6. The aforementioned formwork is Multiple columnar sections extending in the vertical direction, A wall connecting the aforementioned column sections and It has, The column portion includes a second structural portion, The wall portion includes the first structural portion. The molding method according to feature 4.

7. Furthermore, A recovery process in which the second structural part is selected and recovered after demolding, A recycling process in which the second resin, which is the main component of the recovered second structural part, is reused as a molding material. Execute The molding method according to feature 4.

8. A molded product for construction and civil engineering, characterized by being molded by the molding method of claim 1 or claim 2.

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