JP2017202619A - Molding apparatus and molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a three-dimensional object with higher accuracy while reducing occurrence of a lamination failure.SOLUTION: A molding apparatus is provided for manufacturing a three-dimensional object by laminating, on a stage, layers of a thermoplastic molding material carried by a carrier, and the apparatus includes: heating means for heating a lamination surface of the three-dimensional object on the stage; laminating means for laminating a layer of the molding material carried by the carrier onto the lamination surface of the three-dimensional object on the stage; and control means for controlling the heating means and the laminating means. The control means controls in such a manner that the lamination surface is heated to a temperature equal to or higher than the softening temperature of the molding material by the heating means and that the molding material at a temperature lower than the softening temperature is laminated on the lamination surface.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a modeling apparatus and a modeling method.

In recent years, three-dimensional modeling techniques called additive manufacturing (AM), three-dimensional printers, rapid prototyping (RP), and the like have attracted attention (in this specification, these techniques are collectively referred to as AM techniques). AM technology slices three-dimensional shape data of a three-dimensional model to generate a plurality of slice data, and builds a three-dimensional object (three-dimensional object) by laminating a modeling material on a stage in sequence based on the slice data. Technology).
In Patent Document 1, an image made of a thermoplastic modeling material is formed by an electrophotographic method, a single material layer is formed by heating and melting the image, and then the material layers are sequentially stacked and fixed. Thus, a technique for producing a three-dimensional object has been proposed.

US Patent Application Publication No. 2013/0186558

In the AM technology of Patent Document 1, when a material layer is laminated on a three-dimensional object (hereinafter referred to as an intermediate shaped object) that is being produced, the material layer and the surface of the intermediate shaped object are brought to a temperature higher than the glass transition temperature (Tg) of the modeling material. Heating. The thermoplastic material becomes viscous when the temperature is higher than the glass transition temperature. Therefore, by heating the material layer to the glass transition temperature or higher, the adhesive force between the material layer and the material layer carrier can be increased.
However, if the adhesive force between the material layer and the transport body becomes strong, a part of the material layer remains on the transport body without being stacked on the intermediate shaped object during stacking, resulting in stacking failure. There is a concern that

  The present invention has been made in view of the circumstances as described above, and an object thereof is to reduce the occurrence of stacking faults and to produce a three-dimensional object with higher accuracy.

The first aspect of the present invention is:
In a modeling apparatus for producing a three-dimensional solid object by laminating a thermoplastic modeling material supported on a carrier on a stage,
Heating means for heating the laminated surface of the three-dimensional object on the stage;
Lamination means for laminating the modeling material carried on the carrier on the lamination surface of the three-dimensional object on the stage;
Control means for controlling the heating means and the laminating means;
Have
The control means controls the heating so that the laminated surface is heated to a temperature higher than or equal to the softening temperature of the modeling material, and the modeling material having a temperature lower than the softening temperature is laminated on the laminated surface. A modeling apparatus is provided.

The second aspect of the present invention is:
A modeling method by a modeling apparatus for producing a three-dimensional solid object by laminating a thermoplastic modeling material supported on a carrier on a stage,
A heating step of heating the laminated surface of the three-dimensional object on the stage;
Lamination for laminating the modeling material having a temperature lower than the softening temperature supported on the carrier on the laminating surface of the three-dimensional object on the stage heated to the softening temperature or higher of the modeling material by the heating step. Process,
The modeling method characterized by including this is provided.

  According to the present invention, it is possible to reduce the occurrence of stacking faults and produce a three-dimensional object with higher accuracy.

The figure which shows typically the whole structure of the modeling apparatus which concerns on embodiment The figure for demonstrating the modeling process of the modeling apparatus which concerns on this embodiment The figure which shows typically the modeling apparatus which concerns on 2nd Embodiment. The figure which shows typically the modeling apparatus which concerns on 3rd Embodiment. The figure which shows the modeling apparatus which concerns on 4th Embodiment typically The figure which shows typically the modeling apparatus which concerns on 5th Embodiment The figure which shows typically the modeling apparatus which concerns on 6th Embodiment The figure which shows typically the modeling apparatus which concerns on 7th Embodiment The figure which shows typically the modeling apparatus which concerns on 8th Embodiment. Schematic diagram showing an image forming unit that arranges material layers using an electrophotographic process

DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be exemplarily described with reference to the drawings. However, unless otherwise specified, various control procedures, control parameters, target values, etc., such as dimensions, materials, shapes, and relative arrangements of the members described in the following embodiments are described in the present invention. It is not intended to limit the scope of the above to only those.
The present invention relates to an additive manufacturing technique (AM technique), that is, an apparatus for forming a three-dimensional object (three-dimensional object) by two-dimensionally arranging modeling materials and laminating them in layers.
As the modeling material, various materials can be selected according to the application, function, purpose, etc. of the three-dimensional object to be produced. In this specification, a material constituting a three-dimensional object for modeling is referred to as “structural material”, and a portion formed of the structural material is referred to as a structure. A material that constitutes a support body (for example, a column that supports the overhang portion from below) for supporting the structure being manufactured is referred to as a “support material”. When it is not necessary to distinguish between the two, the term “modeling material” is simply used. As the structural material, for example, a thermoplastic resin such as PE (polyethylene), PP (polypropylene), ABS, PS (polystyrene) can be used. As the support material, a material having thermoplasticity and water solubility can be preferably used in order to simplify the removal from the structure. Examples of the support material include carbohydrates, polylactic acid (PLA), PVA (polyvinyl alcohol), and PEG (polyethylene glycol).

Further, in this specification, digital data obtained by slicing three-dimensional shape data of a three-dimensional model intended for modeling into a plurality of layers along the stacking direction is referred to as “slice data”. The slice data is generated by adding information such as support material data as necessary. A layer formed of a modeling material based on slice data is referred to as a “material layer”. This material layer is composed of an image formed by one or a plurality of image forming units (image forming means), and an image formed by each image forming unit is referred to as a “material image”. In other words, the “material layer” is a layer of particles formed by combining one or a plurality of material images according to the type of modeling material to be used.
Also, a three-dimensional model to be produced using the modeling apparatus (that is, 3 given to the modeling apparatus)
A three-dimensional object represented by the three-dimensional shape data) is referred to as a “modeling object”. A three-dimensional object (three-dimensional object) produced (output) by the modeling apparatus is referred to as a “modeled object”. In the case where the modeled object includes the support body, a portion excluding the support body becomes a “structure” constituting the modeled object. In addition, a three-dimensional object (laminated product) on a stage that is in the process of being manufactured using a modeling apparatus is referred to as an “intermediate modeled object”.

[Characteristic configuration and modeling method of this embodiment]
Below, the characteristic structure and modeling method of the modeling apparatus which concern on embodiment of this invention are demonstrated with the whole structure of a modeling apparatus. FIG. 1 is a diagram schematically illustrating the overall configuration of the modeling apparatus according to the present embodiment. Drawing 2A-Drawing 2D are figures for explaining a modeling process of a modeling device concerning this embodiment. 2A shows the transfer process of the material layer M and the heating process of the intermediate shaped object S, FIG. 2B shows the transport process of the material layer M, FIG. 2C shows the stacking process of the material layer M, 2D shows a fixing process of the material layer M.

As shown in FIG. 1, the modeling apparatus 1 is schematically configured to include a control unit U1, a material layer forming unit U2, and a stacking unit U3.
The control unit U1 is a unit that performs processing for generating slice data of a plurality of layers from the three-dimensional shape data of the modeling target, control of each part of the modeling apparatus 1 such as the material layer forming unit U2 and the stacking unit U3. The material layer forming unit U2 is a unit that forms the material layer M made of the modeling materials Ma and Mb using an electrophotographic process. The material layer forming unit U2 automatically detects the type of the modeling material Ma, Mb to be set and sends information on the modeling material to the control unit U1, or the operator directly inputs it to the control unit U1. Recognize the type of modeling material. The laminated unit U3 is a unit for producing a modeled object by sequentially laminating and fixing a plurality of material layers formed by the material layer forming unit U2. The modeling apparatus 1 has a configuration capable of changing the closest distance between the material layer forming unit U2 and the stacking unit U3. In the present embodiment, the material layer forming unit U2 is movable in the horizontal direction in FIG. It is configured.

  The material layer forming unit U2 will be specifically described below. First, based on the slice data generated by the control unit U1, material images are formed by the image forming units 10a and 10b. The material images formed by the image forming units 10a and 10b are transferred to the intermediate carrier 111 by the transfer devices 104a and 104b, respectively, and become the material layer M. When the material layer M is formed on the intermediate carrier 111, the material layer forming unit U2 moves to the lamination unit U3 side, and the intermediate carrier 111 and the second intermediate carrier 20 come into contact with each other. An electric field is formed between the intermediate carrier 111 and the second intermediate carrier 20 by a high voltage power source (not shown), so that the material layer M on the intermediate carrier 111 is electrostatically transferred to the second intermediate carrier 20. Transcription (FIG. 2A).

  While the material layer M transferred from the material layer forming unit U2 to the second intermediate carrier 20 of the stacking unit U3 is conveyed to the stacking position N as it is, the intermediate shaped object S on the stage 23 has its stacking surface Sa. Is heated by the heater 22 until the temperature reaches the target temperature (FIGS. 2A and 2B). As a feature of this embodiment, this target temperature is set to be equal to or higher than the softening temperature of each modeling material. The softening temperature of the modeling material is set based on the type of modeling material recognized by the control unit U1. Specifically, the control unit U1 may be set with reference to a table showing the relationship between the material type and the softening temperature. The table may be held by the control unit itself or may be held outside the control unit. Whether or not the laminated surface Sa has reached the target temperature may be determined based on the relationship between the heater temperature and the heating time required to heat the laminated surface Sa measured in advance until reaching the target temperature, or the radiation temperature. The determination may be made by monitoring the laminated surface Sa in total. Further, when the material layer M is transferred from the material layer forming unit U2 to the second intermediate carrier 20, the material layer forming unit U2 is moved from the stacking unit U3 so as not to be affected by the heat generated in the stacking unit U3. Move away (FIG. 2B).

Here, the softening temperature indicates the temperature dependence of the storage elastic modulus and loss elastic modulus in the shear direction of a compact formed by pressing an aggregate of particles of material (modeling material) into a cylindrical shape having a diameter of 10 mm and a thickness of 1 mm. The temperature at which the storage elastic modulus is 10 MPa when measured as follows. That is when the temperature is measured at a rate of 2 ° C./min with a rotary rheometer with an angular frequency of 1 Hz. Further, the stacking position N is a position where the material layer M is stacked (step of stacking the material layer on the intermediate shaped object S), and in the configuration of FIG. 1, the second intermediate carrier 20 and the stage 23 are the material layer. The portion that abuts through M and the intermediate shaped object S is the stacking position N.
When the material layer M carried by the second intermediate carrier 20 reaches the lamination position N, the material layer M on the second intermediate carrier 20 comes into contact with the lamination surface Sa of the intermediate shaped article S, and the intermediate shaped article Transferred to S and laminated (FIG. 2C).

At this time, since the lamination surface Sa of the intermediate shaped article S heated to the softening temperature or higher has viscosity, a strong adhesive force Mf ′ is generated between the material layer M and the laminated surface Sa. On the other hand, each temperature of the second intermediate carrier 20 and the material layer M is set to be lower than the softening temperature (normal temperature or higher), and thus the material layer itself does not become viscous. The adhesion force Mf between 20 and the material layer M is a relatively low value. In this way, the second intermediate carrier 20 is obtained by heating the laminated surface Sa of the intermediate shaped article S to the softening temperature or higher and setting the temperatures of the second intermediate carrier 20 and the material layer M to be lower than the softening temperature. The upper material layer M can be more reliably transferred onto the intermediate shaped object S.
When the material layer M is heated to the softening temperature or higher, the material layer M becomes viscous, so that the adhesion force Mf between the second intermediate carrier 20 and the material layer M increases, and the material on the second intermediate carrier 20 is increased. A part of the layer M is not transferred onto the intermediate shaped article S, and stacking faults remaining on the second intermediate carrier 20 are likely to occur.
When the material layer M is laminated on the intermediate shaped article S on the stage 23, the stage 23 moves to a position where the heater 22 is heated, and the portion of the material layer M laminated on the intermediate shaped article S is moved by the heater 22. It is melted and fixed to the intermediate model S (FIG. 2D).

As described above, the present embodiment is characterized in that the material layer M having a temperature lower than the softening temperature is transferred and stacked on the intermediate shaped object S having the temperature of the stacked surface Sa equal to or higher than the softening temperature. Thereby, generation | occurrence | production of the lamination | stacking defect which modeling material remains on the 2nd intermediate | middle support body 20 can be suppressed, and it becomes possible to produce a modeling thing with higher precision.
Below, the specific example of the modeling apparatus which can apply this invention suitably is demonstrated using 1st-8th embodiment. In any of the first to eighth embodiments, the same effect as described above can be obtained. In addition, in the above-mentioned embodiment and 1st-8th embodiment, the same code | symbol is attached | subjected about the same component.

<First Embodiment>
The first embodiment will be described below.
First, the configuration of the control unit U1 of the present embodiment will be described.
[Controller unit]
As shown in FIG. 1, the control unit U1 has, as its functions, a three-dimensional shape data input unit U10, a slice data calculation unit U11, a material layer formation unit control unit U12, a lamination unit control unit U13, and the like.

  The three-dimensional shape data input unit U10 has a function of receiving three-dimensional shape data of a modeling object from an external device (for example, a personal computer). As the three-dimensional shape data, data created and output by a three-dimensional CAD, a three-dimensional modeler, a three-dimensional scanner, or the like can be used. Although the file format is not ask | required, for example, an STL (Stereolithography) file format can be used preferably.

The slice data calculation unit U11 slices the modeling object expressed by the three-dimensional shape data at a predetermined pitch, calculates the cross-sectional shape of each layer, and uses it for image formation in the material layer forming unit U2 based on the cross-sectional shape. It has a function of generating data (slice data). Furthermore, the slice data calculation unit U11 analyzes the cross-sectional shape of the three-dimensional shape data or the upper and lower layers, determines the presence or absence of an overhang portion (portion floating in the air), and is used for forming the support body as necessary. Generate slice data including data.
The material layer forming unit U2 of the present embodiment can form a material layer using a plurality of types of modeling materials. Therefore, a material layer corresponding to slice data including data for forming a material image made of each modeling material can be formed. As the file format of the slice data, for example, multi-value image data (each value represents the type of modeling material) or multi-plane image data (each plane corresponds to the type of modeling material) can be used.

  The material layer forming unit control unit U12 has a function of controlling the material layer forming process in the material layer forming unit U2 based on the slice data generated by the slice data calculating unit U11. As will be described later, it is also the control unit U1 that controls the developing device so that the particles of the modeling material constituting the material image are arranged to satisfy a predetermined condition. Further, the stacking unit control unit U13 has a function of controlling the stacking process in the stacking unit U3.

Although not shown, the control unit U1 also includes an operation unit, a display unit, and a storage unit. The operation unit has a function of receiving an instruction from the user. For example, power on / off, various device settings, operation instructions, and the like can be input. The display unit has a function of presenting information to the user. For example, various setting screens, error messages, operation statuses, and the like can be presented. The storage unit has a function of storing three-dimensional shape data, slice data, various setting values, and the like.
The control unit U1 is configured in hardware by a computer having a CPU (Central Processing Unit), a memory, an auxiliary storage device (hard disk, flash memory, etc.), an input device, a display device, and various I / Fs. Can do. Each of the functional units U10 to U13 described above is realized by a CPU reading and executing a program stored in an auxiliary storage device and controlling necessary devices. However, some or all of the functional units described above may be configured by a circuit such as an ASIC or FPGA, or may be executed by another computer using a technique such as cloud computing or grid computing. .

[Material layer forming unit]
Next, the configuration of the material layer forming unit U2 will be described.
The material layer forming unit U2 is a unit that forms a material layer made of a modeling material using an electrophotographic process. The electrophotographic process is a method for forming a desired material image on an image carrier (photosensitive member) as follows. First, the image carrier is uniformly charged, and the charged image carrier is exposed according to image information, thereby forming a latent image (electrostatic latent image) according to the image information on the image carrier. Then, developer particles (modeling material particles) are attached to the latent image portion on the image carrier to form a developer image on the image carrier. A desired material image is formed on the image carrier by such a series of processes.

As shown in FIG. 1, the material layer forming unit U2 includes a first image forming unit 10a, a second image forming unit 10b, and a transfer unit 11. The material layer forming unit U2 can move in the horizontal direction together with the material layer forming unit U2. Yes.
The first image forming unit 10a is an image forming unit for forming a material image using the modeling material Ma. The first image forming unit 10a includes an image carrier 100a, a charging device 101a that charges the image carrier 100a, an exposure device 102a that exposes the image carrier 100a to form a latent image, and develops the latent image with a modeling material Ma. Developing device 103 for forming a material image on the surface of image carrier 100a
a. The first image forming unit 10a has a cleaning device 105a for cleaning the image carrier 100a.

The second image forming unit 10b is an image forming unit for forming a material image using the modeling material Mb. Similar to the first image forming unit 10a, the second image forming unit 10b includes an image carrier 100b, a charging device 101b, an exposure device 102b, a developing device 103b, and a cleaning device 105b.
The transfer unit 11 includes transfer devices 104a and 104b, an intermediate carrier 111, a second cleaning device 112, and an image detection sensor 113. The material images formed by the image forming units 10a and 10b are transferred to the intermediate carrier 111 by the transfer devices 104a and 104b to form a material layer.

  In this embodiment, a structural material made of a thermoplastic resin or the like is used as the modeling material Ma, and a support material having thermoplasticity and water solubility is used as the modeling material Mb. Note that when the cross section has no overhang portion and does not require a support body, image formation in the image forming portion 10b is not performed. In that case, the material layer is formed only from the material image of the structural material. The diameter of the particles of each modeling material is preferably 5 μm or more and 50 μm or less.

These image forming units 10 a and 10 b are arranged along the surface of the intermediate carrier 111 in the transport direction of the intermediate carrier 111.
In FIG. 1, the image forming unit 10 a using the structural material is disposed upstream of the image forming unit 10 b using the support material in the rotation direction of the intermediate carrier 111 (the moving direction of the belt surface). The arrangement order of the forming portions is not limited to this, and can be set as appropriate. Further, the number of image forming units is not limited to two, and one or a plurality of image forming units may be provided. That is, the image forming unit can be set to an appropriate number according to the specifications of the modeling apparatus and the type and number of modeling materials to be used.

Hereinafter, the configuration of each part of the material layer forming unit U2 will be described in detail. However, in the description common to the image forming units 10a and 10b, the subscripts a and b attached to the reference numerals of the constituent members are omitted for convenience of description, and are described as the image forming unit 10, the image carrier 100, and the like. In some cases.
FIG. 10 is a diagram schematically illustrating a configuration of the image forming unit 10 in which a material layer is arranged using an electrophotographic process.
(Image carrier)
The image carrier 100 is a member for carrying a latent image. In this embodiment, a photosensitive drum in which a photoconductive layer having photoconductivity is formed on the outer peripheral surface of a metal cylinder such as aluminum is used. As the photoconductor, an organic photoconductor (OPC), an amorphous silicon photoconductor, a selenium photoconductor, or the like can be used, and the type of the photoconductor may be appropriately selected according to the application and required performance of the modeling apparatus. The image carrier 100 is rotatably supported by a frame (not shown), and rotates at a constant speed counterclockwise in FIG. 10 by a drive source (not shown) when forming a material image.

(Charging device)
The charging device 101 is charging means for uniformly charging the surface of the image carrier 100. In this embodiment, a non-contact charging method using corona discharge is used, but other charging methods such as a roller charging method in which a charging roller is brought into contact with the surface of the image carrier 100 may be used.
(Exposure equipment)
The exposure apparatus 102 is an exposure unit that exposes the image carrier 100 according to image information (slice data) and forms a latent image on the surface of the image carrier 100. The exposure apparatus 102 includes, for example, a light source such as a semiconductor laser or a light emitting diode, a scanning unit having a polygon mirror that rotates at high speed, and an optical member such as an imaging lens.

(Developer)
The developing device 103 uses a known contact one-component developing system, and supplies a modeling material (here, a particle of a structural material or a support material) as a developer to the image carrier 100, thereby developing the latent image. It is. In the present specification, an image visualized with a developer on the image carrier 100 is referred to as a material image.
The developing device 103 has a so-called developing cartridge structure and is preferably provided detachably with respect to the material layer forming unit U2. This makes it easy to replenish and change the developer (structural material, support material) by exchanging the cartridge. Further, the image carrier 100, the developing device 103, the cleaning device 105, and the like may be integrated into a cartridge (so-called process cartridge) so that the image carrier itself can be replaced. When the wear and life of the image carrier 100 are particularly problematic due to the type, hardness, and particle size of the structural material and support material, the process cartridge configuration is more practical and convenient.

(Cleaning device)
The cleaning device 105 is a unit that collects particles of the modeling material remaining on the image carrier 100 without being transferred, and cleans the surface of the image carrier 100. In this embodiment, a blade type cleaning device 115 that scrapes off particles with a cleaning blade that is brought into contact with the image carrier 100 in the counter direction is employed. However, a brush type or electrostatic adsorption type cleaning device may be used. Good.
(Transfer device)
The transfer device 104 provided in the transfer unit 11 is a transfer unit that transfers a material image formed on the peripheral surface of the image carrier 100 to the surface of the intermediate carrier 111. The transfer device 104 is disposed on the opposite side of the image carrier 100 with the intermediate carrier 111 interposed therebetween, and a voltage having a polarity opposite to the charging polarity of the material image on the image carrier 100 is applied, thereby Specifically, the material image is transferred to the intermediate carrier 111. Transfer from the image carrier 100 to the intermediate carrier 111 is also referred to as primary transfer. In this embodiment, a transfer method using corona discharge is used, but a transfer method other than a roller transfer method or an electrostatic transfer method may be used.

(Intermediate carrier)
The intermediate carrier 111 is a carrier (conveyance body) to which the material image formed in each image forming unit 10 is transferred. After the material image formed of the structural material is transferred from the first image forming unit 10a to the intermediate carrier 111, the material image is aligned with the position on the intermediate carrier 111, and the second image downstream of the first image forming unit 10a. The material image formed of the support material is transferred from the two image forming unit 10b. As a result, one (one layer) material layer is formed on the surface of the intermediate carrier 111.
The intermediate carrier 111 is an endless belt member made of a material such as resin or polyimide, and is stretched around a plurality of rollers 114 and 115 as shown in FIG. A tension roller may be provided in addition to the rollers 114 and 115 so that the tension of the intermediate carrier 111 can be adjusted. At least one of the rollers 114 and 115 is a driving roller, and the intermediate carrier 111 is rotated clockwise in FIGS. 1 and 10 by a driving force of a driving source (not shown) when forming the material layer. The roller 114 is a roller that forms a secondary transfer portion with the second intermediate carrier 20 of the stacked unit U3.

(Second cleaning device)
The second cleaning device 112 is a means for cleaning the modeling material and the like attached to the surface of the intermediate carrier 111. In this embodiment, a blade type cleaning device is used in which the material is scraped off by a cleaning blade brought into contact with the intermediate carrier 111 in the counter direction. However, a brush type or electrostatic adsorption type cleaning device may be used. .
(Image detection sensor)
The image detection sensor 113 is a detection unit that reads the position of the material layer carried on the surface of the intermediate carrier 111 and the concentration of the modeling material particles. The detection result of the image detection sensor 113 is used for alignment of the material layer, timing control with the stacking unit U3, detection of abnormality of the material layer, and the like. The abnormality of the material layer means that the material layer is not a desired image, no image, thickness variation or image positional deviation exceeds an allowable value, and the like.
The density of the modeling material particles in the material layer can be read by the image detection sensor 113 having a function of detecting the projected area ratio per unit volume of the material layer. Specifically, the image detection sensor 113 only needs to have a function of performing image processing on a grayscale image obtained by illuminating the material layer.

[Laminated unit]
Next, the configuration of the multilayer unit U3 will be described.
The stacking unit U3 is a unit that forms a shaped article by receiving the material layer formed by the material layer forming unit U2 from the intermediate carrier 111, and stacking and fixing them in order.
As shown in FIG. 1, the stacked unit U <b> 3 includes a second intermediate carrier 20, an image detection sensor 21, a heater 22, a stage 23, a cooling device 24, and a third cleaning device 25. Hereinafter, the configuration of each part of the multilayer unit U3 will be described in detail.

(Second intermediate carrier)
The second intermediate carrier 20 is a carrier that receives the material layer formed by the material layer forming unit U2 from the intermediate carrier 111 and carries and conveys the material layer to the stacking position N.
The second intermediate carrier 20 is a cylindrical drum member (cylindrical member) made of a material such as resin, polyimide, or metal such as stainless steel. The second intermediate carrier 20 rotates counterclockwise in FIG. 1 by a driving force of a driving source (not shown). It is desirable to apply a fluorine-based resin such as PTFE or PFA on the surface of the second intermediate carrier 20 in order to reduce the adhesive force Mf with the material layer. Here, PTFE is polytetrafluoroethylene, and PFA is a tetrafluoroethylene perfluoroalkyl vinyl ether copolymer.
(Second image detection sensor)
The second image detection sensor 21 is detection means for detecting the position of the material layer carried on the surface of the second intermediate carrier 20 and the concentration of the modeling material particles. The second image detection sensor 21 is installed downstream of the contact position between the intermediate carrier 111 and the second intermediate carrier 20 and upstream of the stacking position N in the rotational direction of the second intermediate carrier 20. Yes.
The detection result of the second image detection sensor 21 is used for alignment of the material layer, transport timing control to the stacking position N, and the like.

(heater)
The heater 22 is a temperature control unit that controls the temperature of the intermediate model S and the material layer M transferred to the laminated surface Sa of the intermediate model S. As the heater 22, for example, a ceramic heater, a halogen heater, or the like can be used. In addition, the temperature of the heater 22 is preferably set to be equal to or higher than the temperature at which the material layer M melts. Further, by adjusting the distance between the heater 22 and the intermediate shaped article S, the temperature of the laminated surface Sa of the intermediate shaped article S can be controlled. Thus, after the material layer M is transferred to the intermediate shaped object S, the material layer M can be melted and fixed to the intermediate shaped object S by bringing the heater 22 close to the intermediate shaped object S (FIG. 2D). Here, the distance between the heater 22 and the intermediate shaped article S on the stage 23 may be adjusted by moving at least one of the heater 22 and the stage 23 in the vertical direction. Moreover, in this embodiment, the stage 23 is moved to the heating area | region of the heater 22, and the material layer M transcribe | transferred by the lamination | stacking surface Sa of the intermediate modeling thing S is heated as mentioned later. However, it is not limited to this. The stage 23 and / or the heater 22 may be arranged so as to be movable between a position where lamination is performed and a position where heating by the heater 22 is performed.

(stage)
The stage 23 is a flat table on which the material layer M is stacked. The stage 23 is moved vertically and horizontally in FIG. 1 by a driving means such as an actuator (not shown) (normal direction and tangent to the stacking position N shown in FIG. 1 on the outer peripheral surface of the cylindrical second intermediate carrier 20). Direction). By sandwiching the material layer M carried and conveyed to the lamination position N between the stage 23 and the second intermediate carrier 20, the stage from the second intermediate carrier 20 side is caused by the viscosity of the lamination surface Sa of the intermediate shaped article S. The material layer M can be transferred to the 23 side.

It is desirable that a solvent-soluble material or a temperature-sensitive adhesive that changes in adhesion and non-adhesion in response to a temperature change is installed in advance on the surface of the stage 23. In the present embodiment, an example is shown in which a thermoplastic resin (thermoplastic material) Ms is disposed as a material soluble in a solvent. When the thermoplastic resin Ms is provided on the surface of the stage 23, the molded article can be removed from the stage 23 more easily by removing the thermoplastic resin Ms when the modeling is completed. Here, it is desirable that the thermoplastic resin Ms is the same material as the support material having thermoplasticity and water solubility, and the material layer M made of only the support material is formed by the material layer forming unit U2 and laminated on the stage 23. You may produce by. In addition, since the first material layer M is directly transferred onto the thermoplastic resin Ms, when the first material layer M is laminated, the surface of the thermoplastic resin Ms is placed on the thermoplastic resin. It is desirable to set it above the softening temperature of Ms.
Further, in the case where the temperature-sensitive adhesive is provided on the surface of the stage 23, the adhesive force of the temperature-sensitive adhesive is lost below the switching temperature set in advance when the modeling is completed. The modeled object can be removed more easily. As the temperature-sensitive adhesive, a temperature-sensitive adhesive sheet Intellimer (registered trademark) tape manufactured by Nitta Corporation can be used. Here, in the present embodiment, the second intermediate carrier 20, the heater 22, and the stage 23 constitute a stacking unit that stacks the material layer M.

(Cooling system)
The cooling device 24 is a device for cooling the second intermediate carrier 20. Since the second intermediate carrier 20 is in contact with the intermediate shaped object S heated by the heater 22 via the material layer M, the surface is likely to be heated by the heat. Further, since the heaters 22 are arranged adjacent to each other, the temperature is easily raised by the heat of the heaters 22. When the temperature of the second intermediate carrier 20 is equal to or higher than the softening temperature of the material layer M, there is a concern that a stacking failure may occur. For this reason, it is desirable to cool the second intermediate carrier 20 by the cooling device 24. In addition, by cooling the second intermediate carrier 20 with the cooling device 24, it is possible to suppress the influence of heat in the stacked unit U3 from reaching the material layer forming unit U2.
In the present embodiment, the cooling device 24 is installed downstream of the stacking position N in the rotation direction of the second intermediate carrier 20, but is not limited thereto. That is, if the cooling device 24 can cool the second intermediate carrier 20 so that the temperature of the second intermediate carrier 20 does not exceed the softening temperature of the material layer M, the installation position thereof is particularly limited. It is not a thing. The cooling device 24 is desirably air-cooled by a compressor, a fan, or the like, but the cooling method is not particularly limited. For example, a water-cooling method using cooling water from the inside of the second intermediate carrier 20 may be used.
In order to prevent the heat of the heater 22 from being directly applied to the second intermediate carrier 20, it is also preferable to provide a heat insulating member between the second intermediate carrier 20 and the heater 22.

(Third cleaning device)
The third cleaning device 25 is a device for removing the contamination adhered to the second intermediate carrier 20, the modeling material that has not been stacked on the intermediate molding S due to insufficient concentration, and the like from the second intermediate carrier 20. is there. In the third cleaning device 25 of the present embodiment, the contamination and the modeling material are scraped off by the cleaning blade that is brought into contact with the surface (supporting surface) for supporting and transporting the material layer M in the second intermediate carrier 20 in the counter direction. Adopt a blade system. However, the present invention is not limited to this, and a brush type or electrostatic adsorption type cleaning device may be used. In FIG. 1, the third cleaning device 25 is installed downstream of the cooling device 24 in the rotational direction of the second intermediate carrier 20. Alternatively, it may be installed upstream of the cooling device 24.

  These units U1 to U3 may be housed in different housings, or may be housed in one housing. The configuration in which the units U1 to U3 are separated from each other can be easily combined and replaced according to the use of the modeling apparatus, required performance, modeling material to be used, installation space, etc. Therefore, there is an advantage that the degree of freedom and convenience of the device configuration can be improved. On the other hand, the configuration in which all the units are housed in one housing has advantages such as downsizing of the entire apparatus and cost reduction.

Second Embodiment
The second embodiment will be described below.
FIG. 3 is a diagram schematically illustrating the modeling apparatus according to the present embodiment.
In this embodiment, the heater 26 as a heating means is configured in a roller shape having elastic rubber on the surface. A heating unit such as a halogen heater (not shown) is built in the roller, and is the same as that of the first embodiment except that the roller rotates counterclockwise in FIG. In the present embodiment, the rotating shaft of the heater 26 is rotatably supported by the modeling apparatus main body, and the stage 23 moves in the horizontal direction in FIG. It is configured to be heated by the heater 26.

The heater 26 heats the laminated surface Sa of the intermediate shaped article S to the softening temperature or higher by the elastic rubber layer on the surface thereof being in contact with the laminated surface Sa of the intermediate shaped article S. At this time, the rotation operation of the heater 26 and the movement operation in the horizontal direction of the stage 23 are performed while maintaining the state where the elastic rubber layer of the heater 26 and the laminated surface Sa of the intermediate shaped object S are in contact with each other. The laminated surface Sa of the intermediate shaped object S is heated over the entire area.
The surface of the elastic rubber layer of the heater 26 is desirably coated with a fluorine-based resin, whereby the adhesion force generated between the laminated surface Sa of the intermediate shaped article S and the heater 26 can be suppressed. Further, the elastic rubber layer of the heater 26 is sufficiently brought into contact with the laminated surface Sa of the intermediate shaped article S, and the laminated surface Sa of the intermediate shaped article S is pressurized, whereby the laminated surface Sa of the intermediate shaped article S and the laminated surface Sa of the intermediate shaped article S are pressed. Can be removed.

<Third Embodiment>
The third embodiment will be described below.
FIG. 4 is a diagram schematically illustrating the modeling apparatus according to the present embodiment.
In the present embodiment, as shown in FIG. 4, as a heating means, a high temperature bath 27 is installed so as to surround the stage 23, and a hot air generator 28 that generates hot air and sends it into the high temperature bath 27 is installed. Except for this point, the second embodiment is the same as the first embodiment.

By configuring so that the inside of the high-temperature tank 27 is maintained at the target temperature by the hot air generated from the hot air generator 28, the temperature of the laminated surface Sa of the intermediate shaped object S can always be equal to or higher than the softening temperature of the intermediate shaped object S. it can. Moreover, since the atmospheric temperature around the intermediate shaped article S can be kept constant by keeping the inside of the high-temperature tank 27 at a constant temperature, temperature unevenness in the intermediate shaped article S can be reduced. Thereby, it is possible to suppress distortion (deformation) occurring in the intermediate modeling object S due to temperature unevenness in the intermediate modeling object S, and cracking of the intermediate modeling object S due to the distortion.
As shown in FIG. 4, an opening 27a is provided in the upper part of the high-temperature tank 27, and the material layer can be transferred from the second intermediate carrier 20 to the stage 23 through the opening 27a. .
Moreover, the structure which added the heater 22 of 1st Embodiment to the heating part containing the above-mentioned high temperature tank 27 shown in FIG. 4, ie, the lamination surface Sa of the intermediate shaped article S on the stage 23 which can move the inside of the high temperature tank 27. It is good also as a structure heated by the heater 22. FIG.

<Fourth embodiment>
The fourth embodiment will be described below.
FIG. 5 is a diagram schematically illustrating the modeling apparatus according to the present embodiment.
In the present embodiment, apart from the heater 22, the second heater 29 is provided as temperature control means for controlling the temperature of the material layer M transferred to the laminated surface Sa of the intermediate shaped article S, except that the second heater 29 is provided. This is the same as in the first embodiment. In the second heater 29, for example, a ceramic heater, a halogen heater or the like is incorporated, and the surface 29a on the stage 23 side is polished. The surface 29a of the second heater 29 is a contact surface when the second heater 29 comes into contact with the intermediate shaped article S on the stage 23, as will be described later. The laminated surface 29a of the second heater 29 is desirably polished so that the average roughness is 1 μm or less. In the present embodiment, the temperature of the heater 22 is equal to or higher than the softening temperature of the material layer M and lower than the temperature at which the material layer M melts, and the temperature of the second heater 29 is set to be equal to or higher than the temperature at which the material layer M melts. It is desirable that

Below, the process of heating the intermediate shaped article S on the stage 23 with the second heater 29 unique to this embodiment will be described.
First, when the material layer M is laminated on the lamination surface Sa of the intermediate shaped article S on the stage 23, the stage 23 moves to the right in the horizontal direction in FIG. 5 until it is located below the second heater 29. After the stage 23 is positioned below the second heater 29, the second heater 29 descends and comes into contact with the material layer M on the stage 23, so that the material layer M is heated and / or pressurized to the intermediate shaped object S. It is fixed.
After the material layer M is fixed to the intermediate shaped article S, the heating operation of the second heater 29 is stopped, and the temperature of the laminated surface Sa of the intermediate shaped article S is lowered to a temperature below the temperature at which the material layer M melts. The second heater 29 moves upward and is separated from the intermediate shaped article S to which the material layer M is fixed. In order to lower the temperature of the second heater 29, means for cooling the second heater 29 may be provided. The cooling method at this time may be an air cooling method or a water cooling method, and is not particularly limited.

Further, it is desirable that a release agent such as a fluororesin is applied to the surface 29 a of the second heater 29.
Moreover, it is good for the pressure sensor to be installed in several places in the surface of the back side of the surface 29a among the 2nd heaters 29. FIG. Thereby, when the 2nd heater 29 pressurizes the material layer M laminated | stacked on the intermediate molded article S on the stage 23, it feeds back the measured value of each pressurization sensor to the lamination | stacking unit control part U13, and a material layer M and the intermediate shaped article S can be uniformly pressurized. Thereby, a model with higher accuracy can be produced.

<Fifth Embodiment>
The fifth embodiment will be described below.
FIG. 6 is a diagram schematically illustrating the modeling apparatus according to the present embodiment.
In the present embodiment, as shown in FIG. 6, the stacked unit U <b> 3 includes the third intermediate carrier 30, the preheating heater 31, the cooling device 34, the fourth cleaning device 36, the image detection sensor 21, the heater 22, and the stage 23. It is the same as that of 1st Embodiment except the point provided. Hereinafter, the configuration of each part of the multilayer unit U3 unique to the present embodiment will be described in detail.

(Third intermediate carrier)
The third intermediate carrier 30 is an endless belt member formed of a metal such as SUS (stainless steel), a material such as resin, polyimide, and the like. As shown in FIG. It is stretched around a metal roller 35. Here, the elastic rollers 32 and 33 have an elastic rubber layer made of urethane or silicone. The metal roller 35 is a roller made of metal such as SUS or aluminum. At least one of the elastic rollers 32 and 33 and the metal roller 35 is a drive roller.

The elastic roller 32 is a roller that is disposed at a position facing the roller 114 of the material layer forming unit U <b> 2 and forms a secondary transfer portion with the roller 114. Further, as shown in FIG. 6, when the material layer M formed by the material layer forming unit U2 is electrostatically (electrically) transferred to the third intermediate carrier 30, the elastic roller 32 is supplied with a high voltage power source 37. A voltage is applied by.
In this embodiment, the elastic roller 32 is rotatably supported by the modeling apparatus main body, and the material layer forming unit U2 is configured to be movable in the horizontal direction in FIG. When the material layer M is transferred from the intermediate carrier 111 of the material layer forming unit U2 to the third intermediate carrier 30 of the laminated unit U3, the material layer forming unit U2 moves to the laminated unit U3 side. As a result, the intermediate carrier 111 and the third intermediate carrier 30 come into contact with each other to form a secondary transfer portion.

(Pre-heater)
The preheater 31 is installed to preheat the material layer M that is electrically carried and conveyed by the third intermediate carrier 30 so as to approach the softening temperature of the material layer M. As shown in FIG. 6, the material layer M on the third intermediate carrier 30 is heated to a temperature lower than the softening temperature of the material layer M, so that the material layer M on the third intermediate carrier 30 is intermediately shaped. After the transfer to S, the heating time for heating the material layer M with the heater 22 can be shortened.
The elastic roller 33 is disposed so as to face the stage 23 positioned at the stacking position N via the third intermediate carrier 30. As shown in FIG. 6, the material layer M carried by the third intermediate carrier 30 and conveyed to the stacking position N is sandwiched between the elastic roller 33 and the intermediate shaped object S together with the third intermediate carrier 30, thereby 3 The material layer M on the intermediate carrier 30 is transferred to the intermediate shaped object S.

A high voltage power source 38 is connected to the elastic roller 33 as a voltage applying means so that a voltage can be applied to the elastic roller 33. Thereby, at the time of transfer of the material layer M, in addition to the viscosity of the lamination surface Sa of the intermediate shaped object S, an electrostatic force can be used, and the material layer M on the third intermediate carrier 30 can be more easily and more reliably. Can be transferred to the intermediate shaped object S.
Further, the surface potential meter 39 for measuring the potential of the laminated surface Sa of the intermediate shaped article S measures the potential of the laminated surface Sa of the intermediate shaped article S before transferring the material layer M, and feeds back the measurement result to the high-voltage power supply 38. It is desirable to do.

(Second cooling device)
The second cooling device 34 is a cooling device having the same function as the cooling device 24 of the first embodiment. In this embodiment, the 2nd cooling device 34 is arrange | positioned so that a cold wind may be applied to the back surface of the surface which carries the material layer M in the 3rd intermediate | middle support body 30. As shown in FIG. Therefore, when the third intermediate carrier 30 is air-cooled, the contamination adhered to the surface of the third intermediate carrier 30 and the modeling material remaining on the third intermediate carrier 30 without being transferred to the intermediate model S are blown off. The third intermediate carrier 30 can be cooled with stronger wind power.

(4th cleaning device)
The fourth cleaning device 36 is means for collecting the modeling material and contamination remaining on the third intermediate carrier 30 and cleaning the surface of the third intermediate carrier 30. The fourth cleaning device 36 of the present embodiment is installed so as to sandwich the third intermediate carrier 30 with the metal roller 35. In the present embodiment, the fourth cleaning device 36 employs a blade method in which particles or contaminants of the modeling material are scraped off by a cleaning blade brought into contact with the third intermediate carrier 30 in the counter direction. This is not a limitation. For example, as a cleaning method, a brush method or an electrostatic adsorption method may be used.

<Sixth Embodiment>
The sixth embodiment will be described below.
FIG. 7 is a diagram schematically illustrating the modeling apparatus according to the present embodiment.
In the present embodiment, as shown in FIG. 7, the elastic rollers 32 and 33 are configured to be movable, and the material layer forming unit U2 is fixed to the modeling apparatus main body. The preheating heater 31 is also configured to be movable. When the elastic rollers 32 and 33 move, the preheating heater 31 moves to a position away from the third intermediate carrier 30.

When the material layer M is transferred from the intermediate carrier 111 to the third intermediate carrier 30, the elastic roller 32 moves to the roller 114 side of the material layer forming unit U2, and at the same time, the elastic roller 33 moves by the same distance. As a result, the third intermediate carrier 30 takes a transfer position (a position indicated by a dotted line 30a in FIG. 6) from which the material layer M is transferred from the intermediate carrier 111, and comes into contact with the intermediate carrier 111 to form the secondary transfer portion. Form. At this time, the elastic roller 33 moves in a direction approaching the elastic roller 32 and the metal roller 35.
When the material layer M is transferred to the third intermediate carrier 30, the elastic roller 33 moves to a position where the laminated surface Sa of the intermediate shaped article S and the third intermediate carrier 30 can come into contact with each other. Simultaneously with the movement of the elastic roller 33, the elastic roller 32 moves in the direction approaching the elastic roller 33 and the metal roller 35 by the distance moved by the elastic roller 33. As a result, the third intermediate carrier 30 is positioned away from the intermediate carrier 111. While the elastic rollers 32 and 33 move, the material layer M is conveyed toward the stacking position N by the third intermediate carrier 30, but until the movement of the elastic rollers 32 and 33 is completed, by the image detection sensor 21. It is configured not to reach the detection area.

When the movement of the elastic rollers 32 and 33 is completed, the material layer M on the third intermediate carrier 30 passes through the detection area by the image detection sensor 21 and is transferred to the intermediate shaped object S.
In the present embodiment, two of the three rollers that stretch the third intermediate carrier 30 are configured to be movable. However, the present invention is not limited to this. In other words, at least one of the plurality of rollers that stretch the intermediate carrier is configured to be movable, and the intermediate carrier is separated from the material layer forming unit U2 by the movement of the roller except when the material layer M is transferred. Position. Accordingly, the material layer forming unit U2 can be configured not to be affected by the heat generated in the stacked unit U3.

<Seventh embodiment>
The seventh embodiment will be described below.
FIG. 8 is a diagram schematically illustrating the modeling apparatus according to the present embodiment.
In the present embodiment, as illustrated in FIG. 8, the modeling apparatus includes a heater 22, image forming units 10 a and 10 b, a second heater 29, and a stage 23. In the modeling apparatus of this embodiment, the material images are sequentially transferred from the image carriers 100a and 100b to the laminated surface Sa of the intermediate model S on the stage 23 without using the intermediate carrier as in the above-described embodiment. The material layer M is formed on the intermediate model S.

Below, the modeling operation | movement of the modeling apparatus of this embodiment is demonstrated.
First, the stage 23 moves to a position facing the heater 22 (FIG. 8). At this position, heating by the heater 22 is performed so that the temperature of the laminated surface Sa of the intermediate shaped article S on the stage 23 is equal to or higher than the softening temperature of the intermediate shaped article S.
When the laminated surface Sa of the intermediate shaped object S is heated to a temperature equal to or higher than the softening temperature of the intermediate shaped object S, the stage 23 is moved to the facing portion of the image carrier 100a, and the material image made of the modeling material Ma is the intermediate shaped object S. Transcribed above.

When the material image made of the modeling material Ma is transferred, the stage 23 is moved to the opposite portion of the image carrier 100b, and the material image made of the modeling material Mb is transferred onto the intermediate shaped object S.
Thus, the material layer M is formed on the intermediate shaped article S by transferring the material image made up of the modeling materials Ma and Mb. Thereafter, the stage 23 is moved to the opposite portion of the second heater 29, and the material layer M is sandwiched between the second heater 29 and the intermediate shaped article S, so that the material layer M is heated and / or pressurized and is intermediate. It is fixed on the shaped object S.
Here, since the image carriers 100a and 100b are in contact with the heated intermediate model S via the material image, there is a concern that the heat of the intermediate model S is transmitted and the temperature rises. For this reason, it is desirable to install cooling devices 106a and 106b for cooling the image carriers 100a and 100b. The cooling device 106 is disposed downstream in the rotation direction of the image carrier 100 and upstream of the cleaning device 105 from the stacking position where the image carrier 100 contacts the intermediate shaped object S via the material image. Good. Further, the image carrier 100 may have only one configuration, and after the material image is formed on the single image carrier 100, the material image is transferred to form the material layer on the intermediate model S. May be.

<Eighth Embodiment>
The eighth embodiment will be described below.
9A to 9D are diagrams schematically illustrating the modeling apparatus according to the present embodiment.
FIG. 9A shows the overall configuration of the modeling apparatus. As illustrated in FIG. 9A, the modeling apparatus of the present embodiment includes an image forming unit 10, a fourth intermediate carrier 40, a transfer auxiliary member 41, a third heater 46, and a stage 23. 9B to 9D are views for explaining the positional relationship among the fourth intermediate carrier 40, the transfer auxiliary member 41, the third heater 46, and the stage 23. FIG. Hereinafter, the configuration unique to the present embodiment will be described in detail.

(Fourth intermediate carrier)
On the fourth intermediate carrier 40, the material image formed by each image forming unit 10 is transferred to form the material layer M. That is, after the material image of the modeling material Ma is transferred from the upstream image forming unit 10a, the material image of the modeling material Mb is transferred from the downstream image forming unit 10b. Thus, one material layer M is formed.
The fourth intermediate carrier 40 is an endless belt member made of a material such as resin or polyimide, and is stretched around a plurality of rollers 42, 43, and 44 as shown in FIG. 9A. A tension roller may be provided in addition to the rollers 42, 43, and 44 so that the tension of the fourth intermediate carrier 40 can be adjusted. At least one of the rollers 42, 43, and 44 is a driving roller, and the fourth intermediate carrier 40 is rotated counterclockwise in the figure by the driving force of a motor (not shown) when the material layer is formed.

(Transfer auxiliary member)
The transfer auxiliary member 41 is composed of a flat plate made of a metal such as SUS or aluminum, and is installed so as to face the stage 23 with the fourth intermediate carrier 40 interposed therebetween, as shown in FIGS. 9A and 9B.
The material layer M conveyed to the stacking position N facing the intermediate shaped object S by the fourth intermediate carrier 40 is sandwiched between the transfer auxiliary member 41 and the intermediate shaped object S, so that the material layer M is placed on the intermediate shaped object S. Transferred and laminated. When the material layer M is transferred, the fourth intermediate carrier 40 and the rollers 42, 43, 44 are stopped. Note that a heater may be built in the transfer assisting member 41, and the temperature of the heater is set to be equal to or lower than the softening temperature of the material layer M. It is desirable that an elastic member such as urethane or silicone is attached to the surface of the transfer auxiliary member 41 on the fourth intermediate carrier 40 side, so that the material layer M and the fourth intermediate carrier 40 are in contact with each other. It becomes easy to do.

(heater)
The third heater 46 is a temperature control unit that controls the temperature of the intermediate shaped article S and the material layer M transferred and laminated on the intermediate shaped article S. The third heater 46 has a first position that is sandwiched between the fourth intermediate carrier 40 and the stage 23 shown in FIG. 9D and a second position that is separated from the first position shown in FIGS. 9B and 9C. It is installed so that it can move between them. 9D, the third heater 46 positioned at the first position is indicated by 46a, and in FIGS. 9B and 9C, the third heater 46 positioned at the second position is indicated by 46b. In the present embodiment, the third heater 46 is configured to be movable in a direction orthogonal to the transport direction of the fourth intermediate carrier 40 on the belt surface of the fourth intermediate carrier 40 at the stacking position N.

  When the material layer M is stacked, the intermediate shaped article S is heated by the third heater 46 positioned at the first position shown in FIG. 9D, and then the material layer M reaches the stacking position N. The third heater 46 is moved to the second position shown in FIGS. 9B and 9C. Then, when the material layer M is transferred to the intermediate shaped article S, the third heater 46 is positioned again at the first position shown in FIG. 9D. Then, after the material layer M is transferred to the intermediate shaped object S, the intermediate shaped object S to which the material layer M has been transferred and the third heater 46 are brought close to each other, so that the portion of the transferred material layer M in the intermediate shaped object S Is melted and fixed to the intermediate shaped article S. As the third heater 46, for example, a ceramic heater or a halogen heater can be used. The temperature of the third heater 46 is preferably set to be equal to or higher than the temperature at which the material layer M melts, and by adjusting the distance between the third heater 46 and the intermediate model S, the laminated surface Sa of the intermediate model S Temperature can be controlled.

(stage)
In the present embodiment, the stage 23 is configured to be movable only in the stacking direction of the material layer M (direction perpendicular to the belt surface of the fourth intermediate carrier 40 at the stacking position N) by driving means such as an actuator (not shown). Has been.
The stage 23 is lowered downward (in a direction away from the stacking position N) before the material layer M is stacked, and is moved upward when the material layer M is stacked. The position of the stage 23 at this time is set by adjusting the distance between the stage 23 and the third heater 46 based on the temperature of the laminated surface Sa of the intermediate shaped article S. Then, heating by the third heater 46 is performed until the temperature of the laminated surface Sa of the intermediate shaped article S on the stage 23 becomes equal to or higher than the softening temperature of the intermediate shaped article S. When the material layer M is conveyed to the stacking position N, the stage 23 is raised, and the material layer M is sandwiched between the stage 23 and the transfer auxiliary member 41, whereby the material layer M is transferred to the intermediate shaped object S. When the material layer M is transferred to the intermediate shaped article S, the stage 23 moves downward, and then the third heater 46 moves to the first position shown in FIG. Is melted and fixed to the intermediate shaped object S.

  Each embodiment described above is intended to exemplify the embodiment of the present invention, and can be combined or variously modified as much as possible without departing from the gist of the present invention. It is.

  DESCRIPTION OF SYMBOLS 1 ... Modeling apparatus, 20 ... 2nd intermediate carrier, 22 ... Heater, 23 ... Stage, Ma, Mb ... Modeling material, S ... Intermediate model

Claims (19)

In a modeling apparatus for producing a three-dimensional solid object by laminating a thermoplastic modeling material supported on a carrier on a stage,
Heating means for heating the laminated surface of the three-dimensional object on the stage;
Lamination means for laminating the modeling material carried on the carrier on the lamination surface of the three-dimensional object on the stage;
Control means for controlling the heating means and the laminating means;
Have
The control means controls the heating so that the laminated surface is heated to a temperature higher than or equal to the softening temperature of the modeling material, and the modeling material having a temperature lower than the softening temperature is laminated on the laminated surface. Modeling equipment. The softening temperature refers to the temperature dependence of the storage elastic modulus and loss elastic modulus in the shear direction of a molded body obtained by press-molding the aggregate of modeling materials into a cylindrical shape having a diameter of 10 mm and a thickness of 1 mm, and an angular frequency of 1 Hz. The modeling apparatus according to claim 1, wherein the storage elastic modulus is a temperature at which the storage elastic modulus becomes 10 MPa when the temperature is measured at a rate of 2 ° C./min with a rotary rheometer. The modeling apparatus according to claim 1, wherein the heating unit maintains an ambient temperature around the three-dimensional object on the stage at a target temperature in order to heat the three-dimensional object on the stage. The stage and / or the heating means are movably arranged between a position when the lamination by the lamination means is performed and a position when the three-dimensional object on the stage is heated by the heating means. The modeling apparatus according to claim 1, wherein the modeling apparatus is provided. After the modeling material is stacked on the stacked surface of the three-dimensional object on the stage, the function of pressing the three-dimensional object on the stage on which the modeling material is stacked and / or heating the stacked modeling material. The modeling apparatus according to claim 1, further comprising a member having a function.   The surface of the stage on which the modeling material is laminated is preliminarily provided with a layer formed of a solvent-soluble material or a temperature-sensitive adhesive that changes in adhesion and non-adhesion in response to a temperature change. The modeling apparatus according to any one of claims 1 to 5, wherein the modeling apparatus is provided. The solvent-soluble material is a thermoplastic material,
When the modeling material is laminated directly on the thermoplastic material layer, the control means heats the thermoplastic material layer to a temperature equal to or higher than the softening temperature of the thermoplastic material by the heating means. The modeling apparatus according to claim 6. Having a material layer forming means for forming a material layer made of the modeling material based on the slice data of the three-dimensional model;
8. The carrier according to claim 1, wherein the carrier is a transport body that transports the material layer formed by the material layer forming unit to a stacking position where the stacking unit performs stacking. The modeling apparatus of any one of Claims. 9. The apparatus according to claim 8, further comprising preheating means for heating the material layer so that the temperature of the material layer carried on the carrier and transported toward the stacking position approaches the softening temperature. Modeling equipment. 9. The cleaning apparatus according to claim 8, further comprising: a cleaning unit that is disposed downstream of the stacking position in the conveying direction of the material layer by the carrier and that cleans a carrying surface that carries the material layer in the carrier. Or the modeling apparatus of 9. 11. The cooling device according to claim 8, further comprising a cooling unit that is disposed downstream of the stacking position in the conveying direction of the material layer by the carrier and cools the carrier. Modeling equipment. The carrier electrically carries the material layer,
Voltage application means for applying a voltage to the carrier,
The laminating means applies a voltage to the carrier by the voltage application means when laminating the material layer on the carrier on the lamination surface of a three-dimensional object on the stage. The modeling apparatus according to any one of 8 to 11. The modeling apparatus according to claim 8, wherein the carrier is a belt member made of resin or metal. A plurality of rollers for stretching the carrier;
The plurality of support members are positioned at a transfer position where the material layer is transferred from the material layer forming unit to the support member, or at a position away from the material layer forming unit with respect to the transfer position. The molding apparatus according to claim 13, wherein at least one of the rollers is movably disposed. The modeling apparatus according to claim 8, wherein the carrier is a cylindrical member made of resin or metal. An image forming unit that forms an image made of the modeling material based on slice data of the three-dimensional model,
The modeling apparatus according to claim 1, wherein the carrier is a member on which an image of the modeling material is formed in the image forming unit. A plurality of the image forming units are provided,
The image of the modeling material respectively formed by each image forming unit based on slice data for one layer is sequentially stacked on the stack surface of the three-dimensional object on the stage. Modeling equipment. After the image of the modeling material carried on the carrier is laminated on the lamination surface of the three-dimensional object on the stage, cooling for cooling a region of the carrier on which the image of the modeling material is carried The modeling apparatus according to claim 16 or 17, further comprising: means. A modeling method by a modeling apparatus for producing a three-dimensional solid object by laminating a thermoplastic modeling material supported on a carrier on a stage,
A heating step of heating the laminated surface of the three-dimensional object on the stage;
Lamination for laminating the modeling material having a temperature lower than the softening temperature supported on the carrier on the laminating surface of the three-dimensional object on the stage heated to the softening temperature or higher of the modeling material by the heating step. Process,
A modeling method comprising:

Images