Form, method for manufacturing form, and method for manufacturing concrete panel

Abstract

A form according to the present disclosure comprises a sheathing-board shaped article that constitutes the bottom wall of the form. The sheathing-board shaped article is a resin shaped article that is formed by stacking shaping layers formed in a single continuous path. The sheathing-board shaped article includes a sheathing board part and a support part for supporting the sheathing board part. The support part includes: a plurality of leg parts that are in contact with the sheathing board part and are arranged at certain intervals along a direction orthogonal to the stacking direction of the shaping layers; and a plurality of connection parts that are not in contact with the sheathing board part and connect adjacent ones of the plurality of leg parts. The leg parts extend from one end to the other end of the sheathing board part in the stacking direction. In a cross section of the sheathing-board shaped article along a plane orthogonal to the stacking direction, the sheathing board part is formed by one line part of the single continuous path.

Description

Formwork, method for manufacturing formwork, and method for manufacturing concrete panels

[0001] This disclosure relates to formwork, a method for manufacturing formwork, and a method for manufacturing concrete panels.

[0002] Concrete is generally obtained by pouring fresh concrete into formwork, curing it, and then removing the formwork. Traditionally, wooden and metal forms have been used. In recent years, formwork made with 3D printers has been used to easily produce concrete with complex three-dimensional shapes.

[0003] Patent Document 1 discloses a method for constructing a molded object. The method includes an outer frame molding step, a reinforcement step, and an outer frame removal step. In the outer frame molding step, an outer frame (hereinafter also referred to as "mold") having a shape corresponding to at least a part of the outer frame of the target molded object and surrounding a hollow space is integrally molded using a 3D printer that molds three-dimensional objects. In the reinforcement step, the target molded object is reinforced by filling the hollow space with a reinforcing material. In the outer frame removal step, the outer frame molded in the outer frame molding step is removed after filling with the reinforcing material in the reinforcement step. Examples of molding materials include thermoplastics, thermosetting plastics, metals, glass, ceramics, concrete, and wood. Examples of reinforcing materials include concrete and resin materials.

[0004] Patent Document 1: Specification of Japanese Patent No. 6277033

[0005] However, Patent Document 1 does not specifically disclose the structure of the formwork that is removed after the reinforcing material has been filled.

[0006] Concrete panels having a three-dimensional curved surface can be manufactured using the formwork 200 shown in Figure 8. The formwork 200 comprises a formwork shaped object 210A made by material extrusion and side formwork 220. The formwork shaped object 210A constitutes the bottom plate of the formwork 200. The formwork shaped object 210A has a formwork portion 211 for forming a three-dimensional curved surface.

[0007] The formwork 210A is materialized using a 3D printer with a material extrusion method, based on 3D model data, by stacking layers along the stacking direction D1. The layers are formed by a single continuous path R210A. In order to prevent the unfinished object, in which the layers are stacked, from tipping over during additive manufacturing, the maximum thickness T210 of the formwork 210A must be a certain thickness. The maximum thickness T210 represents the maximum thickness of the formwork 210A in the gravity direction D3, which is perpendicular to the stacking direction D1 of the layers.

[0008] As a formwork structure with a maximum thickness T200 having a constant thickness, a method for forming a cylindrical formwork structure 210A, as shown in Figures 9 and 10, is conceivable. As shown in Figure 10, the cylindrical formwork structure 210A has a formwork section 211 and two legs 212A that support the formwork section 211. The single-stroke path R210A that forms the formwork structure 210A is formed by a single track. The formwork section 211 is supported only by the two legs 212A. Therefore, the cylindrical formwork structure 210A does not have sufficient strength (hereinafter also simply referred to as "casting strength") to suppress deformation of the formwork section 211 caused by the load of fresh concrete poured into the formwork 200. Therefore, the cylindrical formwork structure 210A is prone to deformation due to the load of fresh concrete. As a result, the formwork structure 210A may not be able to accurately form concrete panels with the desired shape.

[0009] As a formwork that offers superior casting strength, the formwork 210B shown in Figure 11 is a possible example. The formwork 210B has a formwork section 211 and a plurality of legs 212B that support the formwork section 211. The single-stroke path R210B that forms the formwork 210B is formed only by the connection of two parallel tracks. The molten resin extruded from the nozzle of a 3D printer using the material extrusion method undergoes thermal shrinkage when it solidifies. At this time, the molded layer of the formwork section 211 is prone to deformation. In other words, the dimensions of the formwork section 211 of the formwork 210B may deviate from the dimensions of the 3D model data. As a result, the formwork 210B may not be able to accurately form concrete panels with the desired shape.

[0010] Embodiments of this disclosure have been made in view of the above, and aim to provide a formwork, a method for manufacturing the formwork, and a method for manufacturing a concrete panel that can accurately form a concrete panel having a desired shape.

[0011] The means for solving the above problems include the following embodiments: <1> A formwork into which fresh concrete is poured, comprising a formwork formwork forming a formwork bottom wall, wherein the formwork formwork is a resin formwork formed by stacking molded layers formed in a single continuous path, wherein the formwork formwork has a formwork portion in contact with the fresh concrete and a support portion that supports the formwork portion, wherein the support portion includes a plurality of legs that are in contact with the formwork portion and are spaced apart along a perpendicular direction perpendicular to the stacking direction of the molded layers, and a plurality of connecting portions that are not in contact with the formwork portion and connect adjacent legs among the plurality of legs, wherein the legs extend from one end to the other in the stacking direction of the formwork portion, and in a cross-section when the formwork formwork is cut by a plane perpendicular to the stacking direction, the formwork portion is formed by one of the track portions of the single continuous path. <2> The formwork according to <1>, wherein the leg portion indicates a first leg portion, the connecting portion includes at least one second leg portion, the second leg portion extends from one end to the other in the stacking direction of the formwork portion, and in the cross-section, the second leg portion is formed by a plurality of track portions that constitute a return path in the single-stroke path. <3> The formwork according to <2>, wherein the first leg portion and the second leg portion are arranged alternately at equal intervals along the orthogonal direction. <4> The formwork according to any one of <1> to <3>, wherein the casting strength of the formwork is 1 MPa or more, and the casting strength indicates the surface pressure required to deform the formwork portion by 0.5 mm in the orthogonal direction. <5> The formwork according to any one of <1> to <4>, wherein the formwork is a resin molded product formed by stacking the molded layers by a material extrusion method. <6> A mold according to any one of <1> to <5> above, wherein the resin molded product contains used resin. <7> A mold according to any one of <1> to <6> above, wherein the resin molded product contains biomass-derived resin.<8> A method for manufacturing a formwork described in any one of <1> to <7> above, comprising: forming the molded layer in the single-stroke path by a material extrusion method, and stacking the molded layers to produce the formwork molded object. <9> A method for manufacturing a concrete panel, comprising: preparing the formwork described in any one of <1> to <7> above and the fresh concrete; pouring the fresh concrete into the formwork, curing it to form a concrete panel; and demolding the formwork from the concrete panel.

[0012] According to embodiments of this disclosure, a formwork, a method for manufacturing the formwork, and a method for manufacturing a concrete panel are provided that can accurately form a concrete panel having a desired shape.

[0013] Figure 1 is a perspective view of a concrete panel according to the first embodiment. Figure 2 is a perspective view of the formwork according to the first embodiment. Figure 3 is a partially enlarged perspective view of the formwork molded along the line III-III in Figure 2. Figure 4 is a diagram illustrating the manufacturing method of the concrete panel according to the first embodiment. Figure 5 is a partially enlarged perspective view of the formwork molded according to the second embodiment. Figure 6 is a partially enlarged perspective view of the formwork molded according to the third embodiment. Figure 7 is a perspective view of the 3D model data of the molded object according to Example 1. Figure 8 is a perspective view of the formwork according to Comparative Example 1. Figure 9 is a perspective view of the formwork molded according to Comparative Example 1. Figure 10 is a partially enlarged perspective view of the formwork molded along the line X-X in Figure 9. Figure 11 is a partially enlarged perspective view of the formwork molded according to Comparative Example 2.

[0014] In this disclosure, the "~" indicating a numerical range is used to mean that the numbers before and after it are included as the lower and upper limits. In numerical ranges described in stages in this disclosure, the upper or lower limit described in one numerical range may be replaced with the upper or lower limit of another numerical range described in stages. In numerical ranges described in this disclosure, the upper or lower limit of that numerical range may be replaced with the values ​​shown in the examples. In this disclosure, the term "process" is included not only in the sense of an independent process, but also in the sense that the intended purpose of the process is achieved even if it cannot be clearly distinguished from other processes. In this disclosure, when referring to the amount of each component in a composition, if there are multiple substances corresponding to each component in the composition, it means the total amount of the multiple substances present in the composition unless otherwise specified.

[0015] (1) Formwork The formwork of the present disclosure is a formwork into which fresh concrete is poured. The formwork includes a formwork molded object that constitutes the bottom wall of the formwork. The formwork molded object is a resin molded object formed by stacking molded layers formed in a single continuous path. The formwork molded object has a formwork portion that is in contact with the fresh concrete and a support portion that supports the formwork portion. The support portion includes a plurality of legs and a plurality of connecting portions. The plurality of legs are in contact with the formwork portion and are spaced apart along an orthogonal direction perpendicular to the stacking direction of the molded layers. The plurality of connecting portions are not in contact with the formwork portion and connect adjacent legs among the plurality of legs. The legs extend from one end to the other in the stacking direction of the formwork portion. In the cross-section obtained by cutting the aforementioned formwork with a plane perpendicular to the stacking direction, the formwork portion is formed by one track section of the previous single-stroke drawing path, and the leg portion is formed by a plurality of track sections that constitute a return path of the single-stroke drawing path.

[0016] In this disclosure, “formwork” refers to a temporary structure that maintains the shape and dimensions of poured fresh concrete and supports it until the concrete reaches an appropriate strength. “Fresh concrete” refers to concrete in an unhardened state. “3D printer” refers to a device used for 3D printing. “3D printing” refers to a method of creating an object by depositing material using two-dimensional printing technology (e.g., a print head and nozzle). “Resin molded object” refers to a molded object made from a resin composition. “Molded object” refers to a laminate formed by bonding molded layers based on 3D model data using a 3D printer.

[0017] Because the formwork of this disclosure has the above configuration, concrete panels having a desired shape can be formed with high precision. This effect is presumed to be due to, but is not limited to, the following reasons. In this disclosure, the support portion includes a plurality of legs that are in contact with the formwork and are spaced apart along an orthogonal direction perpendicular to the stacking direction of the formed layers. The legs extend from one end of the formwork in the stacking direction to the other. Therefore, the casting strength required to suppress deformation of the formwork due to the load of fresh concrete poured into the formwork in this disclosure is higher than the casting strength of the cylindrical formwork structure 210A (see Figure 10). In other words, the formwork of this disclosure is less prone to deformation due to the load of fresh concrete poured into the formwork. In this disclosure, the support portion does not come into contact with the formwork and includes a plurality of connecting portions that connect adjacent legs among the plurality of legs. In the cross-section obtained by cutting the aforementioned formwork with a plane perpendicular to the stacking direction, the formwork portion is formed by one of the track sections of the single-stroke path. In other words, the formwork portion of this disclosure is not formed solely by the connection of two parallel tracks. Therefore, due to thermal shrinkage of the molded layer, the formwork portion of this disclosure is less prone to deformation than the formwork portion 211 of formwork 210B (see Figure 11). In other words, the dimensions of the formwork portion of this disclosure are less likely to deviate from the dimensions of the 3D model data. As a result, it is presumed that the formwork of this disclosure can accurately form concrete panels with a desired shape.

[0018] The surface of a formwork molded object has lamination marks. "Lamination marks" refer to multiple striated irregularities formed on the surface of the formwork molded object due to the stacking of the molded layers. These striated irregularities typically extend in a direction perpendicular to the direction in which the molded layers are stacked. The direction in which the molded layers are stacked can be determined from the lamination marks.

[0019] The casting strength of the formwork is preferably 1 MPa or higher. This casting strength represents the surface pressure required to deform the formwork by 0.5 mm in the orthogonal direction. A casting strength of 1 MPa or higher for the formwork indicates sufficient strength to suppress deformation of the formwork caused by the load of fresh concrete poured into the formwork. A casting strength of 1 MPa or higher for the formwork suppresses deformation of the formwork caused by the load of fresh concrete. The casting strength of the formwork is preferably as high as possible, and may be 5 MPa or higher, 10 MPa or higher, or 100 MPa or lower.

[0020] The maximum thickness of the formwork is appropriately selected according to the size of the formwork. The maximum thickness of the formwork may be 0.005 to 0.01 times, or 0.01 to 0.02 times, the length in the stacking direction of the formwork. If the maximum thickness of the formwork is 0.02 to 1 time, the unfinished object with stacked layers during additive manufacturing is less likely to tip over.

[0021] The size and shape of the formwork in this disclosure are not particularly limited and can be appropriately selected according to the size and shape of the concrete panel.

[0022] (1.1) Formwork The formwork of the present disclosure comprises formwork which constitutes the bottom wall of the formwork. The formwork is used to mold fresh concrete.

[0023] Formwork is a resin-based structure formed by stacking structures created in a single continuous path. In other words, formwork is created by additive manufacturing using a 3D printer. The additive manufacturing process for formwork is not particularly limited and is appropriately selected depending on the material of the formwork and the size of the concrete panel. Examples of additive manufacturing processes include material extrusion (MEX), powder bed fusion (PBF), binder injection (BJT), directed energy deposition (DED), material jetting (MJT), sheet lamination (SHL), and vat photopolymerization (VPP).

[0024] Preferably, the aforementioned formwork is a resin-molded object formed by stacking molded layers using a material extrusion method. This allows for the production of formwork objects with a larger size (length: 1 m or more) than resin-molded objects produced by other additive manufacturing processes other than material extrusion (MEX).

[0025] The shape and size of the formwork are not particularly limited and are selected as appropriate according to the shape and size of the concrete panels, etc.

[0026] Formwork typically has lamination marks from the additive manufacturing process. The size and number of lamination marks are not particularly limited and are selected as appropriate according to the shape and size of the concrete panel, etc.

[0027] The formwork consists of a formwork section and a support section. The formwork section and the support section are formed as a single unit by a 3D printer.

[0028] (1.1.1) Formwork The formwork is in contact with the fresh concrete. In other words, the surface of the fresh concrete that is in contact with the formwork is formed to conform to the shape of the surface of the formwork that is in contact with the fresh concrete (hereinafter also referred to as the "casting surface").

[0029] In the cross-section of the formwork molded object when cut by a plane perpendicular to the stacking direction, the formwork portion is formed by one of the lines of a single continuous drawing path. As a result, deformation of the formwork portion due to thermal shrinkage of the molded layer is suppressed compared to when the formwork portion is formed by the joining of at least two lines.

[0030] The width of the track section (i.e., the thickness of the formwork) is not particularly limited and can be appropriately selected depending on the material of the formwork. The width of the track section may be 1 mm to 10 mm, or 10 mm to 100 mm.

[0031] The shape and size of the concrete placement surface are not particularly limited and are selected as appropriate according to the shape and size of the concrete panel, etc. The concrete placement surface may have a complex three-dimensional shape (e.g., a curved surface) and surface texture (e.g., an uneven shape).

[0032] (1.1.2) Support Section The support section supports the formwork. This suppresses deformation of the formwork caused by the load of fresh concrete poured into the formwork.

[0033] The support section includes multiple legs (hereinafter also referred to as "first legs") and multiple connecting sections.

[0034] (1.1.2.1) The first leg support includes a plurality of first legs. The first legs are in contact with the formwork and are spaced apart along a perpendicular direction. The first legs extend from one end to the other in the stacking direction of the formwork.

[0035] The first leg may be formed by multiple track sections that constitute a turnaround path in a single-stroke path. The multiple track sections that constitute the turnaround path may or may not be connected to each other. The shape of the first leg as viewed from the stacking direction is not particularly limited and may be straight, curved (e.g., V-shaped and W-shaped), polygonal, or irregular. A straight line may or may not extend along the direction of gravity. "Direction of gravity" refers to a direction perpendicular to the stacking direction and the perpendicular direction. The number of track sections that constitute one first leg (i.e., a turnaround path) may be selected appropriately according to the shape and size of the concrete panel, and may be two to four.

[0036] The number of first legs is selected appropriately according to the size of the concrete panel, etc. The number of first legs may be 2 to 5, 5 to 20, or 20 to 100.

[0037] The spacing between adjacent first legs in the orthogonal direction is appropriately selected according to the shape and size of the concrete panel, etc. Multiple first legs may or may not be arranged at equal intervals in the orthogonal direction.

[0038] (1.1.2.2) The connecting support portion includes the connecting portion. The connecting portion is not in contact with the formwork portion and connects adjacent first legs among a plurality of first legs.

[0039] Due to the nature of the shaping layer being formed in a continuous path, the connection part is inevitably formed. The connection part may extend from one end to the other end in the stacking direction of the block plates.

[0040] The connection part preferably includes at least one second leg portion. The second leg portion extends from one end to the other end in the stacking direction of the block plates. In the cross section, the second leg portion is formed by a plurality of line portions that constitute a turning path in the continuous path. That is, the second leg portion does not contact the block plate portion. Thereby, compared with the case where the connection part does not include the second leg portion, the deformation of the block plate portion due to the thermal shrinkage of the shaping layer and the deformation of the block plate portion due to the load of the fresh concrete driven into the formwork are suppressed.

[0041] The number of the second leg portions is not particularly limited and is appropriately selected according to the size of the concrete panel and the like. The number of the second leg portions may be 2 to 5, or may be 5 to 20, or may be 20 to 100. The number of the second leg portions arranged between the first leg portions adjacent to each other in the orthogonal direction is not particularly limited and may be 1 to 5, or may be 5 to 20.

[0042] The interval between the second leg portions adjacent to each other in the orthogonal direction is appropriately selected according to the shape and size of the concrete panel and the like. The plurality of second leg portions may be arranged at equal intervals or may not be arranged at equal intervals in the orthogonal direction.

[0043] When the connection part includes at least one second leg portion, it is preferable that the first leg portion and the second leg portion are alternately arranged at equal intervals along the orthogonal direction. Thereby, compared with the case where the first leg portion and the second leg portion are not alternately arranged at equal intervals along the orthogonal direction, the deformation of the block plate portion due to the load of the fresh concrete driven into the formwork is suppressed.

[0044] (1.1.3) The side wall resin molded object may further include a block plate molded object for side wall that constitutes the side wall of the formwork.

[0045] (1.1.4) Materials (1.1.4.1) Thermoplastic resin formwork The formwork contains a thermoplastic resin, and the tensile modulus of the thermoplastic resin at 25°C is preferably 400 MPa or more. This gives the formwork sufficient hardness. Therefore, the formwork is less likely to deform when fresh concrete is poured. As a result, the formwork of this disclosure can accurately form concrete panels having a desired shape. The tensile modulus of the thermoplastic resin is more preferably 1000 MPa or more, and even more preferably 2000 MPa or more, from the viewpoint of reducing the thickness of the resin formwork in order to ensure the necessary rigidity as formwork for concrete panels.

[0046] The tensile modulus is measured in accordance with JIS K7161-2:2014. The test specimen is type 1A, the test temperature is 23 degrees Celsius, and the test speed is 1.0 mm / min.

[0047] The resin molded object may contain a thermoplastic resin, or may consist solely of a thermoplastic resin.

[0048] In this disclosure, "thermoplastic resin" means a resin with a tensile modulus of 6.0 × 10⁻⁶ at 25°C. ８ This indicates a thermoplastic resin with a strength of Pa or higher.

[0049] The thermoplastic resin is not particularly limited, and known thermoplastic resins can be used. Examples include general-purpose plastics, engineering plastics, and super engineering plastics. Examples of general-purpose plastics include high-density polyethylene (HDPE), low-density polyethylene (LDPE), propylene polymers (propylene homopolymer (PP), etc.), polyvinyl chloride (PVC), polyvinylidene chloride polystyrene (PS), polyvinyl acetate (PVAc), polytetrafluoroethylene (PTFE), acrylonitrile butadiene styrene resin (ABS resin), styrene acrylonitrile copolymer (AS resin), and acrylic resin (PMMA, etc.). Examples of engineering plastics include polyamide (PA), polyacetal (POM), polycarbonate (PC), modified polyphenylene ether (m-PPE, modified PPE, PPO), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), syndiotactic polystyrene (SPS), and cyclic polyolefin (COP). Examples of super engineering plastics include polyphenylene sulfide (PPS), polytetrafluoroethylene (PTFE), polysulfone (PSF), polyethersulfone (PES), amorphous polyarylate (PAR), polyetheretherketone (PEEK), thermoplastic polyimide (PI), and polyamideimide (PAI). Thermoplastic resins may be used individually or in combination of two or more types.

[0050] If the resin molded object contains thermoplastic resin, the thermoplastic resin content may be 0.1% to 100% by mass, 10% to 70% by mass, or 20% to 60% by mass, relative to the total mass of the resin molded object.

[0051] (1.1.4.2) Filler resin molded product may contain a filler. Examples of fillers include inorganic powders, glossy inorganic powders, composite inorganic powders, and inorganic fibers. Examples of inorganic powders include talc, titanium dioxide, black titanium dioxide, and ultramarine. Examples of glossy inorganic powders include bismuth oxychloride, titanium dioxide coated mica, iron oxide coated mica, and iron oxide coated titanium mica. Examples of composite inorganic powders include fine particle titanium dioxide coated titanium mica, fine particle zinc oxide coated titanium mica, barium sulfate coated titanium mica, and titanium dioxide-encapsulated silica. Examples of inorganic fibers include glass fibers. A single type of filler may be used, or two or more types may be used in combination.

[0052] The shape of the filler may be spherical, plate-shaped, or needle-shaped. The filler may be porous or non-porous.

[0053] If the resin molded object contains a filler, the filler content may be 5% to 70% by mass relative to the total mass of the resin molded object.

[0054] (1.1.4.3) Thermoplastic elastomer resin molded products may contain a thermoplastic elastomer or may consist of a thermoplastic elastomer.

[0055] A "thermoplastic elastomer" is a material that possesses rubber-like elasticity. Specifically, a "thermoplastic elastomer" has a tensile modulus of 6.0 × 10⁻⁶ at 25°C. ８ This refers to thermoplastic resins with a Pa rating of less than 1.5.

[0056] The thermoplastic elastomer may be a copolymer containing structural units derived from an α-olefin and structural units derived from another olefin different from the α-olefin. Examples of α-olefins include 1-butene, 1-pentene, 1-hexene, 3-methyl-1-butene, 3,3-dimethyl-1-butene, 4-methyl-1-pentene, and 1-octene. Preferred other olefins different from the α-olefin are olefins having 2 to 4 carbon atoms, such as ethylene, propylene, and butene.

[0057] If the resin molded product contains a thermoplastic elastomer, the thermoplastic elastomer content may be 0.1% to 100% by mass or 10% to 70% by mass, relative to the total amount of the resin molded product.

[0058] (1.1.4.4) Used resin: It is preferable that the resin molded product contains used resin. This reduces the environmental burden.

[0059] The used resin is not particularly limited as long as it is a used resin. The used resin may be the resin used in the resin molded object of the mold of the disclosure, or it may be the resin used in an object other than the resin molded object of the mold of the disclosure.

[0060] (1.1.4.5) Biomass-derived resin: It is preferable that the resin molded product contains a biomass-derived resin. Since biomass-derived resin is a carbon-neutral material, it can reduce the environmental burden in the manufacturing of resin molded products.

[0061] Monomers used as raw materials for biomass-derived thermoplastic resins can be obtained by cracking biomass naphtha or by synthesis from biomass-derived ethylene. Biomass-derived thermoplastic resins are obtained by polymerizing the biomass-derived monomers synthesized in this way using the same method as when using conventionally known petroleum-derived thermoplastic resins. Polymers of thermoplastic resins synthesized using bio-derived monomers as raw materials become biomass-derived thermoplastic polymers. The content of bio-derived thermoplastic polymer in the raw material monomers is greater than 0% by mass, may be 100% by mass, or less than 100% by mass, relative to the total amount of raw material monomers. The "biomass content" indicates the content of biomass-derived carbon and is calculated by measuring radioactive carbon (C14). Atmospheric carbon dioxide contains a certain percentage of C14 (approximately 105.5 pMC). Therefore, it is known that the C14 content in plants that grow by taking in atmospheric carbon dioxide (e.g., corn) is also about 105.5 pMC. It is also known that fossil fuels contain almost no C14. Therefore, by measuring the proportion of C14 in the total carbon atoms in the polymer, the biomass-derived carbon content in the raw material can be calculated. The thermoplastic polymer used as a raw material in this disclosure may include a thermoplastic polymer obtained by recycling, so-called recycled polymer. "Recycled polymer" includes polymers obtained by recycling waste polymer products, and can be produced, for example, by the method described in DE102019127827 (A1). The recycled polymer may include a marker that identifies it as having been obtained by recycling.

[0062] (1.2) Molding Members The formwork of this disclosure may further comprise molding members different from the formwork. The molding members mold fresh concrete. Examples of molding members include formwork and cores. "Core" refers to a mold placed in a concrete panel to form a hollow section. Examples of materials for the molding members include wood, metal, and resin. The molding members may be known molding members.

[0063] (1.3) Support structures The formwork of the present disclosure preferably further comprises support structures for fixing the side walls of the formwork.

[0064] "Scaffolding" refers to temporary structures used to fix formwork in place.

[0065] The formwork of this disclosure, further equipped with shoring, ensures that the side walls of the formwork are more securely held than in a configuration without shoring. As a result, the desired concrete panels are easier to form.

[0066] The shoring may be any known type of shoring. Examples of materials for the shoring include resin, metal, and resin.

[0067] (2) Method for manufacturing a formwork The method for manufacturing a formwork of the present disclosure is a method for manufacturing a formwork of the present disclosure. The manufacturing method comprises forming the molding layer in a single continuous path by a material extrusion method, and stacking the molding layers to produce the formwork (hereinafter also referred to as the "molding process").

[0068] Because the formwork manufacturing method of this disclosure has the above configuration, it is possible to manufacture formwork that can accurately form concrete panels having a desired shape. Furthermore, the formwork manufacturing method of this disclosure can manufacture formwork while suppressing increases in dimensional accuracy, molding time, and material usage.

[0069] (2.1) Forming Process The method for manufacturing a mold according to the present disclosure includes a forming process. In the forming process, the forming layer is formed in a single continuous path by a material extrusion method, and the forming layer is stacked to produce the formwork.

[0070] The fabrication process is carried out using a 3D printer employing the material extrusion method. Any known 3D printer will suffice.

[0071] (2.2) Installation process If the formwork comprises at least one of the molding member and the support structure, the method for manufacturing the formwork of the present disclosure may further include an installation step. In the installation step, the molding member and the support structure are attached to the formwork. The installation step is performed after the molding step is completed.

[0072] The method for attaching at least one of the molded member and the support structure to the formwork is not particularly limited and may be a known method.

[0073] (3) Method for manufacturing a concrete panel The method for manufacturing a concrete panel according to the present disclosure includes: preparing the formwork and the fresh concrete according to the present disclosure using the method for manufacturing the formwork according to the present disclosure (hereinafter also referred to as the "preparation step"); pouring the fresh concrete into the formwork and curing it to form a concrete panel (hereinafter also referred to as the "concrete forming step"); and demolding the formwork from the concrete panel (hereinafter also referred to as the "demolition step"). The preparation step, the concrete forming step and the demolition step are carried out in this order.

[0074] Since the concrete panel manufacturing method of this disclosure has the above configuration, it is possible to manufacture a desired concrete panel.

[0075] (3.1) Preparation Step The method for manufacturing a concrete panel according to the present disclosure includes a preparation step. In the preparation step, the formwork and fresh concrete according to the present disclosure are prepared.

[0076] Methods for preparing the formwork of this disclosure include, for example, manufacturing the formwork of this disclosure using the formwork manufacturing method described above, and obtaining the formwork of this disclosure from another company. The method for preparing the fresh concrete is not particularly limited and any known method is acceptable.

[0077] The composition of fresh concrete is not particularly limited and is appropriately selected depending on the application of the concrete panel. Fresh concrete may contain cement, aggregate, and water, and may further contain admixtures. Examples of cement include ordinary Portland cement, rapid-hardening Portland cement, ultra-rapid-hardening Portland cement, low-heat Portland cement, and moderate-heat Portland cement. The unit cement content is preferably 270 kg / m³. ３ ~500 kg / m ３It may be. Examples of the aggregate include fine aggregate (e.g., river sand, mountain sand, and land sand, etc.) and coarse aggregate (e.g., river gravel, mountain gravel, and crushed stone, etc.). The unit amount of the aggregate may be 500 kg / m ３ to 1100 kg / m ３ It may be. Examples of the water include tap water and treated sewage water. The unit amount of water may be 100 kg / m ３ to 200 kg / m ３ It may be. Examples of the admixture include air-entraining agent (AE agent), water-reducing agent, foaming agent, blowing agent, setting regulator, hardening accelerator, waterproof agent, water-repellent agent, water-retaining agent, rust inhibitor, thickening agent, pigment, and efflorescence inhibitor, etc.

[0078] (3.2) Mold Release Agent Coating Step The method for manufacturing a concrete panel of the present disclosure preferably further includes applying a mold release agent to the placement surface of the retaining wall-shaped object (hereinafter also referred to as the "mold release agent coating step"). The application of the mold release agent (mold release agent coating step) is performed before the implementation of the formation of the concrete panel (concrete formation step). Thereby, a mold release agent layer is likely to be formed on the placement surface of the retaining wall-shaped object. Therefore, the concrete panel is more easily demolded than when the mold release agent coating step is not performed.

[0079] The mold release agent is not particularly limited. For example, it includes fluorine compound type mold release agents (e.g., triperfluorooctyl phosphate and triperfluorododecyl phosphate, etc.), silicone compound type mold release agents (dimethylpolysiloxane and amino-modified dimethylpolysiloxane, etc.), fatty acid ester type mold release agents (e.g., butyl stearate and hydrogenated castor oil, etc.), and waxes (paraffin wax and microcrystalline wax, etc.). The mold release agent may contain an organic solvent (e.g., toluene and n-hexane, etc.). The application method of the mold release agent is not particularly limited and may be a known method. The amount of one-time application of the mold release agent is not particularly limited and may be a commonly used amount (e.g., 200 cc / m ２ ).

[0080] (3.3) Concrete Forming Process The method for manufacturing a concrete panel according to the present disclosure includes a concrete forming process. In the concrete forming process, fresh concrete is poured into the formwork and cured to form the concrete panel.

[0081] The method of driving in the concrete and the method of curing are not particularly limited and any known method is acceptable.

[0082] (3.4) Demolding Process The method for manufacturing a concrete panel according to the present disclosure includes a demolding process. In the demolding process, the formwork is removed from the concrete panel.

[0083] The method for removing the formwork is not particularly limited and may be a known method.

[0084] (3.5) Concrete Panels The shape and size of concrete panels obtained by the manufacturing method of concrete panels of this disclosure are not particularly limited and are appropriately selected according to the application of the concrete panel. Examples of applications for concrete panels include building materials for civil engineering structures and building structures.

[0085] (4) An example of the formwork of the present disclosure will be described below with reference to Figures 1 to 3.

[0086] (4.1) Formwork The formwork 1A according to the first embodiment is a formwork into which fresh concrete 100U is poured. The formwork 1A is used to manufacture the concrete panel 100 shown in Figure 1. A complex three-dimensional shape is formed on the main surface S100 of the concrete panel 100.

[0087] As shown in Figure 2, the formwork 1A comprises a formwork molded object 10A and a side wall formwork plate 20. The formwork molded object 10A constitutes the bottom wall of the formwork 1A. The side wall formwork plate 20 is fixed to the formwork molded object 10A. The formwork molded object 10A is a resin molded object formed by stacking molded layers formed in a single continuous path R10A (see Figure 3) using a material extrusion method.

[0088] (4.1.1) Formwork As shown in Figure 3, the formwork 10A has a formwork section 11 and a support section 12A. The formwork section 11 is in contact with the fresh concrete 100U. The support section 12A supports the formwork section 11. The formwork section 11 and the support section 12A are formed as a single unit by a 3D printer.

[0089] The casting strength of the formwork 10A is 1 MPa or more. This casting strength indicates the surface pressure required to deform the formwork portion 11 by 0.5 mm in direction D3.

[0090] The maximum thickness T10 of the formwork molded object 10A is appropriately selected according to the size of the formwork molded object 10A, etc. The maximum thickness T10 of the formwork molded object 10A (see Figure 3) may be 0.005 to 0.01 times, and may be 0.01 to 0.02 times, the length of the stacking direction D1 of the formwork molded object 10A. If the maximum thickness T10 of the formwork molded object 10A is 0.02 to 1 time, the unfinished object with the molded layers stacked during additive manufacturing is less likely to tip over.

[0091] (4.1.1.1) Formwork The casting surface S11 of the formwork section 11 has a complex three-dimensional shape (see Figure 2).

[0092] In the cross-section obtained by cutting the formwork 10A with a plane perpendicular to the stacking direction D1, the formwork portion 11 is formed by one of the track sections (see Figure 3) of the single-stroke path R10A.

[0093] The width T11 of the track section (i.e., the thickness T11 of the formwork section 11) (see Figure 3) is not particularly limited and is appropriately selected according to the material of the formwork structure 10A. The width T11 of the track section may be 1 mm to 50 mm.

[0094] (4.1.1.2) Support section The support section 12A includes a plurality of first leg sections 121A and a plurality of connecting sections 122A.

[0095] The first leg portion 121A is in contact with the formwork portion 11 and is spaced apart along the perpendicular direction D2. The first leg portion 121A extends from one end to the other in the stacking direction D1 of the formwork portion 11. The first leg portion 121A is formed by two track sections that constitute a return path in the single-stroke path R10A. The two track sections that constitute the return path are joined to each other by heat welding. The shape of the first leg portion 121A as viewed from the stacking direction D1 of the molded layers is a straight line extending along the direction of gravity D3.

[0096] The connecting portion 122A does not come into contact with the formwork portion 11 and connects adjacent first leg portions 121A among the multiple first leg portions 121A. The connecting portion 122A is inevitably formed due to the nature of the molded layer being formed along a single-stroke path R10A.

[0097] The connecting portion 122A includes a plurality of second leg portions 1221 and a plurality of skirting plate portions 1222.

[0098] The second leg portion 1221 extends from one end to the other in the stacking direction D1 of the formwork portion 11, similar to the first leg portion 121A. In the cross-section when the formwork 10A is cut by a plane perpendicular to the stacking direction D1, the second leg portion 1221 is formed by two track sections that constitute the return path of the single-stroke path R10A. The first leg portion 121A and the second leg portion 1221 are arranged alternately at equal intervals along the orthogonal direction D2.

[0099] The skirting plate portion 1222 connects adjacent first leg portion 121A and second leg portion 1221 in the orthogonal direction D2.

[0100] The formwork 10A preferably contains used resin. The formwork 10A preferably contains biomass-derived resin.

[0101] (4.1.2) Side wall formwork The side wall formwork 20 is made of known formwork. The side wall formwork 20 is made of wood.

[0102] (4.1.3) Effects and Operation As explained with reference to Figures 1 to 3, the formwork 1A includes a formwork molded object 10A. The formwork molded object 10A is a resin molded object formed by stacking molded layers formed by a single-stroke path R10A. The formwork molded object 10A has a formwork portion 11 and a support portion 12A. The support portion 12A includes a plurality of first leg portions 121A and a plurality of connecting portions 122A. In the cross-section when the formwork molded object 10A is cut by a plane perpendicular to the stacking direction D1, the formwork portion 11 is formed by one of the track portions of the single-stroke path R10A. Therefore, the casting strength required to suppress deformation of the formwork portion 11 due to the load of fresh concrete 100U poured into the formwork 1A is higher than the casting strength of a cylindrical formwork molded object 210A (see Figure 10). In other words, the formwork section 11 is less prone to deformation due to the load of the fresh concrete 100U. In addition, the formwork section 11 is not formed solely by the connection of two parallel tracks. Therefore, due to thermal shrinkage of the molded layer, the formwork section 11 is less prone to deformation than the formwork section 211 of the formwork molded object 210B (see Figure 11). In other words, the dimensions of the formwork section 11 are less likely to deviate from the dimensions of the 3D model data. As a result, the formwork 1A can accurately form concrete panels with the desired shape.

[0103] As explained with reference to Figures 1 to 3, the connecting portion 122A includes the second leg portion 1221. In the cross-section when the formwork 10A is cut by a plane perpendicular to the stacking direction D1, the second leg portion 1221 is formed by two track sections that constitute the return path of the single-stroke path R10A. In other words, the second leg portion 1221 is not in contact with the formwork portion 11. As a result, deformation of the formwork portion 11 due to thermal shrinkage of the molded layer and deformation of the formwork portion 11 due to the load of the fresh concrete 100U poured into the formwork 1A are suppressed compared to the case where the connecting portion 122A does not include the second leg portion 1221.

[0104] As explained with reference to Figures 1 to 3, the first leg portion 121A and the second leg portion 1221 are arranged alternately at equal intervals along the orthogonal direction D2. As a result, deformation of the formwork portion 11 caused by the load of fresh concrete 100U poured into the formwork 1A is suppressed compared to when the first leg portion 121A and the second leg portion 1221 are not arranged alternately at equal intervals along the orthogonal direction D2.

[0105] As explained with reference to Figures 1 to 3, the casting strength of the formwork structure 10A is 1 MPa or more. This suppresses deformation of the formwork section 11 caused by the load of the fresh concrete 100U.

[0106] As explained with reference to Figures 1 to 3, the formwork 10A is a resin-formed object created by stacking layers using a material extrusion method. This results in a formwork 10A having a larger size (length: 1 m or more) than objects formed by other additive manufacturing processes other than material extrusion (MEX).

[0107] As explained with reference to Figures 1 to 3, it is preferable that the formwork 10A contains used resin. This reduces the environmental burden.

[0108] As explained with reference to Figures 1 to 3, it is preferable that the formwork molded object 10A contains a biomass-derived resin. Since the biomass-derived resin is a carbon-neutral material, the environmental burden in the manufacturing of the formwork molded object 10A can be reduced.

[0109] (4.2) Method for manufacturing formwork The method for manufacturing formwork of the first embodiment is a method for manufacturing formwork 1A. The manufacturing method includes a molding step and a removal step. The molding step and the installation step are carried out in this order.

[0110] (4.2.1) Molding Process In the molding process, a 3D printer using the material extrusion method is used to form the molded layers in a single continuous path R10A, and the molded layers are stacked to produce a formwork 10A.

[0111] (4.2.2) Installation process In the installation process, the side wall formwork 20 is attached to the formwork molded object 10A. This gives rise to the formwork 1A.

[0112] (4.2.3) Effects and Effects As explained with reference to Figures 1 to 3, the method for manufacturing formwork of the first embodiment is a method for manufacturing formwork 1A. This manufacturing method includes a molding step. As a result, the method for manufacturing formwork of the first embodiment can manufacture formwork 1A that can accurately form concrete panels 100 having a desired shape. Furthermore, the method for manufacturing formwork of the first embodiment can manufacture formwork 1A while suppressing increases in dimensional accuracy, molding time, and material usage.

[0113] (4.3) Method for manufacturing concrete panels The method for manufacturing concrete panels according to the first embodiment includes a preparation step, a concrete forming step, and a demolding step. The preparation step, the concrete forming step, and the demolding step are carried out in this order.

[0114] (4.3.1) Preparation Process In the preparation process, formwork 1A and fresh concrete 100U are prepared. The method for preparing formwork 1A is the method of manufacturing formwork according to the first embodiment. The method for preparing fresh concrete 100U can be any known method.

[0115] (4.3.2) Concrete Forming Process In the concrete forming process, as shown in Figure 4, fresh concrete 100U is poured into the formwork 1A and cured to form the concrete panel 100.

[0116] (4.3.3) Demolding Process In the demolding process, the formwork 1A is removed from the concrete panel 100. This results in the concrete panel 100.

[0117] (4.3.4) Effects and Operation As explained with reference to Figures 1 to 4, the method for manufacturing a concrete panel of the first embodiment includes a preparation step, a concrete forming step, and a demolding step. Thus, the method for manufacturing a concrete panel of the first embodiment can manufacture a desired concrete panel 100.

[0118] (5) Second Embodiment The formwork 1B according to the second embodiment is the same as the formwork 1A according to the first embodiment, except that the shape of the support part is different. The formwork 1B comprises a formwork shaped object 10B and a formwork 20 for the side wall. The formwork shaped object 10B constitutes the bottom wall of the formwork 1B.

[0119] As shown in Figure 5, the formwork 10B has a formwork section 11 and a support section 12B. The support section 12B supports the formwork section 11. The formwork 10B is the same as the formwork 10A except that the support section 12A is changed to the support section 12B.

[0120] The support portion 12B includes a plurality of first leg portions 121B and a plurality of connecting portions 122B.

[0121] The first leg portion 121B is in contact with the formwork portion 11 and is spaced apart along the orthogonal direction D2. The first leg portion 121B extends from one end to the other in the stacking direction D1 of the formwork portion 11. The first leg portion 121B is formed by two track sections that constitute a return path in the single-stroke path R10B. The two track sections that constitute the return path are not connected to each other. The shape of the first leg portion 121B as viewed from the stacking direction D1 of the molded layers is V-shaped. The first leg portion 121B is spaced equally along the orthogonal direction D2.

[0122] The connecting portion 122B does not come into contact with the formwork portion 11 and connects adjacent first leg portions 121B among the multiple first leg portions 121B. The connecting portion 122B is inevitably formed due to the nature of the molded layer being formed along a single-stroke path R10B.

[0123] The connecting portion 122B does not include the second leg portion. The shape of the connecting portion 122B when viewed from the stacking direction D1 of the molded layers is V-shaped. One connecting portion 122B consists of two consecutive apron portions.

[0124] Formwork 1B is the same as formwork 1A, except that support part 12A is changed to support part 12B. Therefore, formwork 1B has the same effects and functions as formwork 1A.

[0125] (6) Third Embodiment The formwork 1C according to the third embodiment is the same as the formwork 1A according to the first embodiment, except that the shape of the support part is different. The formwork 1C comprises a formwork shaped object 10C and a formwork 20 for the side wall. The formwork shaped object 10C constitutes the bottom wall of the formwork 1C.

[0126] As shown in Figure 6, the formwork 10C has a formwork section 11 and a support section 12C. The support section 12C supports the formwork section 11. The formwork 10C is the same as the formwork 10A except that the support section 12A is changed to the support section 12C.

[0127] The support portion 12C includes a plurality of first leg portions 121C and a plurality of connecting portions 122C.

[0128] The first leg portion 121C is in contact with the formwork portion 11 and is spaced apart along the orthogonal direction D2. The first leg portion 121C extends from one end to the other in the stacking direction D1 of the formwork portion 11. The first leg portion 121C is formed by two track sections that constitute a return path in the single-stroke path R10C. The two track sections that constitute the return path are not connected to each other. The shape of the first leg portion 121C as viewed from the stacking direction D1 of the molded layers is V-shaped. The first leg portion 121C is spaced equally along the orthogonal direction D2.

[0129] The connecting portion 122C does not come into contact with the formwork portion 11 and connects adjacent first leg portions 121C among the multiple first leg portions 121C. The connecting portion 122C is inevitably formed due to the nature of the molded layer being formed along a single-stroke path R10C.

[0130] Formwork 1C is the same as formwork 1A, except that support part 12A has been changed to support part 12C. Therefore, formwork 1C has the same effects and functions as formwork 1A.

[0131] The present disclosure will be described in further detail below based on examples. However, the present disclosure is not limited to these examples.

[0132] [1] Example 1 [1.1] Molding Process [1.1.1] Raw Materials The following raw materials were prepared as raw materials for molding.

[0133] [1.1.1.1] Thermoplastic elastomer - "Toughmer (registered trademark) XM-7090" (manufactured by Mitsui Chemicals, Inc., material: propylene polymer, melting point Tm: 98°C, Shore D hardness: 58, MFR: 7.0 g / min, tensile modulus at 25°C: 6.0 × 10⁻⁶) ８ (Less than Pa) Note that the melting point Tm, Shore D hardness, and MFR values ​​are catalog values.

[0134] [1.1.1.2] Thermoplastic plastic - "Prime Polypro (registered trademark) J-105G" (manufactured by Prime Polymer Co., Ltd., material: propylene homopolymer, crystallization temperature Tc: 116.4°C, degree of crystallinity: 52.2%, tensile modulus at 25°C: 6.0 × 10⁸ Pa or higher). Note that the crystallization temperature Tc and Shore D hardness values ​​are catalog values.

[0135] [1.1.1.3] Inorganic filler - "Talc" (product average particle size: 5 μm to 10 μm) "0000" [1.1.1.4] Molding material The thermoplastic elastomer (40 parts by mass), thermoplastic plastic (20 parts by mass), and inorganic filler (40 parts by mass) shown below were blended and kneaded using an extruder (model number KTX-30, manufactured by Kobe Steel, Ltd.) to obtain a PP compound. The obtained PP compound was extruded from a nozzle and cut at 4 mm intervals to obtain particulate molding material of 4 mm × 3 mm × 2 mm. The extruder conditions were as follows: Cylinder temperature: C1 = 50°C, C2 = 90°C, C3 = 100°C, C4 = 120°C, C5 = 180°C, C6 = 200°C, C7 to C14 = 200°C; Die temperature: 200°C; Screw rotation speed: 500 rpm; Extrusion rate: 40 kg / h.

[0136] [1.1.2] A 3D printer for additive manufacturing material extrusion (EXF-12, manufactured by Extrabold Co., Ltd.), slicer software (UltimakerCURA, manufactured by Ultimaker Inc.), and CAD software (CATIA V5, manufactured by Dassault Systèmes Inc.) were used.

[0137] As 3D model data for the formwork, 3D model data 100C shown in Figure 7 was prepared. In Figure 7, the length L1 (see Figure 7) of 3D model data 100C in the stacking direction D1 was 600 mm. The length L2 (see Figure 7) of 3D model data 100C in the orthogonal direction D2 was 400 mm. The length L3 (see Figure 7) of 3D model data 100C in the gravity direction D3 was 60 mm. The maximum thickness L4 (see Figure 7) of 3D model data 100C in the gravity direction D3 was 40 mm.

[0138] Using slicer software, the 3D model data 100C was sliced ​​into sections to generate multiple 2D data sets. Based on these multiple 2D data sets, the application software's setting parameters were set as follows. Based on the setting parameters below, a molded object was produced using a Material Extrusion (MEX) 3D printer. The molded object in Example 1 had a formwork molded object. The formwork molded object in Example 1 was similar to the formwork molded object 10A (see Figure 3), except that the shape of the main surface of the casting surface S11 was different.

[0139] [1.1.2.1] Setting Parameters: • Printing Speed: 1500 mm / min • Nozzle Temperature: 200°C • Layer Thickness: 1.5 mm • Nozzle Diameter: 3 mm • Extrusion Width: 3.6 mm

[0140] [1.2] Installation Process A wooden panel made by a known method was prepared as the side wall formwork 20. The side wall formwork 20 was attached to the formwork structure. This obtained the formwork.

[0141] [1.3] Preparation Process Fresh concrete was prepared by mixing 30 parts by mass of cement, 50 parts by mass of aggregate, 8 parts by mass of water, and 0.3 parts by mass of admixture.

[0142] [1.4] Concrete Forming Process: Fresh concrete was poured into the formwork. After the pouring of the fresh concrete was completed, it was left to stand for one day to cure.

[0143] [1.5] Demolding: The formwork was removed from the concrete panel. This yielded the concrete panel. The concrete panel of Example 1 was similar to concrete panel 100, except that the shape of the main surface S100 was different.

[0144] [2] Comparative Example 1 Except for modifying the 3D model data of the formwork, the formwork and concrete panel were manufactured in the same manner as in Example 1. The formwork of Comparative Example 1 had formwork. The formwork of Comparative Example 1 was the same as the formwork 210A (see Figure 10), except that the shape of the main surface of the casting surface S11 was different.

[0145] [3] Comparative Example 2 Except for modifying the 3D model data of the formwork, the formwork and concrete panel were manufactured in the same manner as in Example 1. The formwork of Comparative Example 2 had formwork. The formwork of Comparative Example 2 was the same as formwork 210B (see Figure 11), except that the shape of the main surface of the casting surface S11 was different.

[0146] [4] Measurement Method The following measurements were performed on the formwork and other molded objects. The measurement results are shown in Table 1.

[0147] [4.1] Printing Time In the printing process, the time from when the 3D printer using the material extrusion method started the additive manufacturing of the formwork to when the additive manufacturing of the formwork was completed was measured. The measured time was defined as "printing time".

[0148] [4.2] In the mass molding process, the mass of the formwork was measured. The measured mass was referred to as "mass".

[0149] [4.3] Deformation under Loading To predict the deformation of formwork during fresh concrete placement, a strength analysis of the formwork was performed using CAE (Computer-Aided Engineering) under the following analysis conditions. As a loading method, the formwork was set up in the position used for fresh concrete placement, and a surface load was applied to the entire surface of the formwork. The magnitude of the surface load was set to approximately twice the expected mass of the fresh concrete. For each of the multiple parts of the formwork, the deformation in the direction of gravity D3 was measured from the position before and after the application of the surface load. The maximum measured value was defined as the "deformation under load".

[0150] [4.3.1] Analysis conditions and software: CATIA V5 GAE; Mesh size: 3.6 mm; Surface load: 500 N; Modulus of elasticity: 2200 MPa; Poisson's ratio: 0.38

[0151] [4.4] Dimensional accuracy The cast surface of the formwork was scanned using a 3D scanner (AMETEK's "HandySCAN BLACK Elite"). The scanned data was analyzed using analysis software (AMETEK's "VXinspect"). The ratio of the area of ​​the cast surface of the formwork that was within ±0.5 mm of the 3D model data to the total area of ​​the cast surface of the formwork was defined as "dimensional accuracy".

[0152]

[0153] [5] Results The amount of change under load in Example 1 was lower than the amount of change under load in Comparative Example 1. The dimensional accuracy of Example 1 was higher than that of Comparative Example 1. The amount of change under load in Example 1 was the same as that of Comparative Example 2, but the dimensional accuracy of Example 1 was higher than that of Comparative Example 2. From the above, it was found that the formwork of Example 1 is "a formwork that can accurately form concrete panels having a desired shape".

[0154] The disclosure of Japanese Patent Application No. 2024-228011, filed on 24 December 2024, is incorporated herein by reference in its entirety. All documents, patent applications, and technical standards described herein are incorporated herein by reference to the same extent as if each individual document, patent application, and technical standard were specifically and individually noted to be incorporated by reference.

Claims

1. A formwork into which fresh concrete is poured, comprising a formwork formwork forming a formwork bottom wall, wherein the formwork formwork is a resin formwork formed by stacking molded layers formed in a single continuous path, the formwork formwork having a formwork portion in contact with the fresh concrete, and a support portion supporting the formwork portion, the support portion including a plurality of legs that are in contact with the formwork portion and are spaced apart along a perpendicular direction perpendicular to the stacking direction of the molded layers, and a plurality of connecting portions that are not in contact with the formwork portion and connect adjacent legs among the plurality of legs, the legs extending from one end to the other in the stacking direction of the formwork, and in a cross-section when the formwork formwork is cut by a plane perpendicular to the stacking direction, the formwork portion is formed by one of the track sections of the single continuous path.

2. The formwork according to claim 1, wherein the leg portion represents a first leg portion, the connecting portion includes at least one second leg portion, the second leg portion extends from one end to the other in the stacking direction of the formwork portion, and in the cross-section, the second leg portion is formed by a plurality of track portions that constitute a return path in the single-stroke path.

3. The formwork according to claim 2, wherein the first leg portion and the second leg portion are arranged alternately at equal intervals along the orthogonal direction.

4. The formwork according to claim 3, wherein the casting strength of the formwork is 1 MPa or more, and the casting strength represents the surface pressure necessary to deform the formwork portion by 0.5 mm in the orthogonal direction.

5. The mold according to claim 1, wherein the formwork is a resin molded object formed by stacking the molded layers by a material extrusion method.

6. The mold according to claim 1, wherein the resin molded object includes used resin.

7. The mold according to claim 1, wherein the resin molded object contains a biomass-derived resin.

8. A method for manufacturing a mold for manufacturing a mold according to any one of claims 1 to 7, comprising: forming the molded layer in the single-stroke path by a material extrusion method, and stacking the molded layers to produce the formwork molded object.

9. A method for manufacturing a concrete panel, comprising: preparing a formwork and fresh concrete as described in any one of claims 1 to 7; pouring the fresh concrete into the formwork, curing it, and forming a concrete panel; and removing the formwork from the concrete panel.

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