JP2004042546A - Method for lamination-molding functional material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for lamination-molding a functional material by which a three-dimensional shape is molded and simultaneously a three-dimensional functional structure partially added with a function such as conductivity is molded. <P>SOLUTION: This method comprises (A) an uncured layer forming process of forming an uncured layer 2a of a photo-setting material 2, (B) a cured layer forming process of forming a cured layer 4 of a specified pattern in the uncured layer, (C) an uncured layer removing process of removing the uncured layer in the formed cured layer, (D) a functional material supply process of supplying a photo-setting material 11 including a functional material 11a in the region of the removed uncured layer and (E) a functional material curing process of curing a photo-setting material 11 including the functional material 11a. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
TECHNICAL FIELD The present invention relates to a method of layering a functional material by a photo-solidification molding method.
[0002]
[Prior art]
The photo-solidification method is also called rapid prototyping or stereolithography, and is a method of curing a photocurable resin with light to create a three-dimensional object.
[0003]
FIG. 4 is a diagram showing the principle of the photo-solidification method. (A) First, data of a three-dimensional model 1 produced by three-dimensional CAD or X-ray CT is sliced horizontally on a computer to create cross-sectional shape data. (B) Next, the liquid surface of the liquid photocurable resin 2 is irradiated with the laser light 3 while scanning along the slice data. The photocurable resin is cured with a certain thickness only at the portion irradiated with the laser beam, and the cured layer 4 is formed according to the cross-sectional shape data. (C) Next, the table 5 on which the cured layer 4 (modeled object) is placed is moved by a pitch obtained by slicing the model 1, and an uncured thin resin layer is formed on the upper surface of the cured layer. At this time, a flattening operation called “recoat” is performed with a member usually called a blade to make the surface of the uncured resin liquid uniform. Similarly, the laser beam 3 is irradiated while scanning according to the cross-sectional shape, and the cured layer is integrated with the immediately preceding cured layer 4. (D) By repeating steps B and C, a target three-dimensional model is formed.
[0004]
The photo-solidification method described above has the feature that a three-dimensional object can be created directly from CAD data without going through a mold, and is used in many fields such as production of master models such as precision casting and production of maps and stereoscopic images. Have been. Further, in order to enhance the accuracy and efficiency of the photo-solidification molding method, "optical molding method" (Japanese Patent Publication No. 5-33900) and "laminated flat plate molding method in light curing molding method" (Japanese Patent Publication No. 7-94149). , "Uniform surface exposure type photocuring molding apparatus" (JP-A-9-141747) and the like have been filed.
[0005]
Further, Japanese Patent Application Laid-Open No. 2002-36374 discloses a means for producing a colored molded article by a photo-solidification molding method. This method comprises a plurality of layers formed by laminating and molding a curable resin, and at least one of the plurality of layers is a method for producing a colored molded article having a colored region formed by adding a coloring agent. Then, a step (A) of forming an outer peripheral wall 6 by curing an area having a predetermined width along the contour of the colored area, and adding a colorant 8 to a liquid phase area 7 in the outer peripheral wall. Step (B) and Step (C) of curing the colored region.
That is, as schematically shown in FIG. 5, in the outer peripheral wall forming step (A), an uncured groove 7 is formed at a fixed distance from the side surface of the model during the modeling step, and the groove 7 is formed in the colorant adding step (B). The colored resin 8 is dropped on the substrate, and in the colored region curing step (C), the dropped portion is irradiated with laser light 9 to be solidified and colored.
[0006]
[Problems to be solved by the invention]
However, in the above-described conventional photo-solidification modeling method, a model or the like having a three-dimensional shape can be manufactured, but a three-dimensional functional structure (for example, three-dimensional wiring) having conductivity added thereto cannot be formed. Was.
[0007]
The present invention has been made to solve such a problem. That is, an object of the present invention is to provide a method for forming a three-dimensional shape and, at the same time, providing a method for forming a three-dimensional functional structure in which a function such as conductivity is added to a part of the three-dimensional shape. is there.
[0008]
[Means for Solving the Problems]
According to the present invention, an uncured layer forming step (A) for forming an uncured layer (2a) of the photocurable material (2), and a cured layer (4) having a predetermined pattern is formed on the uncured layer. A cured layer forming step (B), an uncured layer removing step (C) for removing an uncured layer between the formed cured layers, and a photocurable material containing a functional material (11a) in the removed uncured layer region A functional material supply step (D) for supplying the material (11); and a functional material curing step (E) for curing the photocurable material (11) containing the functional material. A method for additive manufacturing of a functional material is provided.
[0009]
According to the method of the present invention, the cured layer (4) having a predetermined pattern can be formed on the new uncured layer (2a) by the uncured layer forming step (A) and the cured layer forming step (B). . In addition, the uncured layer between the cured layers formed in the uncured layer removing step (C) is removed, and the light containing the functional material (11a) in the uncured layer region removed in the functional material supplying step (D). By supplying the curable material (11), the uncured layer between the formed cured layers can be replaced with the photocurable material (11) including the functional material (11a). Further, by curing the photo-curable material (11) containing the functional material in the functional material curing step (E), a three-dimensional shape is formed, and at the same time, a part of the three-dimensional shape is added with conductivity and the like, thereby providing a three-dimensional function. The structure can be shaped.
[0010]
According to a preferred embodiment of the present invention, the photocurable material (2) is a photocurable resin or a photocurable powder.
Regardless of whether a photocurable resin or a photocurable powder is used, a three-dimensional functional structure can be formed by the same process.
[0011]
The functional material (11a) is a powder or a melt of a resin, a metal, an organic substance, an inorganic substance, a gradient material.
By using these functional materials (11a), a three-dimensional wiring, a functionally graded material, and the like can be formed.
[0012]
The uncured layer removing step (C) is performed by suction of the uncured layer by a suction device or by blowing off the uncured layer by a blower.
According to this method, the uncured layer between the formed cured layers (4) can be easily removed.
[0013]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the present invention will be described with reference to the drawings. In addition, the same reference numerals are given to the common parts in the respective drawings, and the duplicate description will be omitted.
[0014]
FIG. 1 is a process chart showing a first embodiment of the additive manufacturing method of the present invention. In this embodiment, a photo-solidification molding device using a photocurable resin as the photocurable material 2 is used. This solidification molding apparatus includes a light irradiation device 12, a sedimentation device 14, a recoating device 16, a functional material dropping device 18, and a suction device 20.
[0015]
The light irradiation device 12 includes a laser light source 12a and a galvanomirror 12b, emits a laser beam (for example, UV) suitable for curing the photocurable resin 2, and applies the laser beam to the liquid of the photocurable resin 2 by the galvanomirror 12b. Light is condensed at a predetermined position (light curing position) on the surface.
[0016]
The sedimentation device 14 has an elevating table 14a that can be moved up and down in the vertical direction. By lowering the table 14a, the cured layer 4 is settled below the liquid level by optical scanning. The liquid surface of the photocurable resin 2 is supplied with a necessary amount of resin by a liquid surface holding device (not shown) so that the liquid surface is always kept constant.
[0017]
The recoating device 16 has a recoater 16a that moves horizontally on the upper surface of the cured layer 4, and the horizontal movement of the recoater 16a smoothes the upper surface of the uncured layer 2a and uncures on the settled cured layer 4. It is adapted to be covered with the layer 2a.
[0018]
The functional material dropping device 18 has a functional material dropping head 18a, from which the photocurable material 11 including the functional material 11a is dropped onto a predetermined position of the photocurable resin. The functional material dropping device 18 is, for example, an ink jet device.
The functional material 11a is a powder or a melt of a resin, a metal, an organic substance, an inorganic substance, a gradient material. For example, by using a molten metal, a three-dimensional wiring (three-dimensional print pattern) having a small electric resistance can be formed. Further, the composition of the molten metal can be changed in the middle to form a semiconductor, a functionally graded material, or the like. In the case of a material that solidifies alone such as a molten metal, the ratio of the photocurable material 11 may be reduced, or only the functional material 11a may be dropped without the photocurable material.
[0019]
The suction device 20 is a suction device for sucking the uncured layer, for example, a suction port of a vacuum pump. Note that a blower that can blow off the uncured layer may be used instead of the suction device 20.
[0020]
The light irradiation device 12, the functional material dropping device 18 and the suction device 20 described above are two-dimensionally arranged along the liquid surface of the photocurable resin at the liquid surface of the photocurable resin 2 and at a position one step higher than the liquid surface. The position can be controlled freely.
[0021]
In FIG. 1, the method of lamination molding of a functional material according to the present invention includes an uncured layer forming step (A), a cured layer forming step (B), an uncured layer removing step (C), and a functional material supplying step (D). And a functional material curing step (E), which is sequentially performed in this order.
[0022]
In the uncured layer forming step (A), the table 14 is lowered, and the uncured layer 2 a of the photocurable material 2 is formed on the upper surface of the cured layer 4 by the recoater 16.
In the cured layer forming step (B), the uncured layer 2a is irradiated with the laser beam 9 by the light irradiation device 12 to form the cured layer 4 having a predetermined pattern.
In the uncured layer removing step (C), the table 14 is raised and the uncured layer 2a between the cured layers 4 formed by the suction device 20 is removed.
In the functional material supply step (D), the photocurable material 11 including the functional material 11a is dropped on the uncured layer region removed by the functional material dropping device 18.
In the functional material curing step (E), the photocurable material 11 containing the functional material is cured by the light irradiation device 12.
[0023]
In the steps (A) to (E) described above, the additive manufacturing of one layer of the functional material is completed. Next, as shown in (A ′), the table 14 is lowered, and the uncured layer 2 a of the photocurable material 2 is formed on the upper surface of the cured layer 4 by the recoater 16. This step is substantially the same as the uncured layer forming step (A).
[0024]
By repeating the above steps (A) to (E), a three-dimensional functional structure schematically shown in FIG. 3A can be manufactured. This three-dimensional functional structure includes a functional part containing a functional material and a skeleton part containing no functional material.
In this figure, the function part is provided inside and the skeleton part is provided outside, but the present invention is not limited to this, and the function part may be provided outside. Further, the entire structure can be constituted only by the functional parts without the skeleton part.
[0025]
FIG. 2 is a process chart showing a second embodiment of the additive manufacturing method of the present invention. In this embodiment, a photo-solidification molding device using a photocurable powder as the photocurable material 2 is used. This solidification molding apparatus includes a light irradiation device 12, a sedimentation device 14, a recoating device 16, a functional material dropping device 18, and a suction device 20.
[0026]
The sedimentation device 14 has an elevating table 14a that can be moved up and down in the vertical direction. By lowering the table 14a, the cured layer 4 by optical scanning is settled under unreacted powder. The upper surface of the photocurable powder 2 is configured to supply necessary powder from the material supply tank 15a and keep the powder surface constant. In addition, 15b is a material discharge tank.
[0027]
The recoating device 16 has a recoater 16a that moves horizontally on the surface of the powder, and the horizontal movement of the recoater 16a smoothes the upper surface of the uncured layer 2a. It is designed to cover.
[0028]
The light irradiation device 12, the functional material dropping device 18, and the suction device 20 are the same as those in the first embodiment in FIG.
[0029]
In FIG. 2, the method of lamination molding of a functional material of the present invention includes an uncured layer forming step (A), a cured layer forming step (B), an uncured layer removing step (C), and a functional material supplying step (D). And a functional material curing step (E), which is sequentially performed in this order.
[0030]
In the uncured layer forming step (A), the table 14 is lowered, and the uncured layer 2 a of the photocurable material 2 is formed on the upper surface of the cured layer 4 by the recoater 16.
In the cured layer forming step (B), the uncured layer 2a is irradiated with the laser beam 9 by the light irradiation device 12 to form the cured layer 4 having a predetermined pattern.
In the uncured layer removing step (C), the table 14 is raised and the uncured layer 2a between the cured layers 4 formed by the suction device 20 is removed.
In the functional material supply step (D), the photocurable material 11 including the functional material 11a is dropped on the uncured layer region removed by the functional material dropping device 18.
In the functional material curing step (E), the photocurable material 11 containing the functional material is cured by the light irradiation device 12.
[0031]
In the steps (A) to (E) described above, the additive manufacturing of one layer of the functional material is completed. Next, as shown in (A ′), the table 14 is lowered, and the uncured layer 2 a of the photocurable material 2 is formed on the upper surface of the cured layer 4 by the recoater 16. This step is substantially the same as the uncured layer forming step (A).
[0032]
By repeating the above steps (A) to (E), a three-dimensional functional structure schematically shown in FIG. 3B can be manufactured. This three-dimensional functional structure includes a functional part containing a functional material and a skeleton part containing no functional material.
In this figure, the function part is provided inside and the skeleton part is provided outside, but the present invention is not limited to this, and the function part may be provided outside. Further, the entire structure can be constituted only by the functional parts without the skeleton part.
[0033]
According to the method of the present invention described above, the cured layer 4 having a predetermined pattern can be formed on the new uncured layer 2a by the uncured layer forming step (A) and the cured layer forming step (B). In addition, the photocurable layer which removes the uncured layer between the cured layers formed in the uncured layer removing step (C) and includes the functional material 11a in the uncured layer region removed in the functional material supplying step (D) By supplying the material 11, the uncured layer between the formed cured layers can be replaced with the photocurable material 11 including the functional material 11a. Further, by curing the photo-curable material 11 containing the functional material in the functional material curing step (E), a three-dimensional shape is formed, and at the same time, conductivity is added to a part of the three-dimensional shape. Can be shaped.
[0034]
It should be noted that the present invention is not limited to the above-described embodiments and examples, and it is needless to say that various changes can be made without departing from the gist of the present invention.
[0035]
【The invention's effect】
As described above, the additive manufacturing method of a functional material according to the present invention can form a three-dimensional shape and simultaneously form a three-dimensional functional structure in which a function such as conductivity is added to a part thereof. Has excellent effects.
[Brief description of the drawings]
FIG. 1 is a process chart showing a first embodiment of the additive manufacturing method of the present invention.
FIG. 2 is a process chart showing a second embodiment of the additive manufacturing method of the present invention.
FIG. 3 is a schematic diagram of a three-dimensional functional structure according to the additive manufacturing method of the present invention.
FIG. 4 is a diagram illustrating the principle of the photo-solidification molding method.
FIG. 5 is a schematic view of a conventional colored shaping means by a photo-solidification shaping method.
[Explanation of symbols]
1 3D model, 2 photo-curable materials (photo-curable resin, photo-curable powder),
2a uncured layer, 3 laser beam, 4 cured layer, 5 table, 6 outer wall,
7 liquid phase region (uncured groove), 8 colorant (coloring dye),
9 laser light, 11 photo-curable material, 11a functional material,
12 light irradiation device, 12a laser light source, galvanometer mirror 12b,
14 sedimentation device, 14a lifting table,
16 recoating device, 16a recoater,
18 functional material dripping device, 18a functional material dripping head,
20 Suction device

Claims (4)

An uncured layer forming step (A) for forming an uncured layer (2a) of the photocurable material (2), and a cured layer forming step (B) for forming a cured layer (4) having a predetermined pattern on the uncured layer. ), An uncured layer removing step (C) for removing the uncured layer between the formed cured layers, and supplying the photocurable material (11) including the functional material (11a) to the removed uncured layer region. A functional material supplying step (D), and a functional material curing step (E) for curing a photo-curable material (11) containing the functional material. Method. The method according to claim 1, wherein the photocurable material (2) is a photocurable resin or a photocurable powder. 2. The method according to claim 1, wherein the functional material is a resin, a metal, an organic substance, an inorganic substance, a powder of a gradient material or a melt. 3. 2. The method according to claim 1, wherein the uncured layer removing step (C) is performed by suction of the uncured layer by a suction device or by blowing off the uncured layer by a blower. 3.

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