Production method

Abstract

To provide a fabrication method of a widely spreadable product having improved efficiency in absorbing carbon dioxide.SOLUTION: The fabrication method comprises the steps of: laminating a hardening material 3 to fabricate a part of a structural body using a 3D printer; and forcibly carbonation-curing the hardening material 3 in a curing tank 4 to make the hardening agent 3 absorb carbon dioxide, whereby a part of the structural body can be fabricated, and the fabricated portions can mutually be bonded. The hardening agent 3 includes a calcium material as an admixture, reacting with carbon dioxide.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing an article. [Background technology]

[0002] As global warming becomes a major issue, efforts to reduce carbon dioxide emissions are gaining momentum in the industrial sector. In the concrete field, as shown in Patent Document 1 and elsewhere, environmentally friendly concrete has been developed that uses γ-phase di-calcium silicate (hereinafter referred to as γCS), a calcium material that reacts with carbon dioxide, as an admixture to force the concrete to absorb carbon dioxide from an early age, making it carbon negative. This has led to the development of this concrete, the first of its kind in the world to be put to practical use. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-168436 Summary of the Invention [Problem to be solved by the invention]

[0004] However, currently, the use of such concrete is limited to the production of secondary products such as interlocking blocks and sidewalk / roadway boundary blocks. The reason for this is that mass concrete, such as cast-in-place concrete, uses a large amount of concrete, which results in a large amount of carbon dioxide being emitted during production. This means that a large amount of carbon dioxide needs to be absorbed to make the structure carbon negative or carbon neutral, and the carbon dioxide needs to be absorbed all the way to the inside. In fact, if carbon dioxide is to be absorbed all the way to the inside of a 500mm wall component, it would take a long time, requiring a continuous supply of carbon dioxide for over a year. This is not realistic from the standpoint of time and cost.

[0005] The present invention has been made in view of the above problems, and aims to provide a method for producing a product that has improved carbon dioxide absorption efficiency and is highly applicable. [Means for solving the problem]

[0006] To solve the above-mentioned problems 1st The invention A process of creating slice data for producing products using a 3D printer; By 3D printer γC 2 Contains S The method includes a step of producing a product using a hardening material, and performing forced carbonation curing on the hardening material in a curing tank to absorb carbon dioxide into the hardening material. In the process of creating the slice data, the volume of the three-dimensional shape data from which the slice data is created is optimized so that the target amount of carbon dioxide absorption can be obtained during forced carbonation curing, and the volume is set to correspond to the target amount of carbon dioxide absorption. This is a manufacturing method characterized by the above. The second invention is the γC 2 This method includes a step of producing a product using a hardening material containing S, and the hardening material is subjected to forced carbonation curing in a curing tank to absorb carbon dioxide into the hardening material, and the hardening material contains precipitated calcium carbonate that has absorbed carbon dioxide during production. The third invention is the creation of γC by 3D printer. 2 This manufacturing method includes a step of producing a product using a hardening material containing S, and is characterized by stacking the hardening material in a curing tank using a 3D printer, and simultaneously subjecting the hardening material to forced carbonation curing in the curing tank, thereby causing carbon dioxide to be absorbed into the hardening material. The fourth invention is the γC 2 This production method includes a step of producing a product using a hardener containing S, and the hardener is subjected to forced carbonation curing in a curing tank, causing carbon dioxide to be absorbed into the hardener. The forced carbonation curing is carried out by covering the portion where the hardener is layered by the 3D printer with a movable curing tank, and sequentially moving the curing tank as the layering of the hardener progresses. The fifth invention is a process for creating slice data for producing a product using a 3D printer, and a process for printing γC 2 The method includes a step of producing a product using a hardener containing S, and subjecting the hardener to forced carbonation curing in a curing tank to absorb carbon dioxide, and the product is a new structure or part thereof that replaces an existing structure, and in the step of creating slice data, topology optimization technology is used to create three-dimensional shape data of the new structure from three-dimensional shape data of the existing structure, and the slice data is then created from the three-dimensional shape data. The sixth invention is the creation of γC by a 3D printer. 2 This manufacturing method includes the steps of: manufacturing hollow products using a hardening material containing S; and integrating a plurality of the products together using PC steel bars passed through the hollow parts of the products; and is characterized in that the hardening material is subjected to forced carbonation curing in a curing tank, causing carbon dioxide to be absorbed by the hardening material.

[0007] When a product is created using a 3D printer with hardening material, its surface becomes uneven, increasing its surface area. As a result, the carbon dioxide absorption efficiency during forced carbonation curing is improved, making it possible to absorb carbon dioxide in a short period of time, making it applicable to a variety of objects, including small to large structures. Furthermore, using a 3D printer for production makes it easy to create complex shapes composed of thin, narrow parts that have high carbon dioxide absorption efficiency.

[0008] In addition, in the present invention, γC 2 S By using this, it is possible to reduce the amount of carbon dioxide emitted during production while maintaining the amount of carbon dioxide absorbed by the hardener, making it possible to achieve the goal of being carbon neutral or carbon negative, in which the amount of carbon dioxide absorbed by the hardener is equal to or greater than the amount of carbon dioxide emitted during production of the hardener.

[0009] In the fifth invention The product is a structure or a part thereof, and slice data for producing the product by the 3D printer is created using topology optimization technology. do. This allows for the production of structures that minimize the amount of hardener while maintaining sufficient structural performance, thereby reducing carbon dioxide emissions from the hardener. Furthermore, because the structures are made thinner and narrower, the efficiency of carbon dioxide absorption during forced carbonation curing is improved.

[0010] In addition, in the fifth invention The product is a new structure or a part thereof that replaces an existing structure, and the slice data is created from the three-dimensional shape data of the existing structure. 。 This makes it possible to apply the technology of the present invention to applications such as replacing existing structures such as bridges. [Effects of the Invention]

[0011] The present invention can improve the efficiency of carbon dioxide absorption and provide a method for producing a product that is highly applicable. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a flowchart showing a manufacturing method. [Figure 2] A diagram showing an existing structure 10 and a new structure 1. [Figure 3] Example of 3D Printer 2. [Figure 4] FIG. 10 is a diagram illustrating forced carbonation curing of the hardening material 3. [Figure 5] FIG. 4 is a diagram showing a curing tank 4a. [Figure 6] FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0014] FIG. 1 is a flow chart illustrating a fabrication method according to an embodiment of the present invention.

[0015] In this embodiment, first, three-dimensional shape data of a structure is created, and slice data for producing a product using a 3D printer is created from the three-dimensional shape data (S1).

[0016] There are various possible methods for creating 3D shape data, but in this embodiment, the 3D shape data is created by applying known topology optimization technology (see, for example, JP 2021-182201 A). For example, when replacing an existing structure 10, such as a small bridge as shown in FIG. 2(a), with a new structure, topology optimization is performed by inputting mechanical conditions such as load to the 3D shape data obtained by 3D scanning the structure 10. This makes it possible to remove structurally unnecessary parts to reduce weight without changing the structural performance of the existing structure 10, and create 3D shape data for a new structure 1 with only the necessary parts remaining, as shown in FIG. 2(b).

[0017] In addition to topology optimization, it is also possible to apply analytical techniques that optimize the surface area without changing the structural performance of the structure 1. Furthermore, the volume of the structure 1 can be optimized to correspond to the target amount of carbon dioxide (hereinafter referred to as CO2) absorption so as to obtain the target amount of CO2 absorption during forced carbonation curing, which will be described later.

[0018] Slice data is data obtained by slicing the above three-dimensional shape data into upper and lower layers, and is used when producing products using a 3D printer. The method for creating slice data is well known, so its explanation will be omitted.

[0019] In this embodiment, based on the slice data created in S1, the structure 1 or a part thereof (referred to as the structure 1, etc.) is produced using a hardening material with a 3D printer (S2).

[0020] FIG. 3 shows an example of the 3D printer 2. The 3D printer 2 is a layering-type robot arm printer that layers a hardening material 3, such as mortar, ejected from a nozzle at the end of the arm according to slice data. In this embodiment, a hollow portion of the structure 1 described above is produced as the product using the hardening material 3. There are no particular restrictions on the thickness of each layer or the wall thickness during layering. The 3D printer 2 may be a binder jet printer, and even if it is a layering-type 3D printer 2, a printer other than a robot arm type, such as a gantry type with a movable nozzle attached to a gate-shaped frame, can also be used. It is also possible to produce a solid structure 1, etc.

[0021] The shapes obtained through topology optimization are often complex and difficult to produce using conventional construction methods such as setting up formwork and pouring concrete. However, by using 3D printing technology, it is possible to easily produce structures with complex shapes, such as structures 1.

[0022] The hardening material 3 is a material that absorbs CO2, such as SUICOM (registered trademark). SUICOM is concrete that contains γC2S, a calcium material that reacts with CO2, as an admixture. γC2S reacts with CO2 to carbonate, thereby absorbing and fixing CO2.

[0023] In this embodiment, the hardened material 3 is then subjected to forced carbonation curing (S3). Forced carbonation curing is performed by placing the product made of the hardened material 3 in a curing tank 4 and supplying CO2 to the curing tank 4, as shown in FIG. 4, for example. The curing tank 4 has an inlet 41 for supplying CO2 gas into the tank and an outlet 42 for discharging CO2 gas. In addition, the curing tank 4 may be provided with a measuring unit (not shown) for measuring the CO2 concentration in the tank and a pressure adjusting device (not shown) for pressurizing or depressurizing the tank.

[0024] As shown in Figure 3, products made with the hardening material 3 produced by the 3D printer 2 have an uneven surface, resulting in a large surface area. It is also possible to create complex shapes that intentionally increase the surface area. As a result, CO2 absorption efficiency improves and curing time can be shortened. Furthermore, in this embodiment, topology optimization is performed, and by removing parts that are not necessary for structural strength, the thickness and width of the component can be reduced, making it easier for CO2 to be absorbed deep inside, which significantly contributes to shortening the curing time.

[0025] In this embodiment, each part of the structure 1 is fabricated in S2, and after forced carbonation curing in S3, these parts are joined together to form the structure 1. The joining method is not particularly limited, and for example, joining may be performed using an adhesive, or prestressing may be introduced by PC steel or the like passed through the hollow parts of each part to integrate the parts. It is also possible to add separate reinforcing materials such as steel bars or FRP (fiber reinforced plastic) to the structure 1.

[0026] As described above, in this embodiment, by using a 3D printer 2 to produce a product such as a structure 1 using a hardener 3, the surface becomes uneven, increasing the surface area. Furthermore, complex shapes that intentionally increase the surface area can also be produced. As a result, the CO2 absorption efficiency during forced carbonation curing is improved, enabling CO2 absorption in a short period of time, making this method applicable to a variety of targets, including small to large structures. Furthermore, by using a 3D printer 2 to produce a structure 1, etc., it is possible to easily form complex shapes composed of thin, narrow portions that have high CO2 absorption efficiency, making it possible to produce a structure 1, etc. with consistent quality while reducing construction time and manpower.

[0027] Furthermore, by using calcium materials such as γC2S as an admixture in the hardener 3, it is possible to maintain the amount of CO2 absorbed by the hardener 3 while reducing the amount of CO2 emitted during production. This makes it possible to achieve the goal of carbon neutrality or carbon negative, where the amount of CO2 absorbed by the hardener 3 is equal to or greater than the amount of CO2 emitted during production of the hardener 3.

[0028] The amount of CO2 emissions during the production of the hardening agent 3 can be calculated by referring to, for example, the Japan Society of Civil Engineers' "Concrete Library 125." Σ [(amount of each material in hardener 3) x (CO2 emissions per unit amount of each material)]...(Equation 1) On the other hand, the amount of CO2 absorbed by the hardener 3 can be calculated from the amount of calcium in the hardener 3 that reacts with CO2, which is obtained from the mill sheet of the hardener 3. Furthermore, the amount of CO2 absorbed can also be measured by various chemical analyses, and there are no limitations on the method for evaluating the amount of CO2 absorbed.

[0029] Furthermore, in this embodiment, by creating slice data using topology optimization technology, it is possible to obtain a structure 1 etc. that has sufficient structural performance while minimizing the amount of hardener 3, thereby reducing CO2 emissions related to the hardener 3. Furthermore, since the structure 1 etc. is made thinner and narrower, the CO2 absorption efficiency during forced carbonation curing is also improved.

[0030] In addition, in this embodiment, slice data is created from the three-dimensional shape data of an existing structure 10, and the new structure 1 formed by the above method can be used to replace an existing structure 10 such as a bridge, leading to cost reductions, etc.

[0031] However, the present invention is not limited to the above-described embodiment. For example, in this embodiment, SUICOM was used as the hardening agent 3, but the hardening agent 3 is not limited to this and may contain a calcium material that carbonates upon reaction with CO, such as slaked lime or steelmaking slag. Furthermore, in consideration of the pumpability and self-sustainability of the hardening agent 3, it is also possible to add a thickener, an early-strengthening agent, or reinforcing fibers such as organic fibers. Furthermore, as an alternative to reinforcing materials, it is also possible to add steel fibers or glass fibers to improve bending strength and tensile strength.

[0032] Furthermore, in this embodiment, the structure 1, etc. is produced in a factory or the like using a 3D printer 2, and then transferred to a curing tank 4 for forced carbonation curing. However, it is also possible to produce the structure 1, etc. and perform forced carbonation curing on-site at a construction site. For example, as shown in FIG. 5, the portion where the hardening material 3 is layered using the 3D printer 2 can be covered with a movable curing tank 4a, such as a bellows-shaped tank, and forced carbonation curing can be performed by sequentially moving the curing tank 4a as the hardening material 3 is layered. Alternatively, it is also possible to layer the hardening material 3 using the 3D printer 2 in the curing tank 4, and perform forced carbonation curing simultaneously with the layering of the hardening material 3.

[0033] Furthermore, as shown in Fig. 6(a), a curing tank can be used in which air is pumped into a membrane 43 made of resin such as polyvinyl chloride to inflate it into a dome shape, and as shown in Fig. 6(b), a dome-shaped body is constructed by spraying concrete 44 from the inside using the membrane 43 as a formwork, and further, as shown in Fig. 6(c), a covering material 45 is formed on the inner surface of the concrete 44 to prevent absorption of CO2 by the concrete 44, and a curing tank 4b is provided with CO2 gas inlet 41 and outlet 42. Reinforcing bars and the like (not shown) are also buried in the concrete 44.

[0034] In this case, the inner surface of the curing tank 4b is smooth, and there are no pillars or beams within the internal space of the curing tank 4b, allowing for maximum utilization of the internal space. Furthermore, because there are no areas within the curing tank 4b where CO2 can stagnate, after the forced carbonation curing is completed, the high concentration of CO2 gas remaining within the curing tank 4b can be released, improving safety when people enter and exit the tank. As described above, it is also possible to layer the hardening material 3 within the curing tank 4b using a 3D printer 2, and perform forced carbonation curing simultaneously with the layering of the hardening material 3.

[0035] Furthermore, while this embodiment uses admixtures such as γC2S, if the goal is simply to reduce CO2 without being bound by carbon neutral or carbon negative, the surface of the structure 1, etc. is uneven and the structure 1, etc. is thin, so even with a normal cement mix, it is possible to absorb CO2 throughout the entire surface of the component through forced carbonation curing, widening the range of mix options. It is also possible to include calcium carbonate (light calcium carbonate) or aggregate that has absorbed CO2 during manufacturing.

[0036] In this embodiment, a small bridge is formed using the hardening material 3, but the present invention is not limited to this and can be applied to various structures 1, outdoor furniture, sculptures, and the like.

[0037] While the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to these examples. It is clear that those skilled in the art can conceive of various modifications or alterations within the scope of the technical ideas disclosed herein, and it is understood that these modifications also fall within the technical scope of the present invention. [Explanation of symbols]

[0038] 1, 10: Structure 2:3D printer 3: Hardening material 4, 4a, 4b: Curing tank

Claims

1. A process of creating slice data for producing a product using a 3D printer; The method includes a step of producing a product using a hardening material containing γC 2 S by a 3D printer, The hardened material is subjected to forced carbonation curing in a curing tank, so that carbon dioxide is absorbed into the hardened material. This manufacturing method is characterized in that in the process of creating the slice data, the volume of the three-dimensional shape data that is the basis for creating the slice data is optimized to achieve the target amount of carbon dioxide absorption during forced carbonation curing, and the volume is set to correspond to the target amount of carbon dioxide absorption.

2. The method includes a step of producing a product using a hardening material containing γC 2 S by a 3D printer, The hardened material is subjected to forced carbonation curing in a curing tank, so that carbon dioxide is absorbed into the hardened material. The manufacturing method is characterized in that the hardening material contains precipitated calcium carbonate that has absorbed carbon dioxide during manufacturing.

3. The method includes a step of producing a product using a hardening material containing γC 2 S by a 3D printer, A manufacturing method characterized by stacking hardened material in a curing tank using a 3D printer, and simultaneously subjecting the hardened material to forced carbonation curing in the curing tank, thereby causing carbon dioxide to be absorbed into the hardened material.

4. The method includes a step of producing a product using a hardening material containing γC 2 S by a 3D printer, The hardened material is subjected to forced carbonation curing in a curing tank, so that carbon dioxide is absorbed into the hardened material. Forced carbonation curing is a production method characterized in that the part where the hardened material is layered by the 3D printer is covered with a movable curing tank, and the curing tank is moved sequentially as the layering of the hardened material progresses.

5. A process of creating slice data for producing a product using a 3D printer; The method includes a step of producing a product using a hardening material containing γC 2 S by a 3D printer, The hardened material is subjected to forced carbonation curing in a curing tank, so that carbon dioxide is absorbed into the hardened material. The fabrication is a new structure or part thereof that replaces an existing structure; A manufacturing method characterized in that in the process of creating the slice data, three-dimensional shape data of the new structure is created from three-dimensional shape data of the existing structure using topology optimization technology, and the slice data is created from the three-dimensional shape data.

6. A process of producing a hollow product using a 3D printer with a hardening material containing γC 2 S; a step of integrating a plurality of the products together using PC steel members passed through hollow portions of the products; Including, A manufacturing method characterized by subjecting the hardened material to forced carbonation curing in a curing tank, thereby causing carbon dioxide to be absorbed into the hardened material.

7. 7. The method according to claim 1, wherein the amount of carbon dioxide absorbed by the hardener is equal to or greater than the amount of carbon dioxide emitted during the production of the hardener.

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