JP7470007B2 - Material spraying device and material spraying method - Google Patents

Description

This disclosure relates to a material spraying device and a material spraying method for spraying a material that hardens over time.

Various methods of spraying materials have been known in the past. Patent Document 1 describes a construction method for prefabricated joints in which resin mortar is sprayed into the gap between the ends of concrete to form a joint. This construction method uses a self-propelled spraying device that is placed between a pair of concrete pieces.

The self-propelled spraying device is equipped with a traveling formwork that faces a pair of concrete slabs, and the formwork surface of the traveling formwork is formed with multiple openings through which resin mortar from a hose is sprayed. The traveling formwork moves at a speed that corresponds to the hardening reaction time of the resin mortar. In this self-propelled spraying device, the traveling formwork is positioned so that its formwork surface faces the gap between the pair of concrete slabs, and resin mortar is filled into the gap from the hose.

The resin mortar hardens in the gap defined by the pair of concrete slabs and the formwork surface, and after the resin mortar has hardened, the traveling formwork moves upward. In this way, the resin mortar filling work is carried out by the self-propelled spraying device by repeating the process of filling the gap with resin mortar, hardening the filled resin mortar, and moving the traveling formwork upward.

Japanese Patent Publication No. 5-18990

In the self-propelled spraying device described above, the opening for spraying the resin mortar faces in a direction perpendicular to the formwork surface, and the resin mortar is sprayed in a direction perpendicular to the formwork surface. As the resin mortar is sprayed in a direction perpendicular to the formwork surface, the sprayed resin mortar may scatter or bounce back and fall. As the sprayed material may scatter or bounce back and fall in this way, there is a concern that material loss may be significant.

The present disclosure aims to provide a material spraying device and a material spraying method that can reduce material loss.

The material spraying device of the present disclosure comprises a movable formwork that faces the core material of a structure and moves along the core material, and a spray nozzle that sprays material between the movable formwork and the core material, the spray nozzle sprays material in a direction along the formwork surface of the movable formwork into the space formed between the core material and the movable formwork , the material is a cement-based spray material that is self-supporting when sprayed, and the outer shell structure of the structure is constructed by spraying the cement-based spray material.

In this material spraying device, material is sprayed onto the core material. At this time, the movable formwork faces the core material across a space, and the material is sprayed into the space from the spray nozzle. The spray nozzle sprays the material into the space in a direction along the formwork surface of the movable formwork. Therefore, since the material is sprayed into the space surrounded by the core material and the formwork surface of the movable formwork in a direction along the formwork surface, it is possible to prevent the sprayed material from scattering. In other words, it is possible to prevent the sprayed material from scattering or bouncing off. Therefore, the space formed between the core material and the movable formwork can be efficiently filled with material, reducing loss of sprayed material.

The spray nozzle may be provided vertically above the space, and the material may be sprayed vertically downward from the vertically above the space. In this case, the material is sprayed vertically downward into the space formed between the core material and the movable formwork, so that scattering of the material out of the space can be suppressed. This makes it possible to more reliably reduce material loss.

The material spraying device described above includes a moving mechanism for moving the mobile formwork, and the moving mechanism may have a moving frame extending in the direction in which the mobile formwork moves, and a drive unit for moving the mobile formwork along the moving frame. In this case, the mobile formwork can be moved along the moving frame by the driving force of the drive unit. Therefore, the mobile formwork can be easily moved, and the work of spraying and hardening the material can be performed efficiently.

The material spraying device described above may be equipped with a nozzle orientation adjustment mechanism that changes the orientation of the spray nozzle. In this case, the material can be sprayed while changing the orientation of the spray nozzle using the nozzle orientation adjustment mechanism. This reduces bias in the amount of material sprayed and increases the uniformity of the material spray.

The material spraying method disclosed herein comprises the steps of placing a movable formwork in a position opposite the core material of a structure, and spraying material from a spray nozzle between the movable formwork and the core material. In the step of spraying material, the material is sprayed in a direction along the formwork surface of the movable formwork into the space formed between the core material and the movable formwork, the material being a cement-based spraying material that is self-supporting when sprayed, and the outer shell structure of the structure is constructed by spraying the cement-based spraying material.

In this material spraying method, the movable formwork is placed opposite the core material across a space. Then, material is sprayed into the space from a spray nozzle. At this time, the material is sprayed from the spray nozzle into the space in a direction along the formwork surface of the movable formwork. In other words, the material is sprayed in a direction along the core material and the movable formwork. Therefore, the material is sprayed so as not to hit the core material or the formwork surface, which prevents the material from scattering or bouncing back. Therefore, as with the material spraying device described above, the material can be efficiently filled between the core material and the movable formwork, reducing loss of sprayed material.

This disclosure makes it possible to reduce material loss.

Fig. 1(a) is a perspective view showing an example of a steel material for a concrete structure, and Fig. 1(b) is a perspective view showing an example of a core material for a concrete structure. Fig. 2(a) is a perspective view showing a state where a cement-based spraying material is sprayed onto the core material of Fig. 1(b) to form an outer shell, and Fig. 2(b) is a perspective view showing a state where the core material is removed from the constructed outer shell. FIG. 3 is a perspective view showing an example of a completed concrete structure. 4(a), 4(b) and 4(c) are vertical cross-sectional views showing a procedure for spraying material onto a core material by the material spraying device according to the first embodiment. FIG. 5 is a side view showing the movable form of the material spraying device according to the first embodiment. Fig. 6(a) is a diagram showing an example of a sprayed material, and Fig. 6(b) is a diagram showing a different example of the sprayed material from that shown in Fig. 6(a). FIG. 7 is a side view showing an example of the configuration of the material spraying device according to the first embodiment. FIG. 8 is a vertical cross-sectional view of the material spraying device of FIG. 7, as seen from a different direction than that of FIG. 9(a), 9(b) and 9(c) are diagrams showing an example of a state in which the material is sprayed while changing the direction of the nozzle. FIG. 10 is a side view that illustrates a schematic diagram of the nozzle direction changing mechanism of the material spraying device according to the first embodiment. 11(a) and 11(b) are cross-sectional views showing the state in which the material for the second layer is sprayed by the material spraying device according to the first embodiment. Fig. 12(a) is a side view showing a modified example of the movable form of the material spraying device, and Fig. 12(b) is a plan view showing the movable form of Fig. 12(a). 13(a) and 13(b) are vertical cross-sectional views showing a material spraying device according to a modified example. FIG. 14 is a side view showing a material spraying device according to the second embodiment. FIG. 15 is a side view showing a manner in which the movable form of the material spraying device according to the second embodiment is moved. 16(a), 16(b), 16(c) and 16(d) are vertical cross-sectional views showing steps of a material spraying device and a material spraying method according to the third embodiment.

Below, an embodiment of a material spraying device and a material spraying method according to the present disclosure will be described with reference to the drawings. In the description of the drawings, the same or corresponding elements are given the same reference numerals, and duplicated descriptions will be omitted as appropriate. In addition, the drawings may be partially simplified or exaggerated for ease of understanding, and the dimensional ratios, etc. are not limited to those shown in the drawings.

First Embodiment
In the material spraying device and material spraying method according to the first embodiment, a structure is constructed. The structure is, for example, a concrete structure. In general, when constructing a concrete structure, after assembling reinforcing bars, a formwork is arranged so as to surround the reinforcing bars, concrete is poured inside the formwork, and after curing for a certain period of time, the formwork is removed to construct the structure. Thus, in the construction of a structure, a plurality of types of work, including the arrangement of formwork, are mixed, and the work is currently complicated. In addition, in recent years, there has been a shortage of construction skilled workers, and the number of carpenter workers, such as formwork carpenters, has decreased, and there is a concern that it will be difficult to secure carpenter workers in the future.

In the material spraying device and material spraying method according to this embodiment, the outer shell of a structure is constructed by spraying a cement-based spraying material, which eliminates the need to place formwork and allows work to be carried out efficiently. As a result, even in situations where there is a shortage of workers such as carpenters, the work of constructing a structure can be carried out efficiently.

First, an example of the construction of a structure will be described. In this embodiment, a concrete structure is constructed. First, as shown in FIG. 1(a) and FIG. 1(b), a core material 1 is installed. The core material 1 includes, for example, a steel material 2 and an air tube 3. As an example, the steel material 2 includes an H-shaped steel 2b and an L-shaped steel 2c. However, the steel material may be reinforcing bars or the like, and the type is not particularly limited. Furthermore, the core material may include an expanded metal instead of the air tube 3, and the type of the core material is not particularly limited.

First, multiple steel materials 2 are arranged so that their longitudinal direction is aligned with the vertical direction D1, and are lined up along the first direction D2 and the second direction D3. At this time, the multiple steel materials 2 are arranged so that they form a frame in a plan view. The first direction D2 indicates the longitudinal direction of the multiple steel materials 2 in a plan view, and the second direction D3 indicates the transverse direction of the multiple steel materials 2 in a plan view.

In plan view, the multiple steel materials 2 may be arranged to form a rectangular frame. In this case, the four L-shaped steel pieces 2c form the corners of the steel material 2 in plan view, and the multiple H-shaped steel pieces 2b form the sides of the steel material 2 in plan view. For example, each H-shaped steel piece 2b is arranged so that the flange portion faces the outside of the steel material 2 in plan view, and each L-shaped steel piece 2c is arranged so that the outer surface of the L-shape faces the outside of the steel material 2 in plan view.

For example, two groups C1 each consisting of a plurality (three) of H-shaped steel bars 2b aligned along the first direction D2 are aligned along the second direction D3, and then L-shaped steel bars 2c are placed at one end and the other end of each group C1. Then, H-shaped steel bars 2b are placed between the pair of L-shaped steel bars 2c aligned along the second direction D3. The steel materials 2 are arranged as described above as an example, but the type, number and arrangement of the steel materials 2 are not limited to the above example and can be changed as appropriate.

After the steel material 2 is placed, the air tube 3 is placed. The air tube 3 is, for example, columnar. The cross section of the air tube 3 cut in a direction perpendicular to the longitudinal direction is, for example, rectangular with rounded corners. The air tube 3 is placed between a pair of steel materials 2. As a specific example, the air tube 3 is placed between the web of the H-shaped steel 2b and the inner surface of the L-shaped steel 2c, and between the webs of a pair of H-shaped steels 2b aligned along the first direction D2.

For example, the air tube 3 may include a first air tube 3b having a large cross-sectional area when cut in a plane perpendicular to the longitudinal direction, and a second air tube 3c having a small cross-sectional area. As an example, the first air tube 3b is arranged so that the long side of the cross-section is aligned with the first direction D2, and the second air tube 3c is arranged so that the long side of the cross-section is aligned with the second direction D3.

For example, two sets C2 each consisting of a plurality of first air tubes 3b (four in one example) aligned along the first direction D2 are aligned along the second direction D3, and then a plurality of second air tubes 3c (two in one example) are placed between each pair of sets C2. The above is an example of the arrangement of the air tubes 3, but the type, shape, size, number and arrangement of the air tubes 3 are not limited to the above example and can be changed as appropriate.

After the core material 1 (steel material 2 and air tubes 3) is placed, as shown in Figures 2(a) and 2(b), a material M with a certain thickness T is sprayed onto the outer periphery 1b of the core material 1 in a plan view to form the outer shell S1 of the structure S. In this disclosure, "material" refers to a material that hardens over time, and examples of such materials include concrete, mortar, and cement-based materials.

This spraying of material M is performed by the material spraying device and material spraying method according to the present embodiment. In this embodiment, the hardened material M becomes the outer shell S1, making it possible to eliminate the need for a formwork. In addition, since the outer shell S1 of the structure S can be formed by spraying material M, automating the spraying of material M makes it possible to mechanically construct the outer shell S1, which corresponds to the formwork of the structure S. Furthermore, since the outer shell S1 is formed from material M, it is possible to eliminate the need for demolding work, and when a material with higher density and strength than normal concrete is used as material M, it is possible to expect an effect of increasing the durability of the structure of the outer shell S1. In addition, when the core material 1 includes H-shaped steel 2b, the H-shaped steel 2b improves the structural performance of the structure S.

For example, material M is composed of a material that is self-supporting when sprayed from the material spraying device, and can continue to be sprayed in a self-supporting state. As an example, material M is a cement-based material. Material M is sprayed, for example, onto the outer peripheral surface 2d of steel material 2 and the outer peripheral surface 3d of air tube 3. The outer peripheral surface 2d of steel material 2 includes, for example, the outer surface of the flange of H-shaped steel 2b and the outer surface of L-shaped steel 2c. The outer peripheral surface 3d of air tube 3 is the outer surface of air tube 3 exposed between a pair of steel materials 2 (H-shaped steel 2b or L-shaped steel 2c).

After spraying the material M and allowing it to harden, the air tube 3 is removed and the air tube 3 is removed. Then, as shown in Figures 2(b) and 3, a reinforcing bar cage is placed in the hollow portion S2 inside the outer shell S1, and concrete S3 is poured, completing the construction of the structure S, which is a concrete structure.

However, as shown in FIG. 2(a), when spraying material M, if material M is sprayed directly onto the outer periphery 1b of the core material 1 (for example, from a direction perpendicular to the surface of the outer periphery 1b), the sprayed material M may scatter and rebound (the phenomenon in which material M bounces back), resulting in a loss of material M. In addition, it is necessary to finish the side (surface) of the sprayed material M and adjust the thickness T, which is the spray thickness, and further, there may be cases in which it is not possible to secure enough space for spraying material M.

In contrast, the material spraying device and material spraying method according to this embodiment are capable of solving the above-mentioned various problems. Figures 4(a), 4(b), and 4(c) are vertical cross-sectional views that show a schematic view of the material spraying device 10 according to this embodiment. As shown in Figure 4(a), the material spraying device 10 includes a movable formwork 11 that faces the core material 1, and a spray nozzle 12 that sprays the material M.

Figure 5 is an enlarged side view of the mobile formwork 11. As shown in Figures 4 and 5, the mobile formwork 11 includes, for example, a formwork surface portion 11c having a formwork surface 11b facing the core material 1, and a support portion 11d that supports the formwork surface portion 11c on the opposite side of the core material 1.

In this disclosure, "mobile formwork" refers to a formwork that can be moved. "Mobile formwork" includes not only formwork that moves during construction, but also formwork that does not move depending on the situation at the site. As a specific example, it includes a mobile formwork 41 that does not need to be moved because the core material 51 is low, as shown in FIG. 16 described later. In this disclosure, "formwork surface" refers to the surface of the mobile formwork that faces the core material. The "formwork surface" is, for example, a flat surface of the mobile formwork that faces the core material. However, the "formwork surface" may be a surface other than a flat surface, and may be, for example, a curved surface or a shape that has at least a portion of unevenness.

For example, the formwork surface 11b has a rectangular shape, and the formwork surface portion 11c has a plate shape. As an example, the support portion 11d has a trapezoidal shape that decreases in size as it moves away from the formwork surface portion 11c in a side view. However, the shapes of the formwork surface 11b, the formwork surface portion 11c, and the support portion 11d are not limited to the above example and can be changed as appropriate. As an example, the movable formwork may have a curved formwork surface.

The movable formwork 11 is made of, for example, steel. However, the movable formwork 11 may also be made of, for example, wood or resin, and the material of the movable formwork 11 is not particularly limited. The movable formwork 11 is positioned so that the formwork surface 11b faces the core material 1 so that the distance from the core material 1 matches the thickness T described above.

The spray nozzle 12 is supported, for example, by the movable formwork 11. As an example, the spray nozzle 12 is supported by the support portion 11d of the movable formwork 11 via a support mechanism (not shown). The spray nozzle 12 faces the space K formed between the core material 1 and the movable formwork 11. The spray nozzle 12 faces the space K along a direction D5 that intersects (for example, perpendicular to) the direction D4 (for example, the horizontal direction) in which the core material 1 and the movable formwork 11 are aligned. The direction D5 may, for example, coincide with the vertical direction D1. The direction D5 may also be parallel to the formwork surface 11b.

Next, an example of the material spraying method according to this embodiment will be described. First, as shown in Figures 4(a) and 4(b), a movable formwork 11 is installed opposite the core material 1 with a space K between them (step of installing the movable formwork). Then, the spray nozzle 12 is positioned so that it is aligned with the space K along the direction D5 (step of placing the spray nozzle).

As described above, with the spray nozzle 12 positioned, the material M is sprayed from the spray nozzle 12 in the direction D5 (the process of spraying the material). Since the direction D5 is a direction along the formwork surface 11b, the material M is sprayed along the formwork surface 11b.

"Spraying the material in a direction along the formwork surface" includes both spraying the material in the direction in which the movable formwork moves and spraying the material in a direction along the core material. Furthermore, "spraying the material in a direction along the formwork surface" includes not only spraying the material parallel to the formwork surface, but also spraying the material obliquely to the formwork surface (or core material) as shown in FIG. 9 and other figures described below. "Spraying obliquely to the formwork surface" refers to spraying the material by tilting the spray nozzle so that the material does not scatter. In the specific example of FIG. 4, the spray nozzle 12 sprays the material M vertically downward. The material M sprayed from the spray nozzle 12 fills the space K. After being sprayed from the spray nozzle 12, the material M hardens over time (process of hardening the material).

In accordance with the hardening speed of material M (e.g., when material M can stand on its own), as shown in FIG. 4(c), the movable formwork 11 and the spray nozzle 12 move along direction D5 (e.g., vertically upward) (step of moving the movable formwork). For example, the spray nozzle 12 moves integrally with the movable formwork 11 (step of moving the spray nozzle). After that, the spray nozzle 12 sprays material M along direction D5.

As described above, the construction of the outer shell S1 is completed by spraying the material M while repeatedly moving the movable formwork 11 in the direction D5, spraying the material M in the direction D5 of the spray nozzle 12, and allowing the material M to stand on its own. By spraying the material M in this manner, the material M can be sprayed efficiently even in a narrow space where sufficient space for spraying cannot be secured.

Here, the amount of material M sprayed by the spray nozzle 12 may be adjusted according to the hardening speed of the material M. The material spraying device 10 may also be equipped with an injection nozzle 13 that injects, for example, a quick-setting agent or a hardening accelerator into the space K. As an example, the injection nozzle 13 may be fixed to the bottom of the movable formwork 11 and have an opening 13b at the bottom of the formwork surface 11b for spraying the quick-setting agent or the hardening accelerator. The injection nozzle 13 may be a curing agent spraying nozzle that sprays a curing agent onto the filled material M. In this case, the curing agent can be automatically sprayed onto the surface of the filled material M.

The material spraying device 10 may be equipped with a leveling member 19 that levels the surface of the material M when the movable formwork 11 moves along the direction D5. For example, the leveling member 19 is a leveling blade attached to the lower part of the movable formwork 11, and is applied to the surface M5 of the material M exposed from the movable formwork 11 when the movable formwork 11 moves along the direction D5. In this way, the leveling member 19 moves while being applied to the surface M5 of the material M as the movable formwork 11 moves, so that the leveling work of the surface M5 of the material M can be performed automatically as the movable formwork 11 moves.

The method of spraying material M by the material spraying device 10 can be changed as appropriate. For example, as shown in FIG. 6(a), material M may be sprayed in the order of spray area A1, spray area A2, spray area A3, spray area A4, etc., by repeatedly spraying material M along direction D5 into the space K formed between the core material 1 and the movable formwork 11 and moving the movable formwork 11 and the spray nozzle 12 along direction D5.

The material M may be sprayed onto the spray areas A1, A2, A3, and A4 by a plurality of material spraying devices 10. The material spraying devices 10 may also be provided with a sealant 14 that seals the space K at each end of the movable formwork 11 in the direction D6 in which the spray areas A1, A2, A3, and A4 are aligned.

For example, the sealing material 14 is detachable from the movable formwork 11. As an example, the sealing material 14 may be attached to the movable formwork 11 when spraying the material M onto the spray areas A1, A2, A3, and A4 from vertically downward to vertically upward, and may be detached from the movable formwork 11 when spraying has been completed up to the upper ends of the spray areas A1, A2, A3, and A4.

The sealing material 14 makes it possible to prevent leakage of the material M from the space K in the direction D6, thereby further reducing the loss of the material M. In addition, when spraying is performed sequentially along the direction D6, such as spray area A1, spray area A2, spray area A3, spray area A4, etc., for example, when spraying the material M in the adjacent spray area A3, the material M sprayed in the adjacent spray area A4 can be used as a sealing material (e.g., instead of the sealing material 14).

As shown in FIG. 6(b), the material spraying device 10 may be provided with a sealant 14c instead of the sealant 14, which has an uneven surface 14b including a convex portion protruding in the direction D6 and a concave portion recessed in the direction D6 at both ends in the direction D6. In this case, it is possible to spray the material M so that unevenness M1 is formed between the spray area A1 and the spray area A2, between the spray area A2 and the spray area A3, and between the spray area A3 and the spray area A4. Therefore, it is possible to increase the contact area between the spray area A1 and the spray area A2, between the spray area A2 and the spray area A3, and between the spray area A3 and the spray area A4, and therefore it is possible to improve the integrity of the outer shell S1.

Figure 7 is a front view (viewed from a direction perpendicular to the formwork surface 11b) showing an example of the detailed configuration of the material spraying device 10. Figure 8 is a vertical cross-sectional view showing the detailed configuration of the material spraying device 10. As shown in Figures 7 and 8, the material spraying device 10 includes, for example, a moving mechanism 15 that moves the movable formwork 11.

The moving mechanism 15 has, for example, a moving frame 16 extending in the direction D5 in which the movable formwork 11 moves, and a drive unit 17 that moves the movable formwork 11 along the moving frame 16. The drive unit 17 may move the spray nozzle 12. For example, the spray nozzle 12 is movably supported on the movable formwork 11 via the moving frame 16.

When the spray nozzle 12 is supported on the movable formwork 11 via the movable frame 16, the movable formwork 11 and the spray nozzle 12 can be moved as a unit, reducing the effort required to move the spray nozzle 12 as a single unit. As an example, the movable frame 16 has a pair of rails 16b aligned along direction D6 and each extending in direction D5, and the drive unit 17 moves the movable formwork 11 along the pair of rails 16b.

For example, the movable frame 16 may include a nozzle support frame 16c that movably supports the spray nozzle 12. As an example, the nozzle support frame 16c has a pair of pillars 16d that extend vertically upward from the movable formwork 11 and are aligned along the direction D6, and a rail 16f that extends in the direction D6 between the pair of pillars 16d.

As an example, rails 16b are arranged on both ends of the movable formwork 11 in direction D6, and the movable formwork 11 moves along direction D5 between the pair of rails 16b. For example, pillars 16d may extend vertically upward from both ends of the movable formwork 11 in direction D6, and the area between the pair of pillars 16d is the movable area of the spray nozzle 12.

In this case, the spray nozzle 12 is movable in the direction D6 between a pair of pillars 16d. In addition, the rail 16f that movably supports the spray nozzle 12 protrudes, for example, from the pillars 16d toward the core material 1. This realizes a state in which the spray nozzle 12 is positioned vertically above the space K formed between the core material 1 and the movable formwork 11.

The rails 16f may be movable along the direction D5 relative to the columns 16d. In this case, it is possible to adjust the distance of the spray nozzle 12 relative to the movable formwork 11 and the space K. As described above, by providing the movable frame 16 with rails that extend vertically and horizontally, it is possible to automate the movement of the movable formwork 11 and the spraying of the material M by the spray nozzle 12.

The material spraying device 10 may also include rollers 18 attached to the lower part of the moving frame 16. For example, a roller 18 is attached to each of the lower ends of a pair of rails 16b. In this case, the moving frame 16, the movable formwork 11, and the spray nozzle 12 can be moved in the direction D6 by rolling the rollers 18.

As shown in Figures 9(a), 9(b), 9(c) and 10, the angle θ of the spray nozzle 12 with respect to the direction D5 (the direction of spraying the material M from the spray nozzle 12) may be variable. For example, the material spraying device 10 may be equipped with a nozzle orientation adjustment mechanism 22 that changes the orientation (angle θ) of the spray nozzle 12.

In this case, the nozzle orientation adjustment mechanism 22 makes it possible to adjust the angle θ of the spray nozzle 12 relative to the direction D5. As a result, the material M can be sprayed uniformly in the direction D4, which is the direction in which the movable formwork 11 faces the core material 1, thereby improving the uniformity of the spraying of the material M.

As shown in FIG. 11, the material M may be sprayed in multiple layers along direction D4. That is, the material M may be sprayed multiple times along direction D5 so that layers L1 and L2 of material M are stacked in direction D4. In this case, material M is sprayed from the spray nozzle 12 along direction D5 between the core material 1 and the movable formwork 11, and the material M is sprayed and hardened along direction D5 to form layer L1. Thereafter, the movable formwork 11 and the spray nozzle 12 are moved away from layer L1, and material M is sprayed from the spray nozzle 12 along direction D5 between layer L1 and the movable formwork 11 to form layer L2.

For example, the formwork surface portion 11c of the movable formwork 11 may be detachable from the support portion 11d. As an example, as shown in Figures 11(b), 12(a) and 12(b), for example, a formwork surface portion 21c having a formwork surface 21b with irregularities 21d may be attached to the support portion 11d instead of the formwork surface portion 11c. In this case, for example, a convex portion M2 protruding in direction D4 and a concave portion M3 recessed in direction D4 can be formed on the surface of the first layer of material M. As an example, the shape of the irregularities 21d when viewed along direction D5 is trapezoidal.

For example, when spraying material M onto the core material 1 to form layer L1, a formwork surface portion 21c with irregularities 21d is attached to the support portion 11d, and material M is sprayed from the spray nozzle 12 along direction D5 between the core material 1 and the formwork surface 21b. By spraying material M in this manner, it is possible to form layer L1 in which convexities M2 and concave portions M3 are formed when viewed along direction D5. In other words, by attaching formwork surface portion 21c with irregularities 21d extending in direction D5 to support portion 11d and spraying material M, convexities M2 and concave portions M3 can be formed on the surface of layer L1 without resisting movement of the movable formwork 11 in direction D5.

When forming layer L2, a flat formwork surface portion 11c without any irregularities is attached to the support portion 11d, and material M is sprayed from the spray nozzle 12 along the direction D5 between layer L1 and the formwork surface 11b. At this time, material M fills the spaces between the convex portions M2 and concave portions M3 of layer L1 and the formwork surface 11b, and hardens.

This makes it possible to spray the material M so that unevenness is formed between the layers L1 and L2. This makes it possible to increase the contact area between the layers L1 and L2, thereby improving the integrity of the layers L1 and L2. Note that, although the above example describes an example in which the outer shell S1 is constructed from two layers, the layers L1 and L2, the number of layers may be one or three or more.

13(a) and 13(b), the material spraying device 10 may be provided with a roll member 20 that pulls out the curing sheet 20b along the surface M5 of the material M when the movable formwork 11 moves along the direction D5. The roll member 20 is attached to the lower part of the movable formwork 11, for example, and unrolls the curing sheet 20b so as to follow the surface M5 of the material M exposed from the movable formwork 11 when the movable formwork 11 moves along the direction D5. In this case, the roll member 20 unrolls the curing sheet 20b so as to follow the surface M5 of the material M as the movable formwork 11 moves, so that the curing sheet 20b can be automatically placed on the surface M5 of the material M as the movable formwork 11 moves. The curing sheet 20b seals and cures the sprayed material M, improving the quality after hardening. Instead of a mechanism for unrolling the curing sheet 20b, a mechanism for spraying a coating curing material may be provided.

Next, the effects obtained from the material spraying device 10 and material spraying method according to this embodiment will be described in detail. For example, as shown in Figures 4(a), 4(b), and 4(c), in the material spraying device 10 and material spraying method according to this embodiment, material M is sprayed onto core material 1. At this time, the movable formwork 11 faces the core material 1 across space K, and material M is sprayed into space K from the spray nozzle 12.

The spray nozzle 12 sprays the material M into the space K along the direction D5, which is the direction along which the formwork surface 11b of the movable formwork 11 is aligned. Therefore, the material M is sprayed along the core material 1 and the formwork surface 11b of the movable formwork 11, so that the sprayed material M does not scatter. In other words, the sprayed material M can be prevented from scattering or bouncing off. Therefore, the material M can be efficiently filled into the space K formed between the core material 1 and the movable formwork 11, so that the loss of the sprayed material M can be reduced.

The spray nozzle 12 may be provided vertically above the space K, and the material M may be sprayed vertically downward from the vertically above the space K. In this case, the material M is sprayed vertically downward into the space K formed between the core material 1 and the movable formwork 11, so that scattering of the material M out of the space K can be suppressed. Therefore, loss of the material M can be more reliably reduced.

As shown in Figures 7 and 8, the material spraying device 10 includes a moving mechanism 15 that moves the mobile formwork 11, and the moving mechanism 15 may include a moving frame 16 that extends in the direction in which the mobile formwork 11 moves, and a drive unit 17 that moves the mobile formwork 11 along the moving frame 16. In this case, the mobile formwork 11 can be moved along the moving frame 16 by the driving force of the drive unit 17.

As shown in Figures 9(a), 9(b), 9(c) and 10, the material spraying device 10 may be equipped with a nozzle orientation adjustment mechanism 22 that changes the orientation of the spray nozzle 12. In this case, the material M can be sprayed while changing the orientation of the spray nozzle 12 by the nozzle orientation adjustment mechanism 22. This reduces bias in the amount of material M sprayed, and improves the uniformity of the spraying of material M.

In addition, in this embodiment, as illustrated in Fig. 4(a), Fig. 4(b) and Fig. 4(c), the process includes a step of placing a movable formwork 11 at a position opposite to the core material 1, and a step of spraying material from a spray nozzle 12 between the movable formwork 11 and the core material 1. In the step of spraying material, a method of constructing an outer shell (constructing the outer shell of a structure) is described in which the outer shell S1 of the structure S is formed by spraying material M in a direction D5 along the formwork surface 11b of the movable formwork 11 against the space K formed between the core material 1 and the movable formwork 11. According to this method of constructing the outer shell, the hardened material M becomes the outer shell S1, so that a formwork is not required. In addition, since the outer shell S1 can be formed by spraying the material M, the construction of the outer shell S1 can be performed mechanically. Furthermore, since the outer shell S1 is constructed from the material M, a demolding operation is not required, and when a material having a higher density and strength than normal concrete is used as the material M, the effect of increasing the durability of the structure of the outer shell S1 can be expected.

Second Embodiment
Next, a material spraying device 30 and a material spraying method according to a second embodiment will be described with reference to Figures 14 and 15. A portion of the configuration of the material spraying device 30 and the material spraying method according to the second embodiment is the same as a portion of the configuration of the material spraying device 10 and the material spraying method described above, so that the description that overlaps with the above will be omitted as appropriate below.

In the first embodiment described above, a material spraying device 10 was described that includes a movable formwork 11 that moves vertically and a spray nozzle 12 that sprays material M vertically. In contrast, the material spraying device 30 includes a movable formwork 31 that moves along a direction D6 in which the spray areas A1, A2, A3, and A4 are aligned, and a spray nozzle 32 that sprays material M in a direction D5 along the formwork surface of the movable formwork 31.

The material spraying device 30 further includes a pair of moving frames 35 extending in direction D6 and aligned along direction D5. The movable formwork 31 is supported so as to be movable along direction D6 relative to the moving frames 35. The direction D6 in which the movable formwork 31 moves intersects with the direction D5 in which the spray nozzle 32 sprays the material M. As an example, the direction D5 is a vertical direction, and the direction D6 is a horizontal direction.

In the material spraying method according to the second embodiment, material M is sprayed in the order of spraying area A1, spraying area A2, spraying area A3, and spraying area A4, while repeatedly spraying material M into the space formed between the core material 1 and the movable formwork 31 in direction D5 (step of spraying material) and moving the movable formwork 31 and the spray nozzle 32 in direction D6 (step of moving the movable formwork). Specifically, first, in spraying area A1, the formwork surface of the movable formwork 31 is placed in front of the core material 1 across a space (step of positioning the movable formwork), and the spray nozzle 32 sprays material M into this space in direction D5.

The material M is sprayed onto the spray area A1, and the material M in the spray area A1 hardens (the process of hardening the material), the movable formwork 31 is moved in the direction D6 (the process of moving the movable formwork), and the formwork surface of the movable formwork 31 faces the core material 1 across a space in the spray area A2. Then, as described above, the material M is sprayed into the space between the core material 1 and the movable formwork 31 in the spray area A2 by the spray nozzle 32 (the process of spraying the material). As described above, the movement of the movable formwork 31 in the direction D6 and the spraying of the material M from the spray nozzle 32 in the direction D5 between the movable formwork 31 and the core material 1 are repeated, and the series of steps of the material spraying method is completed.

As described above, in the material spraying device 30 and material spraying method according to the second embodiment, the spray nozzle 32 sprays the material M into the space formed between the movable formwork 31 and the core material 1 in the direction D5, which is the direction along the formwork surface of the movable formwork 31. Therefore, since the material M is sprayed along the core material 1 and the formwork surface of the movable formwork 31, it is possible to prevent the sprayed material M from scattering. Therefore, the same action and effect as in the first embodiment can be obtained.

Third Embodiment
Next, a material spraying device 40 and a material spraying method according to the third embodiment will be described. The material spraying device 40 includes a movable formwork 41 and a spray nozzle 42 that sprays the material M in a direction D5 along the formwork surface 41b of the movable formwork 41. In the third embodiment, the height of the core material 51 is lower than the above-mentioned core material 1, so the movable formwork 41 does not move. With the formwork surface 41b of the movable formwork 41 facing the core material 51 across the space K, the spray nozzle 42 sprays the material M into the space K along the direction D5.

In the material spraying method according to the third embodiment, first, as shown in FIG. 16(a), a movable formwork 41 is set up opposite the core material 51 across the space K (step of setting up the movable formwork), and the spray nozzle 42 is positioned so as to be aligned with the space K along the direction D5 (step of placing the spray nozzle).

16(b) and 16(c), material M is sprayed from the spray nozzle 42 in the direction D5 (material spraying process). After the material M is sprayed to fill the space K, the material M is hardened (material hardening process), and then, as shown in FIG. 16(d), the movable formwork 41 is removed from the material M, completing the series of steps of the material spraying method.

As described above, in the material spraying device 40 and material spraying method according to the third embodiment, the spray nozzle 42 sprays the material M into the space K formed between the movable formwork 41 and the core material 51 in the direction D5, which is the direction along the formwork surface 41b of the movable formwork 41. Therefore, the same effects as those of the above-mentioned embodiments can be obtained.

Various embodiments of the material spraying device and material spraying method according to the present disclosure have been described above. However, the present invention is not limited to the above-described embodiments. In other words, it will be easily recognized by those skilled in the art that various modifications and changes are possible to the present invention without changing the gist of the claims. For example, the configuration, shape, size, number, material and arrangement of each part of the material spraying device, as well as the content and order of the steps of the material spraying method, are not limited to those described above and can be modified as appropriate.

For example, in the above-described embodiment, an example was described in which the material M was a cement-based material. However, the material M may be, for example, a resin-based material, or may be a material other than a cement-based material.

In the above-described embodiment, an example was described in which the movable formwork 11 moves along the vertical direction D1. However, the direction in which the movable formwork moves may be a direction other than the vertical direction, such as a horizontal direction or a diagonal direction. In this case, the spray nozzle sprays the material along the formwork surface of the movable formwork, thereby suppressing rebound of the material, and thus the same effect as described above can be obtained. The direction in which the spray nozzle sprays the material is not particularly limited as long as it is along the formwork surface.

In the above-described embodiment, an example was described in which the movable formwork 11 moves along the movable frame 16 in the direction in which the core material 1 extends. However, the direction in which the movable formwork moves and the direction in which the movable frame extends are not limited to the above example. For example, the movable frame may extend in a direction approaching and moving away from the core material, and the movable formwork may move along that direction.

In the above-described embodiment, an example was described in which the outer shell S1 of a structure S was constructed by spraying material M using the material spraying device 10. However, the material spraying device and material spraying method of the present invention can be applied to applications other than the construction of an outer shell structure. As described above, the material spraying device and material spraying method of the present invention can be applied to the construction of concrete structures, and can also be applied to the construction of structures other than concrete structures. For example, the present invention can be applied to repair work on components by spraying material, and can be applied to a variety of work sites.

1...core material, 1b...periphery, 2...steel material, 2b...H steel, 2c...L steel, 2d...periphery, 3...air tube, 3b...first air tube, 3c...second air tube, 3d...periphery, 10...material spraying device, 11...mobile formwork, 11b, 21b...formwork surface, 11c, 21c...formwork surface, 11d...support, 12...spray nozzle, 13...injection nozzle, 13b...opening, 14, 14c...sealing material, 14b...uneven surface, 15...moving mechanism, 16...moving frame, 16b, 16f...rail, 16c...nozzle support Frame, 16d...column, 17...drive, 18...roller, 19...leveling member, 20...roll member, 20b...curing sheet, 21d...unevenness, 22...nozzle direction adjustment mechanism, A1, A2, A3, A4...spraying area, C1, C2...set, D1...vertical direction, D2...first direction, D3...second direction, D4, D5, D6...direction, K...space, L1, L2...layer, M...material, M1...unevenness, M2...convex part, M3...concave, M5...surface, S...structure, S1...shell, S2...hollow part, S3...concrete, θ...angle.

Claims (5)

A movable formwork that faces a core material of a structure and moves along the core material;
A spray nozzle that sprays material between the movable formwork and the core material;
Equipped with
The spray nozzle sprays material into a space formed between the core material and the movable formwork in a direction along a formwork surface of the movable formwork ,
The material is a cement-based spraying material that is self-supporting when sprayed, and the outer shell structure of the structure is constructed by spraying the cement-based spraying material.
Material spraying equipment. The spray nozzle is provided vertically above the space and sprays the material vertically downward from the vertically above the space.
2. The material spraying apparatus of claim 1. A moving mechanism for moving the movable formwork is provided,
The moving mechanism includes a moving frame extending in a direction in which the movable formwork moves, and a driving unit that moves the movable formwork along the moving frame.
3. A material spraying device according to claim 1 or 2. A nozzle direction adjustment mechanism is provided to change the direction of the spray nozzle.
A material spraying device according to any one of claims 1 to 3. A step of placing a movable formwork in a position opposite a core material of a structure;
spraying a material between the movable form and the core material from a spray nozzle;
Equipped with
In the step of spraying the material, the material is sprayed into the space formed between the core material and the movable formwork in a direction along the formwork surface of the movable formwork ,
The material is a cement-based spraying material that is self-supporting when sprayed, and the outer shell structure of the structure is constructed by spraying the cement-based spraying material.
Material spraying method.

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