JP6355063B2 - Solid shape manufacturing method and solid shape manufacturing apparatus - Google Patents

Description

  The present invention relates to a method for manufacturing a three-dimensional object and a three-dimensional object manufacturing apparatus for manufacturing a three-dimensional object.

Conventionally, a method of manufacturing a three-dimensional object (three-dimensional object) by laminating sheet-like members such as a hardened layer and a paper sheet material is known (see, for example, Patent Documents 1 and 2).
Specifically, in Patent Document 1, a solidified material that can be partially vaporized and removed by irradiating laser light is laminated, and the removed portion is filled and cured with a photocurable resin. A method of modeling a three-dimensional object by repeating is disclosed.
Further, in Patent Document 2, a paper sheet material is joined one by one with an adhesive, and each time the joining is performed, the paper sheet material is cut into a cross-sectional shape, and a three-dimensional object is formed by repeating this. A method is disclosed.

Since the technique described in Patent Document 1 repeatedly performs the process of removing the solidified material by irradiating a laser beam, it takes a lot of labor and time until one three-dimensional shaped object is manufactured, The device was expensive.
Similarly, the technique described in Patent Document 2 also requires an adhesive application process and a paper sheet material cutting process in accordance with a cross-sectional shape for each layer, so that there are many techniques until one three-dimensional shape is manufactured. It took time and effort, and the equipment became expensive.

  The present invention has been made to solve the above-described problems, and is a three-dimensional object that can be manufactured with a relatively simple and inexpensive configuration without much effort and time. It is providing the manufacturing method of this and a solid-shaped article manufacturing apparatus.

According to the first aspect of the present invention, there is provided a method for producing a three-dimensionally shaped article, wherein a desired three-dimensionally shaped article is divided into a plurality of sections in a predetermined direction using a heat-meltable powder. An image forming process for forming a corresponding image, an image fixing process for fixing the image formed in the image forming process on the surface of a sheet material that can be dissolved in a predetermined solvent, and an image formed by the image fixing process. A plurality of fixed sheet materials are stacked in a direction corresponding to the predetermined direction so as to correspond to the three-dimensionally shaped object, and each image interposed between the sheet materials is heated and melted to e Bei a loading step of the heavy wear plurality of sheet material, and a removal step of removing dissolved by the solvent portion where no image is formed in said plurality of sheet materials that are heavy wear in the loading step ,Previous The sheet material is water-soluble and is formed to have a thickness in the range of 20 to 100 μm, and the removing step is performed with water vapor having a temperature equal to or higher than a temperature at which the sheet material is dissolved. As the solvent, the step of immersing the plurality of sheet materials in high pressure in the water vapor, or the step of spraying the water vapor on the plurality of sheet materials .

  According to the present invention, there is provided a method for manufacturing a three-dimensional object and a three-dimensional object manufacturing apparatus capable of manufacturing a three-dimensional object with a relatively simple and inexpensive configuration without much effort and time. can do.

It is a whole block diagram which shows the three-dimensionally shaped object manufacturing apparatus in embodiment of this invention. It is a block diagram which shows a part of image forming part. It is a perspective view which shows the process in which a three-dimensional shaped object is manufactured. It is a figure which shows the process in which a three-dimensional shaped object is manufactured in a loading part.

Embodiment.
Hereinafter, embodiments for carrying out the present invention will be described in detail with reference to the drawings. In addition, in each figure, the same code | symbol is attached | subjected to the part which is the same or it corresponds, The duplication description is simplified or abbreviate | omitted suitably.

First, with reference to FIGS. 1 and 2, the configuration of the image forming apparatus 100 functioning as a part of the three-dimensional object manufacturing apparatus and the operation during normal image formation will be described.
FIG. 1 is a configuration diagram illustrating a three-dimensional object manufacturing apparatus including an electrophotographic image forming apparatus 100 (printer) and a stacking unit 200. FIG. 2 is a configuration diagram showing a part of an image forming section (image forming section) in the image forming apparatus 100 (three-dimensional object manufacturing apparatus).
As shown in FIG. 1, a substantially cylindrical toner container 32 </ b> Y of four colors corresponding to each color (yellow, magenta, cyan, black) is installed in an installation unit 31 (toner container cradle) above the image forming apparatus 100. , 32M, 32C, 32K (powder containers) are detachably mounted. Further, storage portions 62Y, 62M, 62C, and 62K of toner replenishing devices are disposed below the toner containers 32Y, 32M, 32C, and 32K, respectively.
An intermediate transfer unit 15 is disposed below the installation unit 31. Image forming portions 6Y, 6M, 6C, and 6K corresponding to the respective colors (yellow, magenta, cyan, and black) are arranged in parallel so as to face the intermediate transfer belt 8 of the intermediate transfer unit 15.

  Referring to FIG. 2, an image forming unit 6Y corresponding to yellow includes a photosensitive drum 1Y as an image carrier, a charging unit 4Y disposed around the photosensitive drum 1Y, and a developing device 5Y (developing unit). , A cleaning unit 2Y, a charge removal unit (not shown), and the like. Then, an image forming process (charging process, exposure process, developing process, transfer process, cleaning process) is performed on the photosensitive drum 1Y, and a yellow image is formed on the photosensitive drum 1Y.

  The other three image forming units 6M, 6C, and 6K have substantially the same configuration as that of the image forming unit 6Y corresponding to yellow except that the color of the toner used is different. A corresponding image is formed. Hereinafter, description of the other three image forming units 6M, 6C, and 6K will be omitted as appropriate, and only the image forming unit 6Y corresponding to yellow will be described.

Referring to FIG. 2, a photosensitive drum 1Y as an image carrier is rotationally driven in a clockwise direction in FIG. 2 by a motor (not shown). Then, the surface of the photosensitive drum 1Y is uniformly charged at the position of the charging unit 4Y (a charging process).
Thereafter, the surface of the photosensitive drum 1Y reaches the irradiation position of the laser beam L emitted from the exposure unit 7, and an electrostatic latent image corresponding to yellow is formed by exposure scanning at this position (in the exposure process). is there.).

Thereafter, the surface of the photosensitive drum 1Y reaches a position facing the developing device 5Y, and the electrostatic latent image is developed at this position to form a yellow toner image (developing process).
Thereafter, the surface of the photosensitive drum 1Y reaches a position facing the intermediate transfer belt 8 and the first transfer bias roller 9Y, and the toner image on the photosensitive drum 1Y is transferred onto the intermediate transfer belt 8 at this position. (This is a primary transfer step.) At this time, a small amount of untransferred toner remains on the photosensitive drum 1Y.

Thereafter, the surface of the photoreceptor 1Y reaches a position facing the cleaning unit 2Y, and untransferred toner remaining on the photoreceptor drum 1Y is collected at this position (cleaning process).
Finally, the surface of the photosensitive drum 1Y reaches a position facing a neutralization unit (not shown), and the residual potential on the photosensitive drum 1 is removed at this position.
Thus, a series of image forming processes performed on the photosensitive drum 1Y is completed.

The image forming process described above is performed in the other image forming units 6M, 6C, and 6K in the same manner as the yellow image forming unit 6Y. That is, the laser beam L based on the image information is emitted from the exposure unit 7 disposed below the image forming unit onto the photosensitive drums of the image forming units 6M, 6C, and 6K. Specifically, the exposure unit 7 emits laser light L from a light source, and irradiates the photosensitive drum through a plurality of optical elements while scanning the laser light L with a polygon mirror that is rotationally driven.
Thereafter, the toner images of the respective colors formed on the respective photosensitive drums through the developing process are transferred onto the intermediate transfer belt 8 in an overlapping manner. In this way, a color image is formed on the intermediate transfer belt 8.

  Here, the intermediate transfer unit 15 includes an intermediate transfer belt 8, four primary transfer bias rollers 9Y, 9M, 9C, and 9K, a secondary transfer backup roller 12, a cleaning backup roller 13, a tension roller 14, and an intermediate transfer cleaning unit 10. Etc. The intermediate transfer belt 8 is stretched and supported by the three rollers 12 to 14 and is endlessly moved in the direction of the arrow in FIG.

The four primary transfer bias rollers 9Y, 9M, 9C, and 9K sandwich the intermediate transfer belt 8 between the photosensitive drums 1Y, 1M, 1C, and 1K to form a primary transfer nip. Then, a transfer bias reverse to the polarity of the toner is applied to the primary transfer bias rollers 9Y, 9M, 9C, and 9K.
The intermediate transfer belt 8 travels in the direction of the arrow and sequentially passes through the primary transfer nips of the primary transfer bias rollers 9Y, 9M, 9C, and 9K. In this way, the toner images of the respective colors on the photosensitive drums 1Y, 1M, 1C, and 1K are primarily transferred while being superimposed on the intermediate transfer belt 8.

  Thereafter, the intermediate transfer belt 8 on which the toner images of the respective colors are transferred in a superimposed manner reaches a position facing the secondary transfer roller 19. At this position, the secondary transfer backup roller 12 sandwiches the intermediate transfer belt 8 with the secondary transfer roller 19 to form a secondary transfer nip. The four color toner images formed on the intermediate transfer belt 8 are transferred onto a sheet material P such as transfer paper conveyed to the position of the secondary transfer nip. At this time, untransferred toner that has not been transferred to the sheet material P remains on the intermediate transfer belt 8.

Thereafter, the intermediate transfer belt 8 reaches the position of the intermediate transfer cleaning unit 10. At this position, the untransferred toner on the intermediate transfer belt 8 is collected.
Thus, a series of transfer processes performed on the intermediate transfer belt 8 is completed.

Here, the sheet material P conveyed to the position of the secondary transfer nip is conveyed from the sheet feeding unit 26 disposed below the image forming apparatus 100 via the sheet feeding roller 27 and the registration roller pair 28. It has been done.
Specifically, a plurality of sheet materials P such as transfer paper are stored in the paper supply unit 26 in a stacked manner. When the paper feed roller 27 is driven to rotate counterclockwise in FIG. 1, the uppermost sheet material P is fed between the rollers of the registration roller pair 28.

  The sheet material P conveyed to the registration roller pair 28 (timing roller pair) temporarily stops at the position of the roller nip of the registration roller pair 28 whose rotation driving has been stopped. Then, the registration roller pair 28 is rotationally driven in synchronization with the color image on the intermediate transfer belt 8, and the sheet material P is conveyed toward the secondary transfer nip. Thus, a desired color image is transferred onto the sheet material P.

Thereafter, the sheet material P on which the color image is transferred at the position of the secondary transfer nip is conveyed to the position of the fixing device 20. At this position, the color image transferred to the surface is fixed on the sheet material P by heat and pressure generated by the fixing roller and the pressure roller. The fixing device 20 may be a known device such as a heater heating method or an electromagnetic induction heating method.
Thereafter, the sheet material P is discharged to the outside of the apparatus through the rollers of the paper discharge roller pair 29. The sheet material P discharged out of the apparatus by the discharge roller pair 29 is sequentially stacked on the stack unit 30 as an output image.
Thus, a series of image forming processes in the image forming apparatus is completed.

Next, the configuration and operation of the developing device in the image forming unit will be described in more detail with reference to FIG.
The developing device 5Y includes a developing roller 51Y that faces the photosensitive drum 1Y, a doctor blade 52Y that faces the developing roller 51Y, two conveying screws 55Y disposed in the developer containing portions 53Y and 54Y, and a developer. The replenishment unit 58Y communicates with the storage unit 54Y through the opening, the density detection sensor 56Y that detects the toner density in the developer, and the like. The developing roller 51Y includes a magnet fixed inside, a sleeve rotating around the magnet, and the like. In the developer accommodating portions 53Y and 54Y, a two-component developer composed of a carrier and a toner is accommodated.

The developing device 5Y configured as described above operates as follows.
The sleeve of the developing roller 51Y rotates in the direction of the arrow in FIG. The developer carried on the developing roller 51Y by the magnetic field formed by the magnet moves on the developing roller 51Y as the sleeve rotates.

  Here, the developer in the developing device 5Y is adjusted so that the toner ratio (toner concentration) in the developer is within a predetermined range. Specifically, the toner (powder) accommodated in the toner container 32Y (powder container) is developed via the toner transport pipe 43Y and the replenishing part 58Y of the toner replenishing device according to the toner consumption in the developing device 5Y. It is replenished in the medicine container 54Y.

  Thereafter, the toner replenished in the developer accommodating portion 54Y is circulated through the two developer accommodating portions 53Y and 54Y while being mixed and stirred together with the developer by the two conveying screws 55Y (in the direction perpendicular to the plane of FIG. 2). In the longitudinal direction). The toner in the developer is attracted to the carrier by frictional charging with the carrier, and is carried on the developing roller 51Y together with the carrier by the magnetic force formed on the developing roller 51Y.

  The developer carried on the developing roller 51Y is conveyed in the direction of the arrow in FIG. 2 and reaches the position of the doctor blade 52Y. The developer on the developing roller 51Y is conveyed to a position facing the photosensitive drum 1Y (development area) after the developer amount is made appropriate at this position. The toner is attracted to the latent image formed on the photosensitive drum 1Y by the electric field formed in the development area. Thereafter, the developer remaining on the developing roller 51Y reaches above the developer containing portion 53Y as the sleeve rotates, and is detached from the developing roller 51Y at this position.

  As described above with reference to FIG. 1, toner containers 32Y, 32M, 32C, and 32K as four types of powder containers are detachably installed on the installation unit 31 (toner container cradle). Each of the toner containers 32Y, 32M, 32C, and 32K is replaced with a new one when it reaches the end of its life (when the toner to be accommodated is almost exhausted). The respective color toners stored in the toner containers 32Y, 32M, 32C, and 32K are appropriately supplied to the developing devices of the image forming units 6Y, 6M, 6C, and 6K by a toner supply device (not shown). .

Hereinafter, the configuration and operation of the three-dimensional object manufacturing apparatuses 100 and 200 that are characteristic in the present embodiment will be described with reference to FIGS. 1, 3, and 4.
Referring to FIG. 1, an electrophotographic image forming apparatus 100 is configured such that a stacking unit 200 (loading device) is detachably installed, and the stacking unit 200 is installed (see FIG. 1). It also functions as a three-dimensional object manufacturing apparatus. That is, the image forming apparatus 100 functions as a normal printer (image forming apparatus) and also functions as a three-dimensional object manufacturing apparatus together with the stacking unit 200.

  When the image forming apparatus 100 functions as a three-dimensional object manufacturing apparatus, a dedicated sheet material is set as the sheet material P in the paper feeding unit 26 and dedicated toner (molding powder) is accommodated. The toner containers 32Y, 32M, 32C, and 32K are set. When the image forming apparatus 100 functions as a three-dimensional object manufacturing apparatus, the sheet material P that has completed the fixing process in the fixing device 20 is not discharged onto the stack unit 30 by the discharge roller pair 29, The paper is discharged toward the stacking unit 200. The paper discharge path is switched by a switching claw (not shown) installed in the conveyance path on the downstream side of the fixing device 20. In addition, switching between normal image forming operation and manufacturing of a three-dimensional object is performed by a user input operation on an operation panel (not shown) installed in the image forming apparatus 100 or on the image forming apparatus 100. This is done by user input to the connected terminal.

In the three-dimensional object manufacturing apparatus according to the present embodiment, a three-dimensional object is manufactured by performing four main processes of an image forming process, an image fixing process, a stacking process, and a removing process.
In the image forming process, one of the cross sections obtained by dividing a desired three-dimensional object W (see FIG. 3C) into a plurality of parts in a predetermined direction using toner as heat-meltable powder. Is a step of forming an image M corresponding to. In this process, image forming units 6Y, 6M, 6C, and 6K as image forming units provided in the image forming apparatus 100 (surfaces of the photosensitive drums 1Y, 1M, 1C, and 1K as image carriers by an electrophotographic method) This is the portion where the image is formed.
The image fixing step is a step of fixing the image M formed in the image forming step on the surface of the sheet material P that is soluble in a predetermined solvent. In this process, a fixing device 20 (an image formed on the surface of the photosensitive drums 1Y, 1M, 1C, and 1K is transferred via the intermediate transfer belt 8 as an image fixing unit provided in the image forming apparatus 100. The sheet material P is heated and pressed together with the image.).
These image forming process and image fixing process are performed in the same manner as the process in the image forming process described above with reference to FIG. In the example of FIG. 3, an image M having a predetermined thickness corresponding to the cross section (fragment) of the three-dimensional object W is formed on the sheet material P by these steps as shown in FIG. The

In the stacking process, the plurality of sheet materials P on which the images M are fixed in the image fixing process described above are stacked in a direction corresponding to a predetermined direction (the height direction) corresponding to the three-dimensional object W. In this step, each of the images M interposed between the sheet material P and the sheet material P is heated and melted so that the plurality of sheet materials P are adhered. In the example of FIG. 3, in this step, as shown in FIGS. 3B and 4A, a plurality of sheet materials P on which the image M is formed are stacked and stacked in the height direction. .
Further, the removing step (dissolving step) is a step of dissolving and removing a portion where the image M is not formed in the plurality of sheet materials P attached in the stacking step with a solvent. In the example of FIG. 3, as shown in FIGS. 3C and 4C, in this example, the portion where the image M is not formed is dissolved and removed, and the desired three-dimensional object W is formed. It is formed.
These loading process and removing process are performed by the loading unit 200.
Of course, the three-dimensionally shaped object W is not limited to the example shown in FIGS. 3 and 4.

Here, as the resin material constituting the powder (molding powder) used for forming the image M related to the three-dimensional object W in this way, for example, polyethylene (melting point: 137 degrees), polypropylene (melting point: 176 degrees), polyvinylidene chloride (melting point: 198 degrees), polyvinyl chloride (melting point: 212 degrees), polycarbonate (melting point: 220 degrees), polystyrene (melting point: 240 degrees), nylon (melting point: 265 degrees), etc. be able to. Further, the particles of the powder for modeling may be selected depending on the size and accuracy of the three-dimensional object to be modeled, but the particle size is preferably about 10 to 300 μm for modeling in a short time with high accuracy.
Specifically, in the present embodiment, toner formed so as to have an average particle diameter in the range of 10 to 300 μm is used as the modeling powder. In particular, when the toner used for manufacturing the three-dimensional object and the toner used for normal image formation (when the image forming apparatus 100 functions as a normal printer) are used in common. The replacement work of the toner containers 32Y, 32M, 32C, and 32K at the time of the function switching described above can be omitted.

In addition, the sheet material P used for forming the image M related to the three-dimensional object W can be selected depending on the size and modeling accuracy of the three-dimensional object to be modeled. In consideration of time, the thickness is preferably about 20 to 200 μm. In consideration of the ease of the above-described removal process, the sheet material P that can use water as a solvent, that is, the water-soluble sheet material P is preferable.
Specifically, in the present embodiment, as the sheet material P, a sheet material having water solubility and a thickness in the range of 20 to 100 μm is used.

Here, in the present embodiment, the stacking unit 200 is provided with a melting processing unit 220 for performing the above-described removal process (melting process) on the plurality of sheet materials P.
Specifically, the dissolution processing unit 220 is configured to immerse the plurality of sheet materials P loaded on the stacking unit 200 in high pressure in the water vapor using water vapor having a temperature equal to or higher than the temperature at which the sheet material P is dissolved as a solvent. Has been. Specifically, the melting processing unit 220 is a state in which the inside of the stacking unit 200 on which the sheet material P is stacked is substantially sealed with blocks 201 to 203, and by injecting high-temperature water vapor from the nozzle toward the inside, A portion of the sheet material P where the image M is not formed is dissolved and removed (see FIG. 4B).
In the present embodiment, the removing step is a step of immersing a plurality of sheet materials P in water vapor using water vapor having a temperature equal to or higher than the temperature at which the sheet material P is dissolved as a solvent. On the other hand, a removal process can also be made into the process of spraying water vapor | steam to several sheet | seat materials P by using the water vapor | steam which became the temperature more than the temperature which the sheet | seat material P melt | dissolves as a solvent. Regardless of which process is used, the remaining sheet P and the image M are heated while the excess portion of the sheet P is dissolved and removed by the high-temperature steam. Fixability (bondability) with each image M located is improved.

In addition, the stacking unit 200 according to the present embodiment is provided with a heat processing unit 210 as a heating unit that heats a plurality of stacked sheet materials P.
Specifically, the heat treatment unit 210 is a heater (or a high-frequency generator) embedded in the blocks 201 to 203 formed of a metal material having high thermal conductivity, and the loading unit is interposed via the blocks 201 to 203. A plurality of sheet materials P stacked on 200 are heated. As described above, by performing the heat treatment, fixability (weldability) between the sheet P and the respective images M positioned above and below in the stacking unit 200 is improved. That is, in the stacking process, the plurality of sheet materials P stacked on the stacking unit 200 are strongly attached to each other.

In the stacking unit 200 according to the present embodiment, a direction corresponding to a predetermined direction (in the present embodiment, the stacking direction) with respect to the plurality of sheet materials P, and a direction intersecting with the direction ( In this embodiment, a pressing means for applying a pressing force is provided in the horizontal direction perpendicular to the loading direction.
Specifically, with reference to FIGS. 1 and 4, the stacking unit 200 is provided with a lower surface block 201, a side surface block 202 as pressure contact means, and an upper surface block 203 as pressure contact means.
The lower surface block 201 functions as a stacking surface on which the sheet material P is stacked.
The side block 202 is a member for aligning the surface direction of the sheet material P stacked on the lower surface block 201, and is disposed so as to surround the four directions of the sheet material P. Is configured to be movable in the horizontal direction by a moving mechanism (not shown). Then, each time the sheet material P is placed on the lower surface block 201, the side block 202 is appropriately moved so as to vibrate in the forward and reverse directions in the horizontal direction, and a horizontal pressing force is applied to the sheet material P. Thus, the bundle of stacked sheet materials P is neatly aligned in four directions (refer to the movement of the side block 202 in the black arrow direction in FIG. 4A).
The upper surface block 203 is a member for applying a pressing force in the stacking direction to the sheet material P stacked on the lower surface block 201, and the retreat position that does not prevent the stacking of the sheet material P and the sheet material P are pressed against each other It is configured to be movable in the vertical direction by a moving mechanism (not shown). After a desired number of sheet materials P are stacked on the lower surface block 201, the upper surface block 203 moves from the retracted position to the pressure contact position, and a pressure contact force in the stacking direction is applied to the stacked sheet materials P, The bundle of sheet materials P is neatly aligned without any gap in the stacking direction (refer to the movement of the upper surface block 203 in the white arrow direction in FIG. 4A). Further, by heating the sheet material P stacked by the heat processing unit 210 in a state where the stacked sheet material P is pressed in the stacking direction, it is possible to improve the adherence to the plurality of sheet materials P during the stacking process. Can do.
In addition, in a state where the stacked sheet material P is pressed in the stacking direction, the sheet material P stacked by the heat processing unit 210 is heated and further removed, so that the remaining sheet is not dissolved by the solvent. Fixability (bondability) between P and the respective images M positioned above and below is improved. That is, as a whole, the three-dimensional object W is in a state where the boundary portions between all the sheet materials P and the images M are further strongly joined.

In the present embodiment, control is performed so that the plurality of sheet materials P are heated by the heat treatment unit 210 (heating means) during the removal process as well as during the stacking process. When the sheet material P is sufficiently bonded and the sheet material P is sufficiently bonded to each other, it is also possible to control the sheet material P to be heated by the heat treatment unit 210 only during the stacking process.
Further, in the present embodiment, the side block 202 and the upper surface block 203 functioning as the pressure contact means during the stacking process are controlled so as to apply the pressure contact force to the plurality of sheet materials P. The block 203 can be controlled to apply a pressing force to the plurality of sheet materials P. When such control is performed, the outer dimensions of the three-dimensional object W to be finally formed even when the outer dimension of the three-dimensional object W changes due to heat treatment or removal treatment (dissolution treatment). Can be finely adjusted so as to have a desired value.

As described above, the manufacturing method of the three-dimensional object W in the present embodiment is to manufacture the three-dimensional object W efficiently at high speed and continuously with a relatively small number of steps. In other words, the three-dimensional object W can be manufactured with a relatively simple and inexpensive configuration without much labor and time.
In particular, in the present embodiment, since the three-dimensional object W is manufactured using the electrophotographic image forming apparatus 100, the particles can be accurately transferred onto the sheet material P with a simple configuration. The problem of the curing depth, which is a concern with the technology of Patent Document 1 or the like, does not occur. That is, the electrophotographic image forming apparatus 100 can form the cross-sectional shape of the three-dimensional object W by continuously transferring the particles with high accuracy and at high speed.
Furthermore, in the present embodiment, since the color image forming apparatus 100 is used, the color three-dimensional object W can be formed relatively easily without performing a coloring process after manufacturing.
Moreover, since the cross-sectional shape of the three-dimensional object formed in this way is laminated | stacked after that and it is welded and joined by heat processing and a pressurization process, the joining property also becomes a high thing.
Furthermore, in the present embodiment, since the sheet material P is immersed in water vapor in the removing step using the water-soluble sheet material P, the sheet material P can be made brittle and when water vapor is sprayed. Even if the force is relatively small, an unnecessary portion of the sheet material P can be separated from the three-dimensional object W relatively easily. In order to separate unnecessary portions of the sheet material P, a separating member made of a brush or the like can be provided separately.
In this embodiment, since the stacking unit 200 is detachably installed on the image forming apparatus 100, the image forming apparatus 100 can be used as a normal printer (image forming apparatus) or a three-dimensional object manufacturing apparatus. Can be used as a user or expand the choice of users.

Finally, as a summary, the manufacturing method of the three-dimensional shaped object W in this Embodiment is demonstrated along process order.
First, prior to starting the manufacturing operation of the three-dimensional object, the toner containers 32Y, 32M, 32C, and 32K in which dedicated sheets P and toner (molding powder) are stored are set in the image forming apparatus 100. Then, data for each cross-sectional shape of the three-dimensional object W designed by CAD or the like is sent to the control unit of the image forming apparatus 100, and image forming processes (images) corresponding to all cross-sectional shapes based on the data. Forming step and image fixing step) are performed in the manner of the image forming process at the time of continuous paper feeding.
That is, the photosensitive drums 1Y, 1M, 1C, and 1K are rotationally driven in each of the image forming units 6Y, 6M, 6C, and 6K, and a plurality of image forming processes are continuously performed at predetermined intervals to supply paper. A plurality of sheet materials P are continuously fed from the unit 26 with a predetermined space between them, and a desired image M (a three-dimensional object W is divided on the sheet material P at the position of the secondary transfer roller 19. The image M corresponds to one of the cross-sectional shapes (fragments)), and the image M is fixed (supposed) on the sheet material P at the position of the fixing device 20. Thereafter, the sheet material P after the image fixing process is placed on the stacking unit 200 surrounded by the lower surface block 201 and the side surface block 202, respectively.
And such a continuous process is performed and the sheet | seat material P corresponding to all cross-sectional shapes is laminated | stacked on the stacking part 200 (temporary shaping). And it mounts so that the upper surface block 203 may press-contact to the uppermost position of the laminated | stacked (temporarily modeled) sheet | seat material P (it is a state of FIG. 4 (A)). At this time, the posture of the laminated sheet material P in the four directions is also adjusted by the movement of the side block 202 functioning as a jogger fence.
And the heat processing with respect to the sheet material P by the heat processing unit 210 is started, and an extra portion of the sheet material P (a portion that does not become the three-dimensionally shaped article W) by the removal processing (melting processing) by the melting processing unit 220. Is dissolved and removed (the state shown in FIG. 4B).
Finally, the sheet material P dissolved from the stacking unit 200 is discharged together with the solvent (water vapor), and a desired three-dimensional object W is formed in the stacking unit 200 (FIG. 4C ) State.) Thereafter, the upper surface block 203 and the side surface block 202 move, and the three-dimensional object W can be taken out from the stacking unit 200.
In addition, it is also possible to configure so that the heat treatment by the heat treatment unit 210 is finished at a timing before and after the removal process is finished, and the blocks 201 to 203 are cooled using a cooling unit. In such a case, it is possible to take out the three-dimensional object W in a sufficiently cooled state from the stacking unit 200.

  As described above, in the present embodiment, an image forming process for forming an image corresponding to one cross section of a desired three-dimensional object using a heat-meltable toner (powder) and a predetermined solvent are used. On the other hand, an image fixing process for fixing the image formed in the image forming process on the surface of the dissolvable sheet material P, and a plurality of sheet materials on which the images are fixed in the image fixing process are stacked and the image is heated and melted. And a removing step of removing a portion where an image is not formed in a plurality of sheet materials stacked in the stacking step by dissolving with a solvent. Accordingly, it is possible to provide a method for manufacturing a three-dimensional object and an apparatus for manufacturing a three-dimensional object that can manufacture a three-dimensional object with a relatively simple and inexpensive configuration without much effort and time. it can.

In this embodiment, the three-dimensional object is manufactured using the color image forming apparatus 100. However, the three-dimensional object can be manufactured using a monochrome image forming apparatus.
Even in such a case, the same effect as that of the present embodiment can be obtained.

  It should be noted that the present invention is not limited to the present embodiment, and it is obvious that the present embodiment can be modified as appropriate within the scope of the technical idea of the present invention, other than suggested in the present embodiment. is there. In addition, the number, position, shape, and the like of the constituent members are not limited to the present embodiment, and the number, position, shape, and the like suitable for implementing the present invention can be achieved.

6Y, 6M, 6C, 6K image forming unit (image forming unit),
20 fixing device (image fixing unit),
100 Image forming apparatus (three-dimensional object manufacturing apparatus),
200 loading unit (three-dimensional object manufacturing device),
201 bottom block,
202 side block (pressure contact means),
203 Upper surface block (pressure contact means),
210 Heat treatment section (heating means),
220 dissolution processing section,
P sheet material, M image, W solid shape object.

Japanese Patent No. 28899797 Japanese Patent No. 2914551

Claims (7)

An image forming step of forming an image corresponding to one of the cross sections obtained by dividing a desired three-dimensional object into a plurality of predetermined directions by using heat-meltable powder;
An image fixing step of fixing the image formed in the image forming step on the surface of a sheet material that is soluble in a predetermined solvent;
A plurality of sheet materials each having an image fixed by the image fixing step are stacked in a direction corresponding to the predetermined direction in correspondence with the three-dimensionally shaped object, and each interposed between the sheet material and the sheet material A stacking step of heat-melting the image and stacking the plurality of sheet materials;
A removal step of dissolving and removing a portion where no image is formed in the plurality of sheet materials stacked in the stacking step with the solvent;
Bei to give a,
The sheet material has water solubility and is formed so that the thickness is in the range of 20 to 100 μm.
The removing step includes a step of immersing the plurality of sheet materials in the water vapor at a high pressure equal to or higher than a temperature at which the sheet material is dissolved, or the water vapor in the plurality of sheet materials. A method for producing a three-dimensional object characterized by being a step of spraying . The powder is a toner formed so that an average particle diameter is within a range of 10 to 300 μm,
The image forming step is a step of forming the image on the surface of an image carrier,
2. The three-dimensional object according to claim 1, wherein the image fixing step is a step of heating and pressurizing together with the image a sheet material on which the image formed on the surface of the image carrier is transferred. Production method. The three-dimensionally shaped object according to claim 1 or 2, wherein the removing step is performed by heating the plurality of sheet materials while applying a pressing force in a direction corresponding to the predetermined direction. Manufacturing method. The stacking step is performed while applying a pressing force to the plurality of sheet materials in a direction corresponding to the predetermined direction or / and a direction crossing the direction. Item 4. A method for producing a three-dimensional object according to any one of Items 3 to 3. An image forming unit that forms an image corresponding to one of the cross sections obtained by dividing a desired three-dimensional object into a plurality of predetermined directions using powder that can be heated and melted;
An image fixing unit that fixes an image formed by the image forming unit on the surface of a sheet material that is soluble in a predetermined solvent;
A plurality of sheet materials each having an image fixed thereon by the image fixing unit are stacked in a direction corresponding to the predetermined direction in correspondence with the three-dimensionally shaped object, and each interposed between the sheet material and the sheet material A stacking unit that heat-melts the image and stacks the plurality of sheet materials;
With
The sheet material has water solubility and is formed so that the thickness is in the range of 20 to 100 μm.
The stacking unit uses the water vapor having a temperature equal to or higher than the temperature at which the sheet material is dissolved as the solvent to immerse the plurality of sheet materials in the water vapor at a high pressure, or to the water vapor in the plurality of sheet materials. The three-dimensional object manufacturing apparatus is configured to melt and remove a portion where no image is formed in the plurality of sheet materials stacked on the stacking portion. The powder is toner,
The image forming unit is an image forming unit that forms the image on the surface of an image carrier,
The image fixing unit is a fixing device that heats and pressurizes together with the image a sheet material on which the image formed on the surface of the image carrier is transferred,
The image forming unit and the fixing device are installed in an image forming apparatus,
The three-dimensional object manufacturing apparatus according to claim 5, wherein the stacking unit is detachably installed on the image forming apparatus. The loading section is
A pressing means for applying a pressing force to the plurality of sheet materials in a direction corresponding to the predetermined direction or / and a direction crossing the direction;
Heating means for heating the plurality of sheet materials;
The three-dimensional object manufacturing apparatus according to claim 5 or 6, characterized by comprising:

Images