Excess polymer material separation and retrieval device, excess polymer material separation and retrieval jig, and excess polymer material separation and retrieval method

Abstract

An excess polymer material separation and retrieval device comprising: a detaching force application mechanism that is capable of applying, to excess polymer material (B) attached to a formed object (10), detaching force for detaching the excess polymer material (B); a first intermediate layer (230) that is capable of allowing the passage of the excess polymer material (B) detached from the formed object (10), due to being provided with a plurality of first hole parts (233); a second intermediate layer (240) that is capable of allowing the passage of the excess polymer material (B) while capturing a contaminant (C) included in the excess polymer material (B), due to being provided with a plurality of second hole parts (243) having smaller sizes than the plurality of first hole parts (233); and a storage part (250) that is capable of receiving and storing the excess polymer material (B).

Description

Excess polymer material separation and recovery device, excess polymer material separation and recovery tool, and excess polymer material separation and recovery method

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

[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 from the object, as well as an apparatus for implementing the method.

[0003] International Publication No. 2023 / 214319

[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 reusing the polymer material.

[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.

[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 in size than the plurality of first holes. This allows the second intermediate layer to allow 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. 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 aspect of the present disclosure is used to separate and recover surplus polymer material, which is unused 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, thereby 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. This allows the second intermediate layer to pass the surplus polymer material that has passed through the first intermediate layer while capturing foreign matter contained in the surplus polymer material. The reservoir is positioned at a distance from the second intermediate layer and facing the fourth major surface, so that the reservoir can 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 aspect of the present disclosure is a method for separating and recovering unused surplus polymer material attached to a modeled object fabricated by three-dimensional additive manufacturing (3D AM), 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 located 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] The term "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 the manufacturing process that 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 the manufacturing process (i.e., the polymer material that did not undergo a chemical change). 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 the manufacturing process (i.e., the polymer material that did not undergo a state change).

[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.

[0012] 8 is a schematic diagram illustrating specifications of an insole as an example of a shaped object manufactured by three-dimensional additive manufacturing. FIG. 1 is a perspective view of the insole shown in FIG. 1. FIG. 2 is a flow diagram illustrating a manufacturing method of an insole to which the surplus polymer material separation and recovery method according to embodiment 1 is applied. FIG. 3 is a schematic diagram illustrating three-dimensional additive manufacturing of an insole. FIG. 4 is a schematic diagram illustrating three-dimensional additive manufacturing of an insole. FIG. 5 is a schematic diagram illustrating another example of three-dimensional additive manufacturing of an insole. FIG. 6 is a perspective view of a jig for separating and recovering surplus polymer material according to embodiment 1. FIG. 7 is an exploded perspective view of the jig for separating and recovering surplus polymer material shown in FIG. 8. FIG. 8 is a schematic cross-sectional view of the jig for separating and recovering surplus polymer material shown in FIG. 4. FIG. 9 is a schematic cross-sectional view illustrating a state in which a shaped object immediately after being manufactured by three-dimensional additive manufacturing is set in the jig for separating and recovering surplus polymer material shown in FIG. 4 in the method for separating and recovering surplus polymer material according to embodiment 1. FIG. 10 is a schematic diagram illustrating centrifugal separation in the method for separating and recovering surplus polymer material according to embodiment 1. FIG. 1 is a schematic cross-sectional view showing the state in which excess polymer material is separated from a shaped object during centrifugation. FIG. 2 is a schematic cross-sectional view for explaining a recovery operation in a method for manufacturing an insole. FIG. 3 is a schematic cross-sectional view for explaining a cleaning process in a method for manufacturing an insole. FIG. 4 is a flow diagram for explaining a method for manufacturing an insole to which a method for separating and recovering excess polymer material according to embodiment 2 is applied. FIG. 5 is a schematic view for explaining separation by gas blowing in a method for separating and recovering excess polymer material according to embodiment 2. FIG. 6 is a schematic view for explaining separation by gas blowing in a method for separating and recovering excess polymer material according to embodiment 3. FIG. 7 is a schematic view for explaining separation by gas blowing in a method for separating and recovering excess polymer material according to embodiment 4.

[0013] Hereinafter, embodiments will be described in detail with reference to the drawings. In the embodiments shown below, an insole is used as an example of a shaped object manufactured by three-dimensional additive manufacturing, and the present invention will be described as being applied to an apparatus for separating and recovering excess polymer material, a jig for separating and recovering excess polymer material, and a method for separating and recovering excess polymer material, which are used in manufacturing the insole. In the embodiments shown below, identical or common parts are designated by the same reference numerals in the drawings, and their description will not be repeated.

[0014] (Embodiment 1) <A. Configuration of insole> Fig. 1 is a schematic diagram for explaining the specification of an insole as an example of a shaped object formed by three-dimensional additive manufacturing, and Fig. 2 is a perspective view of the insole shown in Fig. 1. First, before explaining the device for separating and recovering excess polymer material, the jig for separating and recovering excess polymer material, and the method for separating and recovering excess polymer material according to this embodiment, an insole 5 as a shaped object will be explained with reference to Figs. 1 and 2.

[0015] As shown in Figure 1, the insole 5 is used by being attached to a shoe 1, for example, which is a type of footwear. The shoe 1 has a sole 2 and an upper 3, and when used, the insole 5 is inserted into the shoe 1 through an opening 4 provided in the upper 3. In this way, the insole 5 is placed on the inner sole of the shoe 1 with its underside facing the inner sole, and the insole 5 is thereby attached to the shoe 1.

[0016] When a user puts on the shoe 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 the insole 5 thereby supports the user's foot.

[0017] As shown in Figure 2, the insole 5 has a flat shape, and its outer shape in a plan view roughly matches the outer shape of the inner bottom surface of the shoe 1. The insole 5 is made of a single member, and is composed 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 plurality of unit structures, each of which is a three-dimensional lattice structure, are repeatedly arranged. 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 such unit structures are repeatedly and continuously arranged along three orthogonal axial directions, namely, the front-rear, left-right, and up-down directions, thereby providing a large number of holes inside and on the outer surface of the base layer 6.

[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 (for example, linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE)), polypropylene, ethylene-propylene copolymer, propylene-1-hexene copolymer, propylene-4-methyl-1-pentene copolymer, propylene-1-butene copolymer, ethylene-1-hexene copolymer, ethylene-4-methyl-pentene copolymer, ethylene-1-butene copolymer, 1-butene-1-hexene copolymer, 1-butene-4-methyl-pentene, ethylene-methacrylic acid copolymer, ethylene-methyl methacrylate copolymer, 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, for example, polyamide 6, polyamide 11, polyamide 12, polyamide 66, polyamide 610, polyether block amide (PEBA), etc.

[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 (SBBSB), 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 a hydrogenated product 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 a hydrogenated product 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] The insole 5 is preferably made of a flexible material, and among the above-mentioned materials, it is particularly preferable that the insole be made of urethane acrylate. When the insole 5 is made of urethane acrylate, not only is it excellent in 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 is excellent in cushioning properties, breathability, and durability, and that provides a good wearing comfort.

[0031] Here, various structures can be used as unit structures of the three-dimensional lattice structure of the base layer 6 consisting of a three-dimensional mesh structure, such as a rectangular lattice, a diamond lattice, an octahedral lattice, a double pyramidal lattice, or lattices to which various columnar supports are added.

[0032] Furthermore, instead of the three-dimensional lattice structure described above, the base layer 6 may be configured as a three-dimensional mesh structure in which a plurality of unit structures each having a three-dimensional wall structure are repeatedly arranged. A three-dimensional wall structure is formed by walls whose outer shape is defined by a pair of parallel curved or flat surfaces. Various structures can be used as the unit structures of the three-dimensional wall structure of the base layer 6 made of a three-dimensional mesh structure, such as a Schwarz P structure, a gyroid structure, a Schwarz D structure, an octet structure, or a cubic structure.

[0033] It should be noted that the insole 5 does not necessarily have to be made of the two-layer structure 10 as described above, and may be made of a structure having another structure. For example, the insole 5 may be made of a structure consisting solely of a three-dimensional mesh structure, or may be made of a structure consisting solely of a sheet-like structure.

[0034] <B. Manufacturing Method of Insole> Fig. 3 is a flow diagram for explaining a manufacturing method of an insole to which the method for separating and recovering excess polymer material according to this embodiment is applied. Next, the manufacturing method of the insole 5 will be described with reference to Fig. 3.

[0035] 3, when manufacturing the insole 5 described above, first, in step ST1, three-dimensional additive manufacturing of the insole 5 is performed. In this embodiment, the three-dimensional additive manufacturing of the insole 5 is performed by a liquid vat photopolymerization three-dimensional additive manufacturing method, the details of which will be described later.

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

[0037] Next, in step ST4, the insole 5 from which the excess polymer material has been removed is washed, and then in step ST5, the washed insole 5 is dehydrated and dried. Furthermore, in step ST6, the dehydrated and dried insole 5 is irradiated with ultraviolet light, and then in step ST7, the insole 5 after being irradiated with ultraviolet light is subjected to a heat treatment.

[0038] The above steps complete the manufacture of the insole 5. The irradiation of ultraviolet light onto the insole 5 in step ST6 is performed to promote the curing of the polymer material that has not yet completely cured even after the ultraviolet light irradiation in step ST1, which will be described in detail later.

[0039] <C. Three-dimensional additive manufacturing of insoles> Figures 4 to 6 are schematic diagrams for explaining three-dimensional additive manufacturing of insoles, showing the start, intermediate, and end states of manufacturing, respectively. Figure 7 is a schematic diagram for explaining another example of three-dimensional additive manufacturing of insoles. Next, the three-dimensional additive manufacturing of insoles 5 in step ST1 described above will be described in detail with reference to Figures 4 to 7.

[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 manufacturing 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. 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, for example.

[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 elevator 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 elevator mechanism 403 moves the platform 402 in the vertical direction.

[0042] 4 , in the three-dimensional additive manufacturing device 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 storage 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 storage 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 storage 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 storage tank 401 hardens in a layer while adhering to the inner bottom surface of the storage tank 401 and the lower surface of the platform 402, and a first hardened layer is formed.

[0043] Next, the platform 402 is moved upward (i.e., in the direction of arrow DR1 in the figure) by a predetermined amount by the lifting mechanism 403, thereby peeling the first cured layer from the inner bottom surface of the storage tank 401. In this state, the liquid polymer material A located between the lower surface of the platform 402 and the inner bottom surface of the storage tank 401 is exposed to light of a specific wavelength emitted from the light source, so as to draw a predetermined pattern. As a result, the liquid polymer material A located between the lower surface of the first cured layer and the inner bottom surface of the storage tank 401 is cured in a layer while adhering to the lower surface of the first cured layer and the lower surface of the 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 this configuration, due to the relationship between the shape of the insole 5 to be formed and the posture (i.e., orientation) of the insole 5 during the forming process, it becomes necessary to form the support part 11 separately from the insole 5 as shown in Figures 5 and 6 so that the relatively soft shape of the insole 5 is maintained during the forming process. This support part 11 is to be cut off and removed from the insole 5 after the insole 5 has been formed.

[0048] 7, another example of three-dimensional additive manufacturing of an insole 5 is configured so that the insole 5 is manufactured from the bottom end toward the top end. In this way, the footprint required to manufacture the insole 5 on the platform 402 becomes relatively large, making it difficult to manufacture multiple insoles 5 simultaneously.

[0049] However, on the other hand, when configured in this manner, due to the relationship between the shape of the insole 5 to be formed and the posture (i.e., orientation) of the insole 5 during formation, the support part 11 as shown in Figures 5 and 6 becomes unnecessary and the time required for formation is shortened. In this respect, it is possible to shorten the takt time and there is no problem of generating waste material (i.e., the support part 11 after being separated from the insole 5), which in turn reduces manufacturing costs.

[0050] After the three-dimensional additive manufacturing of the insole 5 described above is completed, surplus polymer material, which is unused liquid polymer material, remains attached to the insole 5. In particular, in a molded object 10 having many holes formed on its surface or inside, such as the insole 5 described above, a large amount of surplus polymer material remains attached due to surface tension. In particular, the liquid polymer material does not easily separate from the molded object 10 due to its relatively high viscosity, and remains attached to the surface and inside of the molded object 10.

[0051] <D. Excess Polymer Material Separating and Recovering Jig> FIG. 8 is a perspective view of the surplus polymer material separating and recovering jig according to this embodiment. FIG. 9 is an exploded perspective view of the surplus polymer material separating and recovering jig, and FIG. 10 is a schematic cross-sectional view taken along line X-X in FIG. 8 . Next, with reference to FIGS. 8 to 10 , the surplus polymer material separating and recovering jig 200A according to this embodiment will be described. Here, the surplus polymer material separating and recovering jig 200A is used in the centrifugation in step ST2 and the recovery operation in step ST3 described above. Furthermore, a portion of the surplus polymer material separating and recovering jig 200A 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 a single 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 on 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 the 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 2121 and a second peripheral wall 2122 extending from the periphery of the second bottom wall 2121. A second flange 2123 extending outward is provided on the upper edge of the second peripheral wall 2122, and a second upper opening 2124 is located inside the second peripheral wall 2122 at the portion where the second flange 2123 is provided. The second peripheral wall 2122 has an inclined shape such that the width and depth of the second container 2120 narrow downward, and a second step 2126 is provided at a predetermined position in the height direction of the second peripheral wall 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, with the difference being that the first bottom wall portion 2111 of the first container 2110 has a lower opening 2115, whereas 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, thereby functioning 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, thereby stably holding the first container 2110 by the second container 2120.

[0058] 10 , in the 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 the second bottom wall 2121 of the second container 2120, and the peripheral wall 212 of the box 210 is formed by the first peripheral wall 2112 of the first container 2110 and the second peripheral wall 2122 of the second container 2120. In addition, the opening 214 provided on the top surface of the box 210 is formed by the 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 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, for example, FIGS. 11 to 13 ) 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 molded object 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 mesh material. The first intermediate layer 230 and the second intermediate layer 240 are both housed inside the box body 210.

[0063] The 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 the first main surface 231, and has a pair of legs 234 provided at its side ends. The first intermediate layer 230 is provided with a plurality of first holes 233 so as to reach both the first main surface 231 and the second main surface 232. In this embodiment, the first intermediate layer 230 is made of a wire mesh, and therefore each of the plurality of first holes 233 is configured to have a generally rectangular shape in a 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 positioned 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 positioned 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 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 configured by the bottom wall section 211 of the box body 210 and the 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] As described above, the first intermediate layer 230 and the second intermediate layer 240 are provided with a plurality of first holes 233 and a plurality of second holes 243, respectively, but the size of the plurality of second holes 243 is configured to be smaller than the size of the plurality of first holes 233. The reason for this configuration will be described in detail later.

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

[0073] Furthermore, 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 above-described substantially rectangular shape in plan view, and may be any shape such as a circular shape in plan view or a hexagonal shape in plan view. Furthermore, the first intermediate layer 230 may be formed, for example, by beam members or the like arranged parallel to each other.

[0074] <E. Centrifugal Separation> Fig. 11 is a schematic cross-sectional view showing a state in which a modeled object immediately after being manufactured by three-dimensional additive manufacturing is set in the above-mentioned jig for separating and recovering surplus polymer material in the method for separating and recovering surplus polymer material according to this embodiment. Fig. 12 is a schematic diagram for explaining centrifugation in the method for separating and recovering surplus polymer material according to this embodiment, and Fig. 13 is a schematic cross-sectional view showing how the surplus polymer material is separated from the modeled object by the centrifugation. Next, with reference to Figs. 11 to 13, the apparatus 100A for separating and recovering surplus polymer material and the method for separating and recovering surplus polymer material according to this 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 system 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 driven to rotate 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, from the viewpoint of shortening the takt time, it is preferable to set a plurality of separation and recovery jigs 200A in the rotating basket 112.

[0078] Here, the separation and recovery jig 200A is positioned so that the bottom wall portion 211 of its box body 210 is located radially outside the centrifuge 110 and the 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 positioned radially outside the centrifuge 110 relative to the shaped object 10.

[0079] By operating the centrifuge 110 in this state, the separation and recovery jig 200A rotates at high speed together with the rotating basket 112, and centrifugal force acts on the separation and recovery 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 object 10 in the direction of the arrow DR4 in the figure, the object 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 object 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 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 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, allowing the excess polymer material B and foreign matter C that have detached from the model 10 to move smoothly into the second space SP2. Here, the sizes of the multiple first holes 233 are 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 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] In this case, 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 molded object 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 into 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 made of a solid polymer composition or a high-viscosity liquid polymer composition can be captured by the second intermediate layer 240, and only the liquid excess polymer material B, which has a relatively low viscosity, 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 made 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 shaped object 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). In this way, the excess polymer material B after the foreign matter C has been removed can 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 apparatus 100A and separation and recovery method according to the present embodiment described above mainly use the centrifuge 110 as the above-described separation force application mechanism, and the first intermediate layer 230, second intermediate layer 240, and storage section 250 provided in the above-described 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 plurality of first holes 233 provided in the first intermediate layer 230, then pass through the plurality of second holes 243 provided in the second intermediate layer 240, and then be received by the storage section 250. Furthermore, when the excess polymer material B passes through the plurality of second holes 243 provided in the second intermediate layer 240, the 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, separation and recovery jig 200A, 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 centrifuging using the centrifuge 110. 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 that has adhered to the shaped object 10.

[0093] <F. Recovery and Cleaning> Figure 14 is a schematic cross-sectional view illustrating the recovery process in the insole manufacturing method. Also, Figure 15 is a schematic cross-sectional view illustrating the cleaning process in the insole manufacturing method. Next, the recovery process and cleaning process in the above-mentioned insole 5 manufacturing method will be described with reference to Figures 14 and 15.

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

[0095] 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 modeled object 10 and the second intermediate layer 240 with the foreign matter C attached thereto, and the second container 2120 contains surplus polymer material B that is substantially free of the foreign matter C. Therefore, by the simple operation of removing the first container 2110 from the second container 2120, it is possible to recover surplus polymer material B that is substantially free of the foreign matter C. The recovered surplus polymer material B can be reused as a raw material for three-dimensional additive manufacturing.

[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 inside of 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 operation 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 process. This makes it possible to simplify the manufacturing process and contributes to reducing manufacturing costs.

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

[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 device 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 opposite the first main surface 131. The first intermediate layer 130 is provided with a plurality of first holes 133 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 opposite the third main surface 141. The second intermediate layer 140 is provided with a plurality of second holes 143 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 excess polymer material still attached to it.

[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 device 100B and separation and recovery method according to this embodiment, the blower 120 as the above-described 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, causing the excess polymer material B to pass through the plurality of first holes 133 provided in the first intermediate layer 130, then pass through the plurality of second holes 143 provided in the second intermediate layer 140, and then be received by the storage section 150; and when the excess polymer material B passes through the plurality of 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.

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

[0109] (Embodiment 3) Figure 18 is a schematic diagram for explaining separation by gas blowing in a method for separating and recovering surplus polymer material according to embodiment 3. Hereinafter, an apparatus 100C for separating and recovering surplus polymer material and a method for separating and recovering surplus polymer material according to this embodiment will be described with reference to Figure 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 manner 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 second embodiment. On the other hand, the stage 160 is made of a shelf-shaped member provided with a window 161, and is disposed between the blower 120 and the second intermediate layer 140.

[0111] Here, the separation and recovery method according to the present embodiment uses a separation and recovery tool 200B having a different configuration from separation and recovery tool 200A according to the first embodiment described above. Specifically, separation and recovery tool 200B includes a box body 210 formed of a single container, and a first intermediate layer 230. Of these, first intermediate layer 230 is basically similar to first intermediate layer 230 provided in separation and recovery tool 200A described in the first embodiment described above, but differs in configuration in that it does not have legs 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, the 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 the excess polymer material 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 apparatus 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 reservoir 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 is attached is in contact with the first main surface 231 of the first intermediate layer 230. As a result, the excess polymer material B passes through the plurality of first holes 233 provided in the first intermediate layer 230, then passes through the plurality of second holes 143 provided in the second intermediate layer 140, and is then received by the storage section 150; further, as the excess polymer material B passes through the plurality of 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, it is possible to perform a single process of separation by blowing gas 1000 using the blower 120, not only to separate the excess polymer material B from the shaped object 10 to which the excess polymer material B has adhered, but also to separate the foreign matter C contained in the excess polymer material B from the excess polymer material B. Therefore, according to this embodiment, it is possible to obtain the effect of easily removing the foreign matter C when recovering the excess polymer material B that has adhered to the shaped object 10.

[0118] Furthermore, in the separation and recovery method according to this embodiment, the separation and recovery jig 200B used in the separation by spraying gas in the above-described step ST2A can also be used in the subsequent cleaning treatment in the above-described step ST4, which facilitates handling of the shaped object 10 in each step, thereby simplifying the manufacturing process and contributing to reducing manufacturing costs.

[0119] (Embodiment 4) Figure 19 is a schematic diagram for explaining separation by gas blowing in a 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 Figure 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 jig 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 manufactured by the three-dimensional additive manufacturing method is set in the separation and recovery jig 200A with the unused surplus polymer material still attached thereto. 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, the gas 1000 is blown against 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 the excess polymer material 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.

[0123] Here, in the separation and recovery method according to this embodiment, the spray gun 170 as the above-described separation force application mechanism, and the first intermediate layer 230, second intermediate layer 240, and storage section 250 provided in the above-described 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, causing the excess polymer material B to pass through the plurality of first holes 233 provided in the first intermediate layer 230, then pass through the plurality of second holes 243 provided in the second intermediate layer 240, and then be received by the storage section 250, and further, when the excess polymer material B passes through the plurality of 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.

[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 spraying gas in the above-described step ST2A can be used as is for the subsequent recovery work in the above-described step ST3 and the cleaning treatment in the above-described 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 Contents Disclosed in the Embodiments) The characteristic configurations disclosed in the above-described embodiments can be summarized as follows.

[0127] [Supplementary Note 1] An apparatus for separating and recovering surplus polymer material, which is unused polymer material attached to a modeled object formed by three-dimensional additive manufacturing, is configured to separate and recover surplus polymer material from the modeled object, the apparatus comprising: a detachment force application mechanism that applies a detachment force to the surplus polymer material to detach the surplus polymer material from the modeled object to which the surplus polymer material is attached in a predetermined detachment direction; a first intermediate layer that has a first main surface that intersects with the detachment direction and a second main surface located on the opposite side to the first main surface, and that restricts movement of the modeled object to which the surplus polymer material is attached in the detachment direction by contacting the first main surface with the modeled object to which the surplus polymer material is attached, and that has a plurality of first holes that allow the surplus polymer material detached from the modeled 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 opposite the third main surface, and having a plurality of second hole portions smaller 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; and a storage portion positioned at a distance from the second intermediate layer in the separation direction and arranged to face the fourth main surface, thereby being able to receive and store 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] The excess polymer material separation and recovery device 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 shaped 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] The excess polymer material separation and recovery device described in Appendix 1, wherein the separation force application mechanism comprises a blower that blows gas onto the modeled object to blow off the excess polymer material 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] [Supplementary Note 4] A jig for separating and recovering surplus polymer material used to separate and recover, from a modeled object formed by a three-dimensional additive manufacturing method, surplus polymer material, which is unused polymer material adhering to the modeled object, comprising: a first intermediate layer having a first main surface and a second main surface opposite to the first main surface, and having a plurality of first holes formed therein, thereby allowing the surplus polymer material that has separated from the model to pass; a second intermediate layer located at a distance from the first intermediate layer, having a third main surface facing the second main surface and a fourth main surface opposite to the third main surface, and having a plurality of second holes smaller in size than the plurality of first holes, 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; 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 is 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, resulting in a jig for separating and recovering surplus polymer material that can easily remove foreign matter from the surplus polymer material.

[0135] [Appendix 5] A jig for separating and recovering excess polymer material according to Appendix 4, further comprising a box having a bottom wall portion and peripheral wall portions and an opening on the top surface, wherein the first intermediate layer is positioned inside the box and at a distance from the opening in the depth direction of the box, and the second intermediate layer is positioned inside the box and at a distance from the first intermediate layer in the depth direction of the box, thereby dividing the space inside the box 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, and the storage portion is constituted by the bottom wall portion and the peripheral wall portion that defines the third space.

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

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

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

[0139] [Appendix 7] The jig for separating and recovering excess polymer material according to appendix 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 excess polymer material separated from the shaped object.

[0141] [Appendix 8] The jig for separating and recovering excess polymer material according to any one of Appendices 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] [Supplementary Note 9] A method for separating and recovering surplus polymer material, which is unused polymer material attached to a modeled object manufactured by three-dimensional additive manufacturing, from the modeled object, comprising the steps of: using a detachment force application mechanism that applies a detachment force to the surplus polymer material to detach the surplus polymer material in a predetermined detaching direction from the modeled object to which the surplus polymer material is attached; a first intermediate layer having a first main surface that intersects with the detaching direction and a second main surface located on the opposite side to the first main surface, and having a plurality of first holes; a second intermediate layer that is located at a distance from the first intermediate layer in the detaching direction, and has a third main surface that faces the second main surface and intersects with the detaching direction and a fourth main surface located on the opposite side to the third main surface, and having a plurality of second holes that are smaller than the plurality of first holes; and a reservoir that is located at a distance from the second intermediate layer in the detaching direction and is arranged to face 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.

[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 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 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 Embodiments, 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.

[0150] REFERENCE SIGNS LIST 1 shoe, 2 sole, 3 upper, 4 shoe opening, 5 insole, 6 base layer, 7 upper layer, 10 shaped 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 Reservoir, 300 Cleaning tank, 301 Cleaning liquid, 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 modeled object created by three-dimensional additive manufacturing, and which separates and recovers the surplus polymer material from the modeled object, comprising: a detachment force application mechanism that applies a detachment force to the surplus polymer material to detach the surplus polymer material from the modeled object to which the surplus polymer material is attached in a predetermined detachment direction; a first intermediate layer that has a first main surface that intersects with the detachment direction and a second main surface located on the opposite side to the first main surface, and that restricts movement of the modeled object to which the surplus polymer material is attached in the detachment direction by contacting the first main surface with the modeled object to which the surplus polymer material is attached, and that has a plurality of first holes that allow the surplus polymer material detached from the modeled 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 opposite the third main surface, and having a plurality of second hole portions smaller than the plurality of first hole portions, thereby enabling 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; and a storage portion positioned at a distance from the second intermediate layer in the separation direction and arranged opposite the fourth main surface, thereby enabling the surplus polymer material that has passed through the second intermediate layer to be received and stored.

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

4. A jig for separating and recovering surplus polymer material used to separate and recover from a modeled object formed by three-dimensional additive manufacturing, surplus polymer material being unused polymer material adhering to the modeled object, the jig comprising: a first intermediate layer having a first main surface and a second main surface opposite to the first main surface, and having a plurality of first holes formed therein, thereby allowing the surplus polymer material that has separated from the modeled object to pass through; a second intermediate layer located at a distance from the first intermediate layer, having a third main surface facing the second main surface and a fourth main surface opposite to the third main surface, and having a plurality of second holes smaller in size than the plurality of first holes, 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; 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. A jig for separating and recovering excess polymer material as described in claim 4, further comprising a box having a bottom wall portion and peripheral wall portions and an opening on the top surface, wherein the first intermediate layer is positioned inside the box and at a distance from the opening in the depth direction of the box, and the second intermediate layer is positioned inside the box and at a distance from the first intermediate layer in the depth direction of the box, thereby dividing the space inside the box 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, and the storage portion is constituted by the bottom wall portion and the peripheral wall portion that defines the third space.

6. A jig for separating and recovering excess polymer material as described in claim 5, wherein the portion of the box that constitutes the storage section is detachable from the other portions of the box.

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

8. A 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.

9. A method for separating and recovering surplus polymer material, which is unused polymer material attached to a modeled object fabricated by three-dimensional additive manufacturing, from the modeled object, and recovering the surplus polymer material, comprising: a detachment force application mechanism capable of applying a detachment force to the surplus polymer material to detach the surplus polymer material in a predetermined detachment direction from the modeled object to which the surplus polymer material is attached; a first intermediate layer having a first main surface intersecting the detachment direction and a second main surface located opposite the first main surface, and having a plurality of first holes; a second intermediate layer located at a distance from the first intermediate layer in the detachment direction, having 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, and having a plurality of second holes smaller than the plurality of first holes; and a storage unit located at a distance from the second intermediate layer in the detachment direction and arranged to face 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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