JP2000202916A - Stereo lithographing method and device produced thereby - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize the easy and low cost production of a complicated shape with a device, by which a matter is housed in a resin case. SOLUTION: In this device, a stereo lithographing method, by which a setting is developed by the irradiation of a light U, is applied to a liquid photosetting resin L. In this case, cases 1-4 made of the photosetting resin L are formed on a stage S. After that, through the once interruption of the irradiation of the light and the utilization between the light irradiations, a turbine 10 is set to the cases 3-4. By continuing setting processes from the above, the remaining portion of the photosetting resin L, resulting in forming cases 6-9 at the side and the upper part of the turbine 10. Thus, even when a whole resin case has a complicated shape or when the turbine itself has a very small size, a device can be easily produced at low cost.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical shaping method and an apparatus manufactured by the method.

[0002]

2. Description of the Related Art As a general method of constructing a mechanical device or a fluid device by incorporating a mechanical component such as a gear or a fluid element such as a turbine or a filter into a resin case, a resin molding is performed in advance. Prepare a split case,
After a mechanical part or a fluid element is incorporated in one split mold case, the other split mold case is attached and fixed to one split mold case.

[0003] However, in the case of such a method, when the split mold case and the mechanical parts have a very complicated shape, the shape of the molding die becomes complicated and the cost increases. In addition, when the apparatus main body has such a complicated shape that it is difficult to assemble by the above method, the assembling by the above method cannot be performed.

Further, when the apparatus itself is a small apparatus that constitutes a micro machine, mechanical parts and fluid elements become very small, so that a microscope or the like must be used for assembling the apparatus. Ultra-precision assembly work on the order of microns is required, and assembly is not easy.
Further, if a gap is formed in the mating surface of each split mold case, there is a possibility that lubricant or fluid inside the case leaks out of the case from the gap during operation.

SUMMARY OF THE INVENTION The present invention has been made to solve such a conventional problem, and an object of the present invention is to make it possible to manufacture a complicated shape at low cost in a device in which an object is housed. It is in. Another object of the present invention is to
An object of the present invention is to make it possible to easily manufacture a device having a shape, a structure, and a size that are difficult to assemble. Still another object of the present invention is to make it possible to reliably prevent a lubricant or a fluid from leaking outside in the device.

[0006]

According to a first aspect of the present invention, there is provided a stereolithography method for irradiating a liquid photocurable resin with light to cure the photocurable resin into a desired shape. During the curing process of the photocurable resin, an object is placed on the cured photocurable resin, and the curing process is continued from this state.

According to a second aspect of the present invention, there is provided an apparatus manufactured by using an optical molding method for irradiating a liquid photocurable resin with light to cure the photocurable resin into a desired shape. During the curing process of the photo-curable resin, the object is placed on the cured photo-curable resin, and the curing process is continued from this state to manufacture the photo-curable resin.

According to a third aspect of the present invention, in the stereolithography method, the object is a movable member supported by a photocurable resin.

According to a fourth aspect of the present invention, in the second aspect, the object is a movable member supported by a photocurable resin.

A stereolithography method according to a fifth aspect of the present invention is characterized in that, in the third aspect, the movable member is a movable member for a micromachine, and is a rotating body or a sliding body.

According to a sixth aspect of the present invention, in the fourth aspect, the movable member is a movable member for a micromachine, and is a rotating body or a sliding body.

A stereolithography method according to a seventh aspect of the present invention is characterized in that, in the third or fifth aspect, the movable member is a turbine or a gear.

According to an eighth aspect of the present invention, in the fourth or sixth aspect, the movable member is a turbine or a gear.

According to a ninth aspect of the present invention, there is provided a stereolithography method according to the first aspect, wherein the object is a fixing member fixed to a photocurable resin.

According to a tenth aspect of the present invention, there is provided an apparatus according to the second aspect.
Wherein the object is a fixing member fixed to a photocurable resin.

[0016] The stereolithography method according to the eleventh invention is characterized in that:
According to a ninth aspect, the fixing member is a fixing member for a micro machine.

The device according to the twelfth aspect of the invention is the first aspect of the invention.
0, the fixing member is a fixing member for a micromachine.

The stereolithography method according to the invention of claim 13 is:
The ninth or eleventh aspect is characterized in that the fixing member is a filter.

The device according to the invention of claim 14 is the device according to claim 1
0 or 12, wherein the fixing member is a filter.

The stereolithography method according to the invention of claim 15 is
The ninth or eleventh aspect is characterized in that the fixing member is a sensor.

The device according to the sixteenth aspect of the present invention is the first aspect of the present invention.
0 or 12, wherein the fixing member is a sensor.

According to a seventeenth aspect of the present invention, there is provided a stereolithography method.
The ninth or eleventh aspect is characterized in that the fixing member is a circuit element.

The device according to claim 18 is the device according to claim 1.
0 or 12, wherein the fixing member is a circuit element.

According to the first and second aspects of the present invention, during the curing process of the photocurable resin, the light irradiation is temporarily interrupted or the object is placed on the cured photocurable resin by using the interval between the light irradiations. The curing process is continued from this state to cure the remaining portion of the photocurable resin. Thus, even if the entire apparatus has a complicated shape, it can be manufactured at low cost without the need for a molding die.

Further, since an arbitrary portion of the photocurable resin can be cured, the photocurable resin has a shape and structure that are difficult to assemble by a conventional method, and can be easily manufactured. Further, since the size of the device to be manufactured is not limited, even if the device itself is a small one that constitutes a micromachine, it can be easily manufactured.

In addition, since the cured portions of the photocurable resin are all integrally formed, leakage of the internal lubricant or fluid to the outside can be reliably prevented.

The object placed on the cured photocurable resin may be a movable member as described in the third or fourth aspect of the invention, or may be a movable member as described in the ninth or tenth aspect. The fixing member as described above may be used.

The movable member may be a movable object for a micromachine and may be a rotating body or a sliding body, and the fixed member may be a movable body for a micromachine. As described, it may be a fixing member for a micromachine.

The movable member may be a turbine or a gear as described in the seventh or eighth aspect of the present invention, and the fixed member may be a filter as described in the thirteenth to eighteenth aspects. , A sensor or a circuit element such as an electric circuit or an electronic circuit.

[0030]

DESCRIPTION OF THE PREFERRED EMBODIMENTS [ First Embodiment] The first embodiment of the present invention
FIGS. 1 to 5 show an optical molding method according to the embodiment of FIG.
This will be described with reference to FIG. Here, an example in which a device in which a turbine is disposed inside a resin case configured by curing a photocurable resin is manufactured will be described. 1 to 4 are views for explaining a processing process of the stereolithography method, and FIG. 5 is an overall perspective view of an apparatus manufactured by the stereolithography method.

In the first embodiment, a case where a free liquid level method without a liquid level regulating plate is used as an optical shaping method is taken as an example, but a liquid level regulating method using a liquid level regulating plate is used. May be adopted, or any other method may be adopted. This is the same in the following second and third embodiments.

In this case, first, the liquid photo-curable resin L is put into a container (not shown), and the stage S provided so as to be able to move up and down is moved upward so that the stage upper surface S
A thin layer of the liquid photocurable resin L is formed between a and the liquid surface. From this state, the liquid surface is irradiated with light U to cure the photocurable resin L.
To form a first cured layer (see FIG. 1).

Next, the stage S is lowered by one step to form a thin layer of the liquid photocurable resin L again between the cured layer and the liquid surface, and from this state, the liquid surface is irradiated with light U. Thereby, a second hardened layer is formed (see FIG. 1). Next, by the same operation as when forming the cured layer,
A third hardened layer is formed. However, when forming the hardened layer, the irradiation position of the light U is controlled so that a circular hole 3a is formed in the center of the hardened layer as shown in FIG.

Next, as shown in FIG. 2, a fourth cured layer having a hole 4a in the center is formed by the same operation as that for forming the cured layer.

Then, as shown in FIG. 3, the turbine 10 is arranged on the fourth hardened layer. At this time, each hole 3a, 4 of the hardened layer
a.

Next, by curing the photocurable resin L on the near side and the back side of the sheet of FIG. 3, a cured layer is sequentially laminated on the cured layer to form a cured layer as shown in FIG. .

Next, a hardened layer 1 as shown in FIG. 4 is formed on the hardened layer (see FIG. 5). In this case, when the hardened layer is formed, by controlling the irradiation position of the light U, each hole 3 formed in the hardened layer is controlled.
a and 4a are formed in each of the hardened layers, respectively, and the turbine 1 is formed in these holes.
The upper part of the 0 axis 10a is arranged (see FIG. 4).

Thus, as shown in FIG. 5, a device (fluid device) 1 having the turbine 10 inside the resin case 20 is completed. This device 1 has a through hole 1a, and a turbine 10 is rotatably arranged in the through hole 1a. In this device 1, by flowing a fluid into the through-hole 1a, the turbine 10 can be rotated by the flow of the fluid.

Here, when the apparatus 1 is to be manufactured using a molding die which is a conventional method, the resin case 2
0 is divided into two, and the turbine 10
After disposing, the other split mold case needs to be attached to one split mold case.

However, in this case, when a gap is formed in the mating surface of each split mold case, the fluid inside the case may leak out of the case from the gap. If the apparatus itself is a small apparatus that constitutes a micromachine, the internal turbine becomes very small, so that it is not easy to assemble the apparatus.

On the other hand, in the present embodiment, since the cured portions of the photocurable resin are all integrally formed, leakage of the fluid to the outside of the case can be reliably prevented. Further, even in the case of a small-sized device such as a micromachine, it can be easily manufactured because it is only necessary to control the light irradiation range and the like.

Further, according to the present embodiment, even if the case has a very complicated shape or structure, any part of the photocurable resin is cured by using the above-mentioned stereolithography. The case can be manufactured easily and inexpensively.

It should be noted that the apparatus may be configured using gears or other movable members instead of the turbine 10. In this case, similarly to the above-described embodiment, it is possible to easily and inexpensively manufacture a product having a complicated shape and structure, to manufacture a product having an arbitrary size, and to prevent leakage of lubricant and the like inside the case. It can be reliably prevented.

[ Second Embodiment ] An optical shaping method according to a second embodiment of the present invention will be described with reference to FIGS. Here, an example in which a device in which a filter is disposed inside a resin case configured by curing a photocurable resin is manufactured will be described. 6 to 9
Is a view for explaining the processing process of the optical shaping method, and FIG. 10 is an overall perspective view of an apparatus manufactured by the optical shaping method. In these figures, the same reference numerals as those in the first embodiment denote the same or corresponding parts.

In this case, as in the case of the first embodiment, the stage S is moved upward inside the liquid photocurable resin L accommodated in a container (not shown), and the stage upper surface Sa and the liquid are cured. A thin layer of liquid photocurable resin L is formed between the surface and the surface. Then, the liquid surface is irradiated with light U to cure the photocurable resin L, thereby forming the first cured layer 31 (see FIG. 6). When the hardened layer 31 is formed, the irradiation range of the light U is controlled so that a hardened layer having a rectangular shape in a plan view is formed as shown in FIG.

Next, the stage S is lowered by one stage to form a thin layer of the liquid photocurable resin L between the first hardened layer 31 and the liquid surface. To form a second hardened layer 31 (see FIGS. 6 and 7). Thereafter, the third to fifth hardened layers 31 are formed in the same manner. In this way, the stacked body 30 of the cured layer 31 is formed on the stage S.

Next, as shown in FIG. 8, the filter F is mounted on the fifth hardened layer 31. From this state, a laminated body 30 ′ of the cured layer 32 is formed on the upper surface of the filter F by the same operation as that for forming the laminated body 30 including the plurality of cured layers 31 (see FIGS. 9 and 10). .

In this way, as shown in FIG. 10, a device (fluid device) 40 in which the filter F is fitted in the longitudinal center portion of the resin case 41 is manufactured. The device 40 has a through-hole 40a, and the fluid can be filtered by flowing the fluid into the through-hole 40a.

Here, when the apparatus 40 is manufactured by using a molding die which is a conventional method, two parts of the laminate 30 and the laminate 30 'are produced as a resin case 41, and these are formed. It is necessary to sandwich and fix the filter F in the portion.

However, in this case, as in the case of the first embodiment, if a gap is formed in the mating surface of each part, the fluid inside the case flows from the gap to the outside of the case. There is a risk of leakage. If the device itself is a small device that constitutes a micromachine, the filter becomes very small, and it is not easy to assemble the device.

On the other hand, in the second embodiment,
Since each of the laminates 30 and 30 'is formed integrally with the filter F interposed therebetween, leakage of fluid to the outside of the case can be reliably prevented. Also, even in the case of a small device such as a micromachine, since the irradiation range of light and the like may be controlled,
It can be easily manufactured.

Further, according to the second embodiment, even if the case has a very complicated shape and structure, any of the photo-curable resins can be formed using the above-mentioned stereolithography. Since the part can be cured, the case can be manufactured easily and inexpensively.

[ Third Embodiment ] An optical shaping method according to a third embodiment of the present invention will be described with reference to FIGS. Here, as in the case of the second embodiment, a case where a device in which a filter is disposed inside a resin case configured by curing a photocurable resin is taken as an example. In the second embodiment, an example is shown in which the cured layer of the photocurable resin is laminated in the longitudinal direction of the case, whereas in the third embodiment, the cured layer of the photocurable resin is laminated in the longitudinal direction of the case. The second embodiment differs from the second embodiment in that an example in which the layers are stacked in a direction perpendicular to the second embodiment is shown.

FIGS. 11 to 13 are views for explaining the working process of the stereolithography method, and FIG. 14 is an overall perspective view of an apparatus manufactured by the stereolithography method. In these figures, the same reference numerals as those in the second embodiment denote the same or corresponding parts.

In this case, first, the hardened layers 35 and 36 are formed on the upper surface Sa of the stage S by the same operation as that for forming the hardened layers 1 to 3 in the first embodiment (see FIG. 11). At this time, when the hardened layer 36 is formed, the irradiation position of the light U is controlled such that a groove 36a extending in the direction perpendicular to the paper of the drawing is formed at the center of the hardened layer 36.

Next, as shown in FIG. 12, the filter F is placed in the groove 36a of the hardened layer 36. From this state, the hardened layers 37, 38, and 39 are formed by the same operation as that for forming the hardened layers 1 to 3 in the first embodiment (see FIGS. 13 and 14). At this time, when forming the hardened layer 38, by controlling the irradiation position of the light U, the grooves opposed to the grooves 36a formed in the hardened layer 36 are formed in the hardened layer 38, respectively.
The upper part of the filter F is arranged in these grooves (see FIGS. 13 and 14).

In this manner, as shown in FIG. 14, a device (fluid device) 40 'in which the filter F is embedded in the resin case 41' is manufactured. This device 40 '
Has a through-hole 40'a, and the fluid can be filtered by flowing the fluid through the through-hole 40'a.

Here, when the apparatus 40 'is manufactured using a molding die which is a conventional technique, a resin case 41' is used.
It is necessary to manufacture two split mold parts, set the filter F in one split mold part, and then fix the other split mold part to one split mold part.

However, in this case, when a gap is formed in the mating surface of each split mold portion, fluid inside the case may leak from the gap to the outside of the case. If the device itself is a small device that constitutes a micromachine, the filter becomes very small, and it is not easy to assemble the device.

On the other hand, in the third embodiment,
Since the cured photo-curing resin is all integrally formed, leakage of fluid to the outside of the case can be reliably prevented. Further, even in the case of a small device such as a micromachine, the device can be easily manufactured because the irradiation range of light and the like need only be controlled.

Further, according to the third embodiment, even if the case has a very complicated shape or structure, any of the photo-curable resin can be formed using the above-mentioned stereolithography processing method. Since the part can be cured, the case can be manufactured easily and inexpensively.

The direction in which the filter is attached to the case is not limited to the direction orthogonal to the flow of the fluid as shown in the second and third embodiments, but is arranged obliquely to the flow of the fluid. May be used.

[ Other Embodiments ] The second and third embodiments will be described.
In the above embodiment, the case where a device including a filter is manufactured has been described as an example, but the device may be configured using a sensor instead of the filter. Further, the device may be configured using circuit elements of an electric circuit or an electronic circuit instead of the filter.

In this case, as in the case of the second and third embodiments, a product having a complicated shape and structure can be manufactured easily and inexpensively, and a product having an arbitrary size can be manufactured.
Moreover, in this case, since the photocurable resin is generally an insulating resin, it is particularly suitable as a holding member for circuit elements.

Further, the present invention can be similarly applied to the case of manufacturing an apparatus including an arbitrary member in addition to a functional material and a chemical substance.

[0066]

As described in detail above, according to the present invention, during the curing process of the photocurable resin, an object is placed on the cured photocurable resin, and the curing process is continued from this state. ing. As a result, even if the device itself has a complicated shape, there is an effect that the device can be manufactured at low cost without requiring a molding die. Further, since an arbitrary portion of the photocurable resin can be cured, the photocurable resin has a shape and structure that are difficult to assemble and can be easily manufactured. In addition, since the size of the device to be manufactured is not limited, an arbitrary size device can be easily manufactured. Further, since the cured photo-curable resin is all formed integrally, there is an effect that the leakage of the lubricant or fluid inside can be reliably prevented.

[Brief description of the drawings]

FIG. 1 is a view for explaining a processing process using an optical shaping method according to a first embodiment of the present invention.

FIG. 2 is a view for explaining a processing process using an optical shaping method according to the first embodiment of the present invention.

FIG. 3 is a view for explaining a processing process using an optical shaping method according to the first embodiment of the present invention.

FIG. 4 is a view for explaining a processing process using the optical shaping processing method according to the first embodiment of the present invention.

FIG. 5 is a diagram showing a production example of a turbine device produced by using the optical shaping method according to the first embodiment of the present invention.

FIG. 6 is a view for explaining a processing process using an optical shaping method according to a second embodiment of the present invention.

FIG. 7 is a view for explaining a processing process using an optical shaping method according to a second embodiment of the present invention.

FIG. 8 is a view for explaining a processing process using an optical shaping method according to a second embodiment of the present invention.

FIG. 9 is a view for explaining a processing process using an optical shaping method according to the second embodiment of the present invention.

FIG. 10 is a view showing a manufacturing example of a filter device manufactured by using an optical shaping method according to a second embodiment of the present invention.

FIG. 11 is a view for explaining a processing process using a stereolithography method according to a third embodiment of the present invention.

FIG. 12 is a view for explaining a processing process using a stereolithography method according to a third embodiment of the present invention.

FIG. 13 is a view for explaining a processing process using an optical shaping method according to a third embodiment of the present invention.

FIG. 14 is a diagram showing a manufacturing example of a filter device manufactured by using an optical shaping method according to a third embodiment of the present invention.

[Explanation of symbols]

 Reference Signs List 1 device 1a through hole 3a, 4a circular hole 10 turbine 10a shaft 20 case 31, 32 hardened layer 35, 36 hardened layer 37, 38, 39 hardened layer 36a groove 40, 40 'device 40a, 40'a through hole 41, 41 'case L liquid photo-curing resin U light S-stage F filter-cured layer

Claims (18)

[Claims] 1. A photolithographic processing method for irradiating a liquid photocurable resin with light to cure the photocurable resin into a desired shape. Wherein the object is placed on the substrate and the curing process is continued from this state. 2. An apparatus manufactured by using an optical shaping method for irradiating a liquid light curable resin with light to cure the light curable resin into a desired shape, the apparatus comprising: A device manufactured by placing an object on a cured photocurable resin and continuing the curing process from this state. 3. The stereolithography method according to claim 1, wherein the object is a movable member supported by a photocurable resin. 4. The apparatus according to claim 2, wherein the object is a movable member supported by a photocurable resin. 5. The stereolithography method according to claim 3, wherein the movable member is a movable member for a micromachine, and is a rotating body or a sliding body. 6. The apparatus according to claim 4, wherein the movable member is a movable member for a micro machine, and is a rotating body or a sliding body. 7. The stereolithography method according to claim 3, wherein the movable member is a turbine or a gear. 8. The apparatus according to claim 4, wherein the movable member is a turbine or a gear. 9. The stereolithography method according to claim 1, wherein the object is a fixing member fixed to a photocurable resin. 10. The apparatus according to claim 2, wherein the object is a fixing member fixed to a photocurable resin. 11. The stereolithography method according to claim 9, wherein the fixing member is a fixing member for a micro machine. 12. The apparatus according to claim 10, wherein the fixing member is a fixing member for a micro machine. 13. The stereolithography method according to claim 9, wherein the fixing member is a filter. 14. The device according to claim 10, wherein the fixing member is a filter. 15. The stereolithography method according to claim 9, wherein the fixing member is a sensor. 16. The device according to claim 10, wherein the fixing member is a sensor. 17. The stereolithography method according to claim 9, wherein the fixing member is a circuit element. 18. The device according to claim 10, wherein the fixing member is a circuit element.