• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
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    • 专利摘要:
    method for fabricating structural body and fabrication apparatus for it is a method for fabricating a structural body that includes a lamination step, while a structural body in process is supported by a support member, laminar, in a plurality sometimes, a layer that is provided on a surface of a transfer member and that must be formed in the structural body in the process structural body or at least part of a surface formed in the process structural body and the support member, and in the lamination step, the support member is moved by changing its state.
    公开号:BR112015012419B1
    申请号:R112015012419-4
    申请日:2013-12-12
    公开日:2021-04-06
    发明作者:Hiroshi Taniuchi；Kazuhiro Nakajima
    申请人:Canon Kabushiki Kaisha；
    IPC主号:
    专利说明:

    [0001] [0001] The present invention relates to a method for making a structural body and a manufacturing apparatus for it. BACKGROUND TECHNIQUE
    [0002] [0002] In recent years, the formation of three-dimensional objects, in which each has a complicated shape designed by a computer, has spread widely. In fields where many types of products, such as mechanical microcomponents and display samples of accommodation and food, are produced in a relatively small amount, the formation of three-dimensional objects as described above has been in increasing demand.
    [0003] [0003] As an example of a method for forming the three-dimensional object as described above, a method is known in which a material to be formed into a three-dimensional object is repeatedly laminated to manufacture a structural body.
    [0004] [0004] According to PTL 1, a method has been revealed in which after a layer that is shaped like a part of a three-dimensional object is formed, standardization is performed by providing a material that is used as a support in order to surround the layer described above. After a support member is formed as described above, a surface formed from that support member and a three-dimensional object in process are then flattened, and a material to be formed on the three-dimensional object is further laminated to the surface thereby flattened. CITATION LIST PTL PATENT LITERATURE 1
    [0005] [0005] Patent Document open to public inspection in JP10-305488 SUMMARY OF THE INVENTION TECHNICAL PROBLEM
    [0006] [0006] However, according to the method revealed in PTL 1, since the support member is formed each time a layer to be formed on the three-dimensional object is laminated, and a large amount of a material that forms the member of support is required, and furthermore, since it is considered the case in which it is required that each layer and the support member be precisely arranged in respective predetermined positions and / or the support member cured in one step of laminating layers is difficult to be removed and cannot be recycled, the manufacturing burden is expected to be high. SOLUTION TO THE PROBLEM
    [0007] [0007] Consequently, the present invention provides a method with the capacity to manufacture a structural body with a high production efficiency while the amount of a material that forms a support member is reduced.
    [0008] [0008] A method for making a structural body according to an aspect of the present invention comprises: a lamination step of, while a structural body in process is supported by a support member, laminating a plurality of times, a layer that is provided on a surface of a transfer member and which must be formed on the structural body in the process structural body or at least part of a surface formed from the process structural body and the support member, and in the lamination step described above, the status of the support member is changed to move the support member.
    [0009] [0009] Additional features of the present invention will become apparent from the following description of exemplary modalities with reference to the accompanying drawings. ADVANTAGE EFFECTS OF THE INVENTION
    [0010] [0010] According to the present invention, a manufacturing method can be provided in which, since the support member is smoothed and is then moved, while the amount of material that forms a new support member is reduced, the body structural is manufactured with a high production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1
    [0011] [0011] Figure 1 is a schematic view showing a laminate forming apparatus as an example of a manufacturing apparatus that performs a method for making a structural body according to a modality. FIGURE 2A
    [0012] [0012] Figure 2A is a schematic cross-sectional view showing the state of a stage of a rolling process in a rolling unit according to the modality. Figure 2B
    [0013] [0013] Figure 2B is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2C
    [0014] [0014] Figure 2C is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. 2D FIGURE
    [0015] [0015] Figure 2D is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2E
    [0016] [0016] Figure 2E is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2F
    [0017] [0017] Figure 2F is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2G
    [0018] [0018] Figure 2G is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2H
    [0019] [0019] Figure 2H is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2I
    [0020] [0020] Figure 2I is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 2J
    [0021] [0021] Figure 2J is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 3
    [0022] [0022] Figure 3 is a schematic perspective view showing an example of a structural body manufactured by the method to manufacture a structural body according to the modality. FIGURE 4
    [0023] [0023] Figure 4 is a block diagram showing a control system for the manufacturing device. FIGURE 5A
    [0024] [0024] Figure 5A is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 5B
    [0025] [0025] Figure 5B is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 5C
    [0026] [0026] Figure 5C is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 5D
    [0027] [0027] Figure 5D is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 5E
    [0028] [0028] Figure 5E is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 5F
    [0029] [0029] Figure 5F is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6A
    [0030] [0030] Figure 6A is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6B
    [0031] [0031] Figure 6B is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6C
    [0032] [0032] Figure 6C is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6D
    [0033] [0033] Figure 6D is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6E
    [0034] [0034] Figure 6E is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6F
    [0035] [0035] Figure 6F is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6G
    [0036] [0036] Figure 6G is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 6H
    [0037] [0037] Figure 6H is a schematic cross-sectional view showing the state of a stage of the lamination process in the lamination unit according to the modality. FIGURE 7
    [0038] [0038] Figure 7 is a schematic view showing the state of a stage of the lamination process according to the modality. FIGURE 8
    [0039] [0039] Figure 8 is a schematic view showing a laminate forming apparatus as an example of a manufacturing apparatus that performs a method for making a structural body according to a modality. MODALITY DESCRIPTION
    [0040] [0040] With reference to the drawings, an embodiment of the present invention will be described.
    [0041] [0041] Figure 3 is a perspective view showing schematically an example of a structural body manufactured by a method for manufacturing a structural body according to the embodiment of the present invention. A structural body 500 having a three-dimensional structure as described above is manufactured by a method, which will be described later, using a structural material such as plastic, metal, or the like. The method for making a structural body according to the modality of the present invention can be used when components of electrical devices, toy models, such as dolls and plastic models, food samples, display models for promoting accommodation and furniture sales , and the like are manufactured as structural bodies.
    [0042] [0042] Figure 1 is a view showing schematically a laminate forming apparatus as an example of a manufacturing apparatus that carries out the method for making a structural body in accordance with the embodiment of the present invention and is a cross-sectional view that schematically shows the state of a manufacturing process along line II of Figure 3 along which the structural body is traversed. In an apparatus 100 having the cross section shown in Figure 1, a pattern of a layer of the structural body that must be newly laminated is formed on a surface of a belt-shaped intermediate transfer member 1 that functions as a transfer member and it is then allowed to pass through each process unit through a conveying mechanism 2, so that a cross-sectional layer 14 having a cross-sectional shape of the structural body is formed. In addition, the cross-sectional layer 14 of the structural body is transported to a laminating position of a laminating unit 1000 which is moved reciprocally in an X direction and is then laminated to a laminated structural body in process 17.
    [0043] [0043] A formatting process on the apparatus 100 begins from an inkjet unit 3 located in the center of the apparatus 100. A pattern 4 is formed by dots of ink on the intermediate transfer member 1 located under the apparatus inkjet 3. Next, a format 6 forming material is applied to the pattern 4 formed from the ink from a format 5 forming material supply mechanism to form a mixture 7, so that the forming material of format 6 is attached to the surface of the intermediate transfer member 1. The material can be applied in the form of a finer powder than the required resolution, and a material that can be formed into a film can be used in some way. For example, a thermoplastic resin that can be formed into a film by a heat treatment can be used in the form of a powder, or glass granules or a powdered material can also be used when an adhesive that is used to form a film is merged with the pattern 4 described above. Among those described above, as long as it is light in weight and capable of forming a robust structural body, a thermoplastic resin is particularly preferred.
    [0044] [0044] The intermediate transfer member 1 functions as a support member that supports a layer of the structural body formed on the surface and also functions as a transfer member that transfers a formed layer to a structural body in process that is already formed by laminating it layer each other. Therefore, transfer member 1 is preferably formed of a material that has a high release property by having an affinity to some extent for a material that forms the structural body. In addition, in order to carry out the transfer in a stable manner, the intermediate transfer member 1 preferably has at least elasticity to some extent. As a preferred material is the intermediate transfer member, for example, a silicone rubber and a fluorinated rubber can be mentioned. Since a material used for standardization can be repelled in some cases in these rubber materials mentioned above, it is more preferable to perform a surface treatment on it according to the material to be used. Although the hardness of rubber is determined depending on the thickness of an elastic body, when the thickness of it is large, a hard rubber is preferably used, and when the thickness is small, a soft rubber is preferably used. When the thickness is large, a rubber that has a hardness of approximately 80 degrees is preferred, and when the intermediate transfer member 1 has a thin belt shape, a thin film formed of a rubber that has a thickness of approximately 0.1 at 0.5 mm and a rubber hardness of approximately 50 to 20 degrees is preferably used. When high precision is required, although a Teflon sheet (trademark) and a soft film coated with a release agent that has a thickness of order of sub-micron, each of which has no elasticity, are preferably used, since machine precision and / or a long process time may be required in some cases, the material is preferably selected according to the application proposal. In addition, when a metal powder or the like is used as the forming material, the surface of the same is preferably processed by a release treatment with the use of boron nitride or the like which has a high heat resistance.
    [0045] [0045] In the apparatus shown in Figure 1, the inkjet unit 3 is shown as an example of a device used to form a layer of the structural body on the intermediate transfer member 1. A method for forming a layer of the structural body with the use of an inkjet method is, as described later, a method in which a shape forming material that forms the structural body is applied in a semi-liquid pattern removed with an ink on the surface of the intermediate transfer member to increase the volume and to form a solid colored layer. However, the method is not limited to the one described above, and for example, an image can also be formed by standardization using a digital recording device of an electronic photographic method, a dispenser method, or the like, or a method of printing plate, such as offset printing or screen printing. In the case of an electronic photographic method using dry toner, an adhesive force is generated on the toner by heating. Among those described above, when an intermediate transfer member that has a high release property is used, an inkjet method is a very preferred method since several colors can be standardized simultaneously without being in contact with the intermediate transfer member 1. Additionally, instead of using a method in which after an image is formed on the surface of the intermediate transfer member 1, a material of the structural body is applied to the image, a layer of the structural body can be formed by directly applying a component to be solidified, such as a resin material, on the surface of the intermediate transfer member 1 by an inkjet method or the like. By the method as described above, the supply mechanism 5 which functions only to supply the format forming material 6 is not required and, therefore, the size of the format forming apparatus can be reduced. In the method in which a pattern is drawn on the surface of the intermediate transfer member 1, and a shaped forming material that forms a solid component is then applied to the pattern, an inkjet method is preferably used to design a pattern. The reason for this is that, since the solid component of an inkjet ink is almost formed of dyes, a solvent component can be removed by evaporation after the format 6 forming material is fixed.
    [0046] [0046] In the apparatus shown in Figure 1, although the format forming material is supplied after an ink pattern is formed, the order of steps is not limited to the same. For example, first, a powder used as the format 6 forming material is supplied to the intermediate transfer member 1, and an ink can then be applied to the powder. As long as the shape-forming material 6 is attached to the surface of the intermediate transfer member 1 according to a desired pattern, the order of steps is not particularly limited.
    [0047] [0047] Next, a portion of the format 6 forming material is removed, which is not fixed as long as it is adhered to the outside of the ink pattern provided on the intermediate transfer member 1. Since the format forming material part 6 which is not in contact with the ink pattern has a low adhesion to the intermediate transfer member 1, when transported by a transport device to the vicinity of an air knife 8 which expels a gas, the part of the shape forming material 6 is peeled off by the wind pressure sent from the air knife 8, is separated from the fixed mixture 7, and is then transported to a removed structural material receiver 9. When the format 6 forming material is a resin powder, since a resin powder is liable to be electrified with static, a static eliminator is preferably used.
    [0048] [0048] The formation of the mixture 7 and the removal of the format 6 forming material may not be carried out sequentially, but simultaneously. For example, when the wind is sent to pattern 4 formed by an ink, and the forming material of format 6 is blown with the wind sent in this way, since a part of the forming material of format 6 is not brought into contact with pattern 4 it is not fixed to the surface of the intermediate transfer member 1, an unnecessary forming material of shape 6 can be removed.
    [0049] [0049] Mixture 7 of format 6 forming material and pattern 4 of the ink remaining on the intermediate transfer member 1 is heated by heaters 11 located on a rear surface side of the intermediate transfer member, and as one liquid component is evaporated, the volume of the mixture 7 is decreased and melted as shown by reference numeral 10 in the drawing, so that a film is formed. If necessary, the surface of the mixture 7 is flattened by a thermal cylinder 13, so that the cross-sectional layer 14 is formed which forms a part of the structural body and which has a surface shape equivalent to a cross-sectional shape of the structural body. In this case, the surface shape of the cross-sectional layer 14 is a cross-sectional shape obtained when a complete structural body is traversed along a direction perpendicular to a lamination direction. The cross-sectional layer 14 is transported under a 20 format forming table of the laminating unit 1000 and is aligned with an in-process structural body by an alignment device (not shown). Then, the laminating unit 1000 which includes a format 21 forming container, the format forming table 20, a lifting mechanism 19, and a support member filling mechanism 15 is lowered and therefore the layer in cross-section 14 is laminated to the formed surface of the structural body in process 17 and a support member 18 which is a support member that supports the structural body in process 17. The support member filling mechanism 15 provided in the laminating unit works to fill in support member 18.
    [0050] [0050] Additionally, in Figure 1, although a device that standardizes a format-forming material is provided on the device, the device is not limited to it. In an apparatus shown in Figure 8 by way of example, shaping is performed by fitting an intermediate transfer sheet 25 to which a shaping material is pre-patterned by another patterning device to a laminating device. Since the standardization step by the other standardization device and the lamination step of the lamination device can be carried out in parallel, and in addition, since the loss time can be reduced even if the tact times of the respective steps are different one on the other, productivity can be significantly improved. In Figure 8, the reference numeral 23 indicates an adhesive application mechanism that works to apply an adhesive to the cross-section layer 14. Additionally, the reference numeral 24 indicates an intermediate transfer sheet used. The remaining structure in the lamination device is similar to that described in the lamination unit shown in Figure 1. The present invention relates to a lamination process in which standardization is not always necessarily carried out on a structural body in a process other than that related to many three-dimensional shape-forming methods and, in other words, a standardization mechanism is not always necessarily provided on the same device. In the present invention, cross-sectional patterns manufactured under ideal conditions for the respective methods and materials can be used. That is, according to a material to be used for the structural body and the precision of its shape formation, the standardization device can be selected without being too limited.
    [0051] [0051] Figure 4 is a block diagram showing a control system of the manufacturing apparatus 100 shown in Figure 1. In the three-dimensional object forming apparatus fully represented as reference numeral 100, reference numeral 101 indicates a CPU that functions as a main control portion of the entire system and controls individual units. Reference numeral 102 indicates a memory that is formed, for example, from ROMs that store a basic program of the CPU 101 and RAMs used to store structural body data 104 inserted through an interface 103 and to perform data processing. When CPU 101 receives a signal that indicates the start of formatting, a process that converts structural body data into slice data that is emitted according to fit conditions is initiated, and at the same time, communication is carried out to confirm the states of the transport mechanism 2, the inkjet unit 3, the format forming material supply mechanism 5, the support member filling mechanism 15, and the lifting mechanism 19. When the states are ready to start shaping, the transport mechanism 2 and the lifting mechanism 19 are moved to the respective predetermined positions according to the information of a position detection 105, and an eject signal is sent to the jet unit. ink 3, so that formatting begins.
    [0052] [0052] Next, with reference to Figures 2A to 2J, 5A and 5B, and 6A to 6H in addition to Figures 1, 3, and 4, the flow of lamination steps will be described. Figures 2A to 2J, 5A and 5B, and 6A to 6H are seen in cross-section where each shows a step of a lamination process in the laminating unit 1000 when viewed from the same cross-sectional position as in Figure 1.
    [0053] [0053] Additionally, in Figure 2A to 2J, the laminating unit 1000 is shown while the lifting mechanism 19 is omitted. Additionally, in Figures 2A to 2J, 5A and 5B, and 6A to 6H, parts of the laminating unit 1000 mechanisms, heaters, and cooling mechanisms may be omitted in some cases.
    [0054] [0054] Then, as shown in Figure 2A, a cross-sectional layer 14 on the surface of the intermediate transfer member 1 is prepared in a position facing the 20 shape formation table.
    [0055] [0055] Then, as shown in Figure 2B, the formation table of format 20 is lowered so that the distance between a transfer surface (the surface of the formation table when a first layer is formed) and the transfer member intermediate approaches a predetermined value and so that the cross-section layer 14 in a molten state is brought into contact with the transfer surface of the 20 shape formation table and, as a result, the thickness of the cross-section layer 14 controlled. Before the surface of the shape-forming table 20 is brought into contact with the cross-section layer 14, or while the surface of the shape-forming table 20 is in contact with it, the cross-sectional layer can be smoothed with heaters 11 in order to promote the melting of the layer in cross section.
    [0056] [0056] Then, as shown in Figure 2C, in a space between the transfer surface (bottom surface) of the shape forming table 20 and the intermediate transfer member 1, a support material 16 in a molten state, forming the support member 18, is injected by the support member filling mechanism 15. The support material 16 is placed in contact with the surface of the intermediate transfer member 1 as is the cross-sectional layer 14.
    [0057] [0057] As the support material 16 that can be used in this modality, a material in which the phase transition between a solid and a liquid can be performed reversibly by an external stimulus can be used. For example, between compounds in which a molten state and a solidified state are reversibly changed by applying a heat stimulus (heating and cooling) through the melting point, a material that does not dissolve a structural body in process and that does not is mixed with the same can be used. In particular, when a thermoplastic is used as the forming material of format 6, as the support material 16, for example, a paraffin wax, a poly (ethylene glycol), or a melt with a low melting point can be used. used. Additionally, in addition to the materials in which the phase transition occurs through a heat stimulus, such as support material 16, for example, an ER fluid that has a fluidity that is changed by an electrical signal, a magnetic fluid, can be used. which has a fluidity that is lost by the application of a magnetic field, and an azobenzene-based compound in which a liquid state obtained by irradiation of light and a solid state obtained by heating are reversibly changed.
    [0058] [0058] When a thermoplastic resin is used as the format 6 forming material, and heat is applied to the support member 18 as a solid-liquid phase transition stimulus, a support member 18 that has a lower melting point than format 6 training material should be used. In the case as described above, as the support material, a poly (ethylene glycol) (PEG) can preferably be used. The reason for this is that this resin can have a desired melting point by adjusting its molecular weight, and additionally, since this resin is dissolved in water, finishing washing to be carried out after the structural body is finished can be easily accomplished.
    [0059] [0059] As shown in Figure 2D, when the support material 16 is completely filled, the cross section layer 14 and the support material 16 are cooled by cooling mechanisms 12, so that the first layer is formed.
    [0060] [0060] As shown in Figure 2E, when the laminating unit is raised, a surface (hereinafter referred to as "first surface" in some cases) formed from the layer of the structural body 17 and the support member 18 is separated from the transfer member intermediate 1. This first surface is a surface that functions as a transfer surface on which a new cross-sectional layer 14 is to be laminated in a subsequent step. Since the molten support material is molded by being restricted by the surface of the intermediate transfer member 1 and the shape forming table 20, the surface (the first surface) formed of the structural body 17 and the support member 18 and located in an intermediate transfer member side 1 is aligned.
    [0061] [0061] Figure 2F shows the state after two layers are laminated to each other. A third new cross-sectional layer 14 is carried so that a second surface 32 thereof located on a side opposite the intermediate transfer member 1 faces a first surface 31 which is formed of the support member 18 and the structural body in process 17 supported by the format forming table 20 and which is located on the side of intermediate transfer member 1.
    [0062] [0062] As shown in Figure 2G, the first surface 31 and the second surface 32 are brought into contact with each other. In this step, from the first surface, the cross-sectional layer 14 is in contact with a surface formed from the structural body in process 17. When the position in an X direction of the shape forming table 20 in the shape forming vessel 21 is controlled , the height of the cross-sectional layer 14 can be controlled.
    [0063] [0063] As shown in Figure 2H, while the first surface 31 and the second surface 32 are in contact with each other, the state of the support member 18 is changed. In this step, the support member 18 is smoothed, and a smoothed support member 18a which has increased fluidity due to smoothing is moved in order to reach the surface of the intermediate transfer member 1 and lateral surfaces of the layer in cross section. If the intermediate transfer member 1 is located on a lower side in a gravity direction, and the shape forming table 20 is located on an upper side in the gravity direction, the support member 18a can be moved using the effect of gravity. Alternatively, if a gas is fed into the shape 20 forming table, by the pressure of the same, the support member 18a can also be moved by a different method from that using the effect of gravity. For the smoothing of the support member, the phase transition of the support member 18 is induced in order to change its fluidity and, for example, depending on a material to be used, the smoothing can be performed by applying energy, such as heating, applying voltage or irradiating light. For example, when the heating is carried out by the heating generated from the heaters 11, the support member 18 can be smoothed.
    [0064] [0064] As shown in Figure 2I, the smoothed support member 18a is solidified, so that the support member 18 is again formed on the surface of the intermediate transfer member 1. If the support member is smoothed by heating, the solidification is performed by cooling. Depending on a material to be used, this step can also be performed by applying energy or by decreasing or absorbing applied energy. For example, the heating smoothed support member 18a can be solidified using the cooling mechanisms 12. As described above, by the process structural body 17 and the solidified support member 18, a first flat surface 31 in contact with the intermediate transfer member 1 is newly formed. As described above, since the support member 18 which supports another part of the structural body 17 is moved without injecting a new support material 16, a part of the first surface 31 which supports the cross-section layer 14 and which functions as a surface transfer layer in which a new cross-sectional layer 14 is subsequently laminated can be formed.
    [0065] [0065] As shown in Figure 2J, when the laminating unit is lifted, the intermediate transfer member 1 is separated from the first newly formed surface 31.
    [0066] [0066] In the next step, if necessary, before a cross-section layer 14 is brought into contact with structural body 17, or while a cross-section layer 14 is in contact with structural body 17, the member of support 18 is moved next to the intermediate transfer member, and the lamination of the cross-section layer 14 and the structural body 17 is repeatedly performed as described above.
    [0067] [0067] As shown in Figure 5A, in a step that follows the step shown in Figure 2J, a cross-sectional layer 14 having a second surface wider than a portion of the structural body 17 of the first surface 31 can also be laminated . The cross-sectional layer can be laminated on at least part of the first surface, and the first surface can be formed only from the structural body. In this case, since the first surface 31 is also formed from the support member 18 before lamination, as shown in Figure 5B, the second surface 32 of the cross-section layer 14 can also be brought into contact with the first surface 31 formed of the support member. According to the step as described above, the transfer can be efficiently carried out. Additionally, for example, following the step shown in Figure 5B, after the support member 18 is moved as shown in Figure 5C by smoothing it and is further solidified as shown in Figure 5D, lamination can be additionally performed as shown in Figure 5E, and subsequently, the support member 18 can also be moved again as shown in Figure 5F by smoothing it out.
    [0068] [0068] Additionally, instead of using support member 18 from the beginning, support member 18 can be used from a desired step in the above process.
    [0069] [0069] As shown in Figure 6A, a cross section layer 14 that is not continuously formed on the surface of the intermediate transfer member 1 is prepared to return to a structural body in process 17. The state of the cross section layer 14 visualized from one side of the laminating unit it is shown in Figure 7. The cross-sectional layer 14 on the intermediate transfer member 1 includes a segment 14a and the other segment 14b. The first surface that functions as a transfer surface is formed from the structural body in process.
    [0070] [0070] As shown in Figure 6B, the cross-sectional layer 14 is laminated to a part of the structural body 17 that is already formed. Although the one segment 14a of the cross-sectional layer 14 is placed in contact with the structural body 17, since the other segment 14b is separated from the structural body 17 and is not in contact with it, the intermediate transfer member 1 is the only member that supports the other segment 14b.
    [0071] [0071] In the lamination steps from the beginning of the one described above, lamination can be performed without a support using the support member, and in the case described above, when lamination is performed intentionally without the use of any support member, the steps can be simplified. In that case, as shown in Figure 6C, at the stage where a layer that requires the support to be laminated, a smoothed support material 16 is first injected.
    [0072] [0072] Additionally, as shown in Figure 6D, the support member 18 is solidified, so that the other segment 14b is fixed.
    [0073] [0073] Then, as shown in Figure 6E, the intermediate transfer member 1 is separated from the lamination unit. As long as it is attached to the structural body in process 17 by the support member 18, the other segment 14b can be moved integrally with the structural body 17. In this embodiment, since the support member 18 is also provided on a surface F of the other segment 14b opposite the intermediate transfer member 1, compared to the case in which the other segment 14b is supported only by the side surfaces S, the bonding force between the structural body 17 and the other segment 14b is high. Additionally, since the intermediate transfer member 1 is separated, a first surface 31 is exposed from the other segment 14b and the structural body 17.
    [0074] [0074] Next, as shown in Figure 6F, the first exposed surface 31 and a second surface 32 of a new cross-sectional layer 14 are made to face each other.
    [0075] [0075] Additionally, as shown in Figure 6G, the first surface 31 and the second surface 32 are placed in contact with each other so that the structural body in process 17, the other segment 14b integrated with it, and the new cross-section laminate layer 14 are integrated with each other like structural body 17, so that a continuous shape is formed.
    [0076] [0076] Then, as shown in Figure 6H, the support member 18 is removed. For example, support member 18 can be automatically removed by heating it. In addition, the support member 18 removed in this way can also be recycled. The support member can be removed after the intermediate transfer member 1 is separated, or after being moved with the complete structural body 17 out of the laminating unit, the support member 18 can be removed in a different container.
    [0077] [0077] As described above, the structural body as shown in Figure 3 can be obtained.
    [0078] [0078] Hereinafter, an example of the present invention will be described. [EXAMPLE 1]
    [0079] [0079] As Example 1, the manufacture of a structural body was performed by forming a laminate using the apparatus shown in Figure 1.
    [0080] [0080] First, the structural body data could be prepared as slice data for each layer that has a predetermined thickness, and in this example, slice data for each layer with a thickness of 100 micrometers was used.
    [0081] [0081] As intermediate transfer member 1, a PET film that was 0.4 mm thick and coated with 0.2 mm thick silicone rubber (trademark: KE-1310, manufactured by Shin-Etsu Chemical Co., Ltd.) which has a rubber hardness of 40 degrees. In order to suppress an ink from being repelled on the surface of the intermediate transfer member 1, the intermediate transfer member 1 was processed under the following conditions by a remote atmospheric pressure plasma treatment apparatus (trademark: APT- 203 rev., Manufactured by Sekisui Chemical Co., Ltd.) for surface modification. SURFACE MODIFICATION CONDITIONS
    [0082] [0082] Gas type flow rate: 1,000 cc / m of air, 6,000 cc / min of N2
    [0083] [0083] Input voltage: 230 V
    [0084] [0084] Frequency: 10 kHz
    [0085] [0085] Treatment rate: 100 mm / min
    [0086] [0086] Then, in order to prevent an ink from spreading on the intermediate transfer member 1, a reaction solution that has the following formula was applied using a nozzle of an inkjet head to a position corresponding to a cross-sectional pattern that forms the cross-sectional layer 14. REACTION SOLUTION FORMULA MATHEMATICS 1 Ca (No3) 2 · 4H2O: 50 parts by mass
    [0087] [0087] Surfactant (trademark: Acetylanol EH, manufactured by Kawaken Fine Chemicals Co., Ltd.): 1 part by mass
    [0088] [0088] Diethylene glycol: 9 parts by weight
    [0089] [0089] Purified water: 40 parts by mass
    [0090] [0090] Then, the ink pattern 4 of a cross-section of the structural body was formed on the intermediate transfer member by applying an ink color that has the formula to follow with the use of a different nozzle of the inkjet head. . INK COMPOSITION
    [0091] [0091] Pigment to follow: 3 parts by mass
    [0092] [0092] Black: carbon black (trademark: MCF 88, manufactured by Mitsubishi Chemical Corp.), Cyan: Pigment Blue 15, Magenta: Pigment Red 7, Yellow: Pigment Yellow 74
    [0093] [0093] Styrene acrylic acid acrylate copolymer (acid value: 240, weighted average molecular weight: 5,000): 1 part by weight
    [0094] [0094] Glycerin: 10 parts by weight
    [0095] [0095] Ethylene glycol: 5 parts by weight
    [0096] [0096] Surfactant (trademark: Acetylanol EH, manufactured by Kawaken Fine Chemicals Co., Ltd.): 1 part by mass
    [0097] [0097] Purified water: 80 parts by mass
    [0098] [0098] Then, polypropylene particles (average particle diameter: 200 micrometers) that function as the format 6 forming material were fed to an ink image 14 on the intermediate transfer member 1 by a knife coating that functions as the mechanism for supplying format 5 training material.
    [0099] [0099] Then, de-electrified air was blown from the air knife 8 at a wind speed of 30 m / s to the intermediate transfer member 1, so that the shape 6 forming material outside the ink image has been removed. .
    [0100] [0100] Next, heating was carried out by heaters 11 on the rear surface of the intermediate transfer member 1, and the mixture 7 of the ink, the reaction solution, and the forming material of format 6 was melted at approximately 170 degrees centigrade and it was formed in a film, so that a flat layer in cross-section 14 has been formed.
    [0101] [0101] Then, after the cross-sectional layer 14 has been transported to the position of the 20 format forming table (Figure 2A) and has been placed in a predetermined position, the 20 format forming table has been lowered to a position in the which the gap in the surface of the intermediate transfer member 1 was 100 micrometers, so that the surface of the formation table of format 20 was placed in contact with the layer in cross section 14 (Figure 2B).
    [0102] [0102] Then, a support material (PEG 2000 (poly (ethylene glycol)), weighted average molecular weight: 2,000) was melted at approximately 70 degrees Fahrenheit and was filled between the 20 format formation table and the limb intermediate transfer 1 (Figure 2C).
    [0103] [0103] Then, the cross-sectional layer 14 and the support material 16 were cooled to 20 degrees centigrade and solidified by circulating cold water in the cooling mechanisms 12 provided on the rear surface of the intermediate transfer member 1, so that the structural body 17 and the support member 18 have been obtained (Figure 2D).
    [0104] [0104] Next, the formation table of format 20 was raised together with the structural body 17 and the support member 18 (Figure 2E), so that the first layer has been completed.
    [0105] [0105] Henceforth, 50 the cross-sectional layers were repeatedly laminated to each other, and the height (thickness) of the structural body in process 17 became 5 mm. During the steps described above, whenever necessary, the support member 18 was melted at 70 degrees centigrade in order to fall on the surface of the intermediate transfer member 1 (Figure 6C) and was then solidified by cooling to 20 degrees centigrade ( Figure 6D), so that a layered surface on the side of the intermediate transfer member 1 obtained after the transfer has been made as a smooth surface formed of the structural body 17 and the support member 18.
    [0106] [0106] When the operation described above is repeatedly performed, and lamination has been performed fully 1,000 times, a laminate that has a height of 10 cm has been formed (Figure 6G).
    [0107] [0107] After the last layer was laminated, before the format 20 forming table was lifted, the molten support member 18 was automatically removed by suction and discharge using the support member filling mechanism 15 ( Figure 6H). Subsequently, the structural body was removed from the format formation table.
    [0108] [0108] In the structural body obtained as described above, no residue of support member and delamination that were caused by the history of heat during the lamination steps, the change with time, and the inclination between the layer in cross section were not observed and the laminating transfer surface.
    [0109] [0109] Although the present invention has been described with reference to the exemplary embodiments, it is to be understood that the invention is not limited to the exemplary embodiments disclosed. The scope of the following claims must be in accordance with the broadest interpretation to cover all such modifications and equivalent structures and functions.
    [0110] [0110] This application claims the benefit of the Patent Application in JP 2012272625, deposited on December 13, 2012, which is hereby incorporated by reference to this document in its entirety.
    权利要求:
    Claims (15)
    [0001]
    Method for making a structural body characterized by the fact that it comprises: a lamination step of, while a structural body in process is supported by a support member (18), laminating a plurality of times, a layer which is provided on a surface of a transfer member (1) and which must be formed in the structural body (17) in the structural body in process, wherein in the lamination step, between the plurality of laminations in the lamination step, between a lamination with a predetermined number and a lamination that follows the lamination with a predetermined number, the support member (18) is moved by changing the state smoothed, and the smoothed support member (18a), which has increased fluidity due to smoothing, is moved in order to reach the surface of the transfer member (1), and lateral surfaces of the laminate layer, as well as forming a surface to receive a layer (14) to be laminated in the next lamination.
    [0002]
    Method according to claim 1, characterized by the fact that the lamination step comprises: a substep of, while the structural body (17) in process is supported by the support member (18), place a second surface (32) of the layer that is provided on the surface of the transfer member (1) and that must be formed in the structural body (17), the second surface (32) being located opposite the transfer member (1), in contact with the structural body in process or at least part of a first surface formed of the structural body (17) in process and the support member (18); a substep of moving the support member (18) to reach the surface of the transfer member (1), smoothing the support member (18) while the first surface (31) and the second surface (32) are in contact with each other; a substep of solidifying the moved support member (18); and a substep of transferring the layer (14) that must be formed in the structural body (17) to the structural body in process (17) and the solidified support member (1) removing the transfer member from the support member (18) that the support member (18) is solidified.
    [0003]
    Method according to claim 2, characterized by the fact that the lamination step additionally comprises: a substep of placing the surface of the exposed support member (18), removing the transfer member (1) from the support member (18) in contact with a surface of an additional layer (14) which is provided on the surface of the transfer member (1) and which must be formed in the structural body (17), the surface of the additional layer being located opposite the transfer member (1).
    [0004]
    Method according to claim 2 or 3, characterized by the fact that when the layer to be formed on the structural body includes one segment and the other segment that are provided on the surface of the transfer member (1) in order to be spaced apart each other's; in the substep of placing the second surface in contact with at least part of the first surface, the support member is placed in a position further away from the transfer member (1) than from the first surface, the one segment of the layer that must being formed in the structural body is brought into contact with a part of the first formed surface of the structural body in process, and the other segment is placed away from the structural body in process; and in the substep of moving the support member, the support member is moved to reach lateral surfaces of the other segment.
    [0005]
    Method according to claim 4, characterized by the fact that, in the substep of moving the support member, the support member is moved in order to be in contact with the surface of the other segment opposite the transfer member.
    [0006]
    Method according to any one of claims 2 to 5, characterized in that the support member is a material to be smoothed by heating, and in the substep of moving the support member, the support member is smoothed by heating the same.
    [0007]
    Method according to claim 6, characterized in that the support member includes a metal.
    [0008]
    Method according to claim 6, characterized in that the support member includes a poly (ethylene glycol) or a paraffin wax.
    [0009]
    Method according to any one of claims 2 to 5, characterized in that the support member is formed of a material which is softened by irradiation of light and which is solidified by heating.
    [0010]
    Apparatus for manufacturing a structural body, the apparatus comprising: a lamination device which, while a structural body in process is supported by a support member, laminates a plurality of times, a layer which is provided on a surface of a transfer member and which must be formed in the structural body in the structural body in process or at least a part of a surface formed from the structural body in process and the support member; and a shifting device arranged to change the state of the support member (18) in order to move the support member, characterized by the fact that: in the laminating device (18), the support member (18) is softened such that the smoothed support member (18a), which has increased fluidity due to smoothing, is moved so as to reach the surface of the transfer member ( 1) and side surfaces of the laminated layer, to form a surface for receiving a layer (14) to be laminated in the next lamination, among the plurality of laminations in the lamination step, the lamination device can change the support member (18) between a lamination with a predetermined number and a lamination that follows the lamination with a predetermined number.
    [0011]
    Apparatus according to claim 10, characterized by the fact that, while the structural body in process is supported by the support member, the lamination device places a second surface of the layer which is provided on the surface of the transfer member and which must be formed on the structural body, the second surface being located opposite the transfer member, in contact with the structural body in process or at least part of a first surface formed of the structural body in process and the support member; the shifting device softens the support member while the first surface and the second surface are in contact with each other in order to move the support member to reach the surface of the transfer member and solidifies the moved support member; and after the support member is solidified by the changing device, the laminating device transfers the layer that must be formed on the structural body in the process structural body or the solidified support member by removing the transfer member from the support member.
    [0012]
    Apparatus according to claim 10 or 11, characterized in that the support member is a material that is softened by heating, and the changing device softens the support member by heating it.
    [0013]
    Apparatus according to claim 12, characterized by the fact that the support member includes a metal.
    [0014]
    Apparatus according to claim 12, characterized in that the support member includes a poly (ethylene glycol) or a paraffin wax.
    [0015]
    Apparatus according to claim 10 or 11, characterized by the fact that the support member is formed of a material which is softened by light irradiation and which is solidified by heating.
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    同族专利:
    公开号 | 公开日
    KR101769692B1|2017-08-18|
    WO2014092205A1|2014-06-19|
    US20150314578A1|2015-11-05|
    JP6292857B2|2018-03-14|
    EP2931499A1|2015-10-21|
    CN104837609A|2015-08-12|
    CN104837609B|2016-10-26|
    EP2931499A4|2016-08-17|
    BR112015012419A2|2017-07-11|
    KR20150091509A|2015-08-11|
    US9604437B2|2017-03-28|
    JP2014133414A|2014-07-24|
    EP2931499B1|2020-08-12|
    RU2602895C1|2016-11-20|
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    法律状态:
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |
    2019-12-10| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-02-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-04-06| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 12/12/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    JP2012-272625|2012-12-13|
    JP2012272625|2012-12-13|
    PCT/JP2013/084001|WO2014092205A1|2012-12-13|2013-12-12|Method for manufacturing structural body and manufacturing apparatus therefor|
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