JP2019157235A - Three-dimension model object production process - Google Patents

Abstract

To provide a three-dimension model object production process in which a three-dimension model object having voids oriented in a desired direction is produced.SOLUTION: Provided is a three-dimension model object production process including: a layer forming step for forming a layer using a flowable composition containing a constituent material powder P and a magnetic anisotropic organic fiber F constituting a three-dimension model object 500 (step S130); a magnetic field application step for applying a magnetic field to the layer (step S140); a void formation step of forming a void in the layer by removing the magnetic anisotropic organic fiber F (step S170); and a sintering step for sintering the constituent material powder P by heating the layer (step S180).SELECTED DRAWING: Figure 13

Description

  The present invention relates to a method for manufacturing a three-dimensional structure.

Conventionally, various methods for producing a three-dimensional structure have been used. Among these, there is a method of manufacturing a three-dimensional structure by forming a layer using a material containing constituent material powder constituting the three-dimensional structure.
For example, Patent Document 1 discloses a method of manufacturing a three-dimensional structure by laminating magnetic metal powders as constituent material powders while being oriented in a magnetic field.

Japanese Unexamined Patent Publication No. 2017-150022

  Three-dimensional structures are used for various purposes. And depending on the use of a three-dimensional structure, it may be desired to manufacture a three-dimensional structure having a gap. As a result of intensive studies by the present inventors, it has been found that the characteristics of the three-dimensional structure differ depending on the shape of the gap provided in the three-dimensional structure. Furthermore, by orienting the gaps provided in the three-dimensional structure in the desired direction, the range of uses of the three-dimensional structure can be expanded, and the performance can be improved even in applications that have been used so far. I found out that

  Therefore, an object of the present invention is to manufacture a three-dimensional structure having voids oriented in a desired direction.

  The manufacturing method of the three-dimensional structure according to the first aspect of the present invention for solving the above problem uses a fluid composition containing constituent material powder and magnetic anisotropic organic fibers constituting the three-dimensional structure. A layer forming step of forming a layer, a magnetic field applying step of applying a magnetic field to the layer, a void forming step of removing the magnetic anisotropic organic fiber to form a void in the layer, and heating the layer And a sintering step of sintering the constituent material powder.

  According to this aspect, a layer is formed using a fluid composition containing constituent material powder and magnetic anisotropic organic fibers, and a magnetic field is applied to the layers to form magnetic anisotropic organic fibers in a desired direction. Orientation is performed to remove the magnetic anisotropic organic fibers to form voids in the layer. That is, a magnetic field is applied in a desired direction according to the magnetic anisotropic organic fiber to be used to orient the magnetic anisotropic organic fiber in a desired direction, and then the magnetic anisotropic organic fiber is removed to form voids. By forming, a three-dimensional structure having voids oriented in a desired direction can be manufactured.

  The manufacturing method of the three-dimensional structure according to the second aspect of the present invention is characterized in that, in the first aspect, the constituent material powder has magnetic anisotropy.

  According to this aspect, not only the magnetic anisotropic organic fibers that form voids, but also the constituent material powders have magnetic anisotropy. For this reason, it is possible to manufacture a three-dimensional structure having voids oriented in a desired direction, and it is possible to improve characteristics of portions other than the voids of the three-dimensional structure according to the application.

  The method for producing a three-dimensional structure according to the third aspect of the present invention is characterized in that, in the first or second aspect, the method includes an orientation fixing step of fixing the orientation state of the layer by the magnetic field application step. .

  According to this aspect, it has the orientation fixing process which fixes the orientation state of the layer by a magnetic field application process. For this reason, even when the fluid composition has a composition that is difficult to maintain the orientation, the voids can be formed while maintaining the orientation state of the layer.

  The method for producing a three-dimensional structure according to the fourth aspect of the present invention is the method according to any one of the first to third aspects, wherein at least the layer formation step and the magnetic field application step are repeated, so that the layer It is possible to manufacture a three-dimensional structure by laminating layers, and the magnetic field direction in the magnetic field applying step is changed in a part of the layers.

  According to this aspect, the magnetic field direction in the magnetic field application step is changed in some layers, so that the shape of the gap can be precisely controlled. For this reason, the range of applications of the three-dimensional structure can be effectively expanded, and the performance can be effectively improved even in applications that have been used so far.

  The manufacturing method of the three-dimensional structure according to the fifth aspect of the present invention is the method according to any one of the first to fourth aspects, wherein the layer forming step forms the layer on a flexible film. It is characterized by.

  Generally, it is difficult to manufacture a thin three-dimensional structure (for example, composed of one layer or two layers). This is because it is difficult to remove the thin three-dimensional structure from the support portion without damaging it. For this reason, when a thin three-dimensional structure is manufactured, a thick three-dimensional structure is manufactured once, and the thick three-dimensional structure is often manufactured by cutting. However, according to this aspect, since the layer forming step forms the layer on the flexible film, the flexible film can be peeled while being deformed (bent) after the three-dimensional structure is manufactured, and is thin. It is easy to remove from the support part (flexible film) without damaging the three-dimensional structure. For this reason, it can manufacture easily, without damaging the thin three-dimensional structure which has the space | gap orientated in the desired direction.

The schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention. The enlarged view of the C section shown in FIG. The schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention. FIG. 3 is an enlarged view of a C ′ portion shown in FIG. 2. 1 is a schematic perspective view of a head base according to an embodiment of the present invention. The top view explaining notionally the relationship between arrangement | positioning of the head unit which concerns on one Embodiment of this invention, and the formation form of a three-dimensional structure. The top view explaining notionally the relationship between arrangement | positioning of the head unit which concerns on one Embodiment of this invention, and the formation form of a three-dimensional structure. The top view explaining notionally the relationship between arrangement | positioning of the head unit which concerns on one Embodiment of this invention, and the formation form of a three-dimensional structure. Schematic explaining conceptually the formation form of a three-dimensional structure. Schematic explaining conceptually the formation form of a three-dimensional structure. The schematic diagram which shows the example of other arrangement | positioning of the head unit arrange | positioned at a head base. The schematic diagram which shows the example of other arrangement | positioning of the head unit arrange | positioned at a head base. The flowchart of the manufacturing method of the three-dimensional structure based on one Example of this invention. The flowchart of the manufacturing method of the three-dimensional structure based on another one Example of this invention. Schematic showing the state of a magnetic anisotropic organic fiber in case the magnetic field is not applied. Schematic showing the state (orientation example) of a magnetic anisotropic organic fiber at the time of applying a magnetic field. Schematic showing the state of the constituent material powder when no magnetic field is applied. Schematic showing the state (example of orientation) of the constituent material powder when a magnetic field is applied. Schematic showing the example of the application method of a magnetic field.

Embodiments according to the present invention will be described below with reference to the drawings.
FIGS. 1-4 is a schematic block diagram which shows the structure of the manufacturing apparatus of the three-dimensional structure based on one Embodiment of this invention.
Here, the three-dimensional structure manufacturing apparatus of the present embodiment includes two types of material supply units (head bases). Among these, FIG.1 and FIG.2 is a figure showing only one material supply part (material supply part which supplies the constituent material of a three-dimensional structure). 3 and 4 show another material supply unit (a material supply unit that supplies a material for forming a support layer that forms a support unit that supports the three-dimensional structure when the three-dimensional structure is formed. ) Only.

  In addition, “three-dimensional modeling” in the present specification indicates that a so-called three-dimensional model is formed, and is, for example, a flat plate shape, a so-called two-dimensional shape (for example, one layer) Forming a shape having a thickness is also included. Further, “support” means not only the case of supporting from the lower side, but also the case of supporting from the lateral side and, in some cases, the case of supporting from the upper side.

  Moreover, the constituent material of a present Example is the constituent material powder P (refer FIG.17 and FIG.18) which comprises a three-dimensional structure, the magnetic anisotropic organic fiber F (refer FIG.15 and FIG.16), a solvent, And a three-dimensional modeling paste (flowable material) containing a binder soluble in the solvent. The support layer forming material of this example is a three-dimensional modeling paste (flowable material) including a support layer forming powder, a solvent, and a binder soluble in the solvent. However, the three-dimensional modeling paste as the constituent material is not limited in composition and physical properties as long as it is a fluid material containing the constituent material powder P and the magnetic anisotropic organic fiber F, and the support layer forming material The three-dimensional modeling paste is not particularly limited in composition and physical properties.

  The three-dimensional structure manufacturing apparatus 2000 (hereinafter, referred to as a forming apparatus 2000) according to the present embodiment has a configuration capable of forming a three-dimensional structure using a support layer forming material in addition to the constituent materials, as will be described later. It has become. However, although the shape etc. which can be formed may be limited, the structure which forms a three-dimensional structure without using a support layer forming material may be sufficient.

The forming apparatus 2000 shown in FIGS. 1 and 3 is moved in the X, Y, and Z directions shown in the figure or rotated around the Z axis by a base 110 and a driving device 111 as a driving means provided in the base 110. A stage 120 is provided that can be driven in the direction.
As shown in FIGS. 1 and 2, a plurality of head units 1400 having one end portion fixed to the base 110 and having a constituent material discharge portion 1230 that discharges a constituent material to the other end portion are held. A head base support portion 130 is provided on which the head base 1100 is held and fixed.
As shown in FIGS. 3 and 4, one end is fixed to the base 110, and the other end is used to form a support layer that discharges a support layer forming material that supports the three-dimensional structure. A head base support portion 730 on which a head base 1600 that holds a plurality of head units 1900 including a material discharge portion 1730 is held and fixed.
Here, the head base 1100 and the head base 1600 are provided in parallel in the XY plane.
The constituent material discharge unit 1230 and the support layer forming material discharge unit 1730 have the same configuration. However, it is not limited to such a configuration.

  On the stage 120, layers 501, 502, and 503 in the process of forming the three-dimensional structure 500 are formed. When the three-dimensional structure 500 is formed (for example, when the orientation state of the layers 501, 502, 503,... 50n is fixed as will be described later), thermal energy is irradiated by a heating unit (not shown). Etc. may be performed. When performing thermal energy irradiation or the like, the three-dimensional structure 500 may be formed on the sample plate 121 using the heat-resistant sample plate 121 in order to protect the stage 120 from heat. The sample plate 121 of this embodiment is made of metal that is sturdy and easy to manufacture. However, as the sample plate 121, for example, by using a ceramic plate, high heat resistance can be obtained, and further, the reactivity with the constituent material of the three-dimensional structure 500 to be degreased or sintered is low. Alteration of the original model 500 can be prevented.

  In FIGS. 1 and 3, for convenience of explanation, three layers 501, 502, and 503 are illustrated, but the layers are stacked up to the shape of the desired three-dimensional structure 500 (up to the layer 50 n in FIGS. 1 and 3). Is done. For example, when manufacturing a thin three-dimensional structure 500 composed of one layer or two layers, a flexible film can be used instead of the sample plate 121. Since the flexible film has flexibility, when the three-dimensional structure 500 is removed from the flexible film, the flexible film can be deformed (bent) and removed. The three-dimensional structure 500 can be easily detached from the flexible film without deforming.

As shown in FIGS. 1 and 3, each of the layers 501, 502, 503,... 50 n is a support layer formed of a support layer forming material discharged from the support layer forming material discharge unit 1730. 300 and a constituent layer 310 formed of constituent materials discharged from the constituent material discharge portion 1230.
In addition, the forming apparatus 2000 of this embodiment is a three-dimensional capable of forming a plurality of layers 501, 502, 503,... 50 n using a support layer forming material in addition to the constituent material of the three-dimensional structure 500. Although it is a manufacturing apparatus of a modeling thing, as mentioned above, the manufacturing apparatus of the three-dimensional modeling object which can form a some layer, without using a support layer forming material may be sufficient.

  FIG. 2 is an enlarged conceptual view of a C portion showing the head base 1100 shown in FIG. As shown in FIG. 2, the head base 1100 holds a plurality of head units 1400. As will be described in detail later, one head unit 1400 is configured by holding a constituent material discharge unit 1230 included in the constituent material supply apparatus 1200 by a holding jig 1400a. The constituent material discharge unit 1230 includes a discharge nozzle 1230a and a discharge driving unit 1230b that discharges the constituent material from the discharge nozzle 1230a by the material supply controller 1500.

  FIG. 4 is an enlarged conceptual diagram of a C ′ portion showing the head base 1600 shown in FIG. As shown in FIG. 4, the head base 1600 holds a plurality of head units 1900. The head unit 1900 is configured by holding a support layer forming material discharge unit 1730 included in the support layer forming material supply apparatus 1700 by a holding jig 1900a. The support layer forming material discharge unit 1730 includes a discharge nozzle 1730a and a discharge driving unit 1730b that discharges the support layer forming material from the discharge nozzle 1730a by the material supply controller 1500.

  As shown in FIGS. 1 and 2, the constituent material discharge section 1230 is connected by a constituent material supply unit 1210 that stores constituent materials corresponding to each of the head units 1400 held by the head base 1100 and a supply tube 1220. Has been. Then, a predetermined constituent material is supplied from the constituent material supply unit 1210 to the constituent material discharge unit 1230. In the constituent material supply unit 1210, the constituent material of the three-dimensional structure 500 that is modeled by the forming apparatus 2000 according to the present embodiment is accommodated in the constituent material accommodating portion 1210a, and each constituent material accommodating portion 1210a is supplied to the supply tube 1220. Are connected to the individual component material discharge sections 1230. In this manner, by providing the individual constituent material accommodating portions 1210a, a plurality of different types of materials can be supplied from the head base 1100.

As shown in FIGS. 3 and 4, the support layer forming material discharge unit 1730 has a support layer forming material that contains a support layer forming material corresponding to each head unit 1900 held by the head base 1600. The supply unit 1710 and the supply tube 1720 are connected. Then, a predetermined support layer forming material is supplied from the support layer forming material supply unit 1710 to the support layer forming material discharge unit 1730. In the support layer forming material supply unit 1710, the support layer forming material constituting the support layer when the three-dimensional structure 500 is formed is accommodated in the support layer forming material accommodating portion 1710a, and each support layer forming material is provided. The material accommodating portion 1710 a is connected to each support layer forming material discharge portion 1730 by a supply tube 1720. As described above, by providing the individual support layer forming material accommodating portions 1710 a, a plurality of different types of support layer forming materials can be supplied from the head base 1600.
In addition, the detail about each paste for 3D modeling as a constituent material used with the forming apparatus 2000 of this embodiment and a support layer forming material is mentioned later.

  The forming apparatus 2000 includes, on the basis of modeling data of a three-dimensional structure 500 output from a data output apparatus such as a personal computer (not shown), the constituent material discharge unit provided in the stage 120 and the constituent material supply apparatus 1200 described above. 1230, and a control unit 400 as a control unit that controls the support layer forming material discharge unit 1730 provided in the support layer forming material supply apparatus 1700. The control unit 400 controls the stage 120 and the constituent material discharge unit 1230 to drive and operate in cooperation, and controls to control the stage 120 and the support layer forming material discharge unit 1730 to drive and operate in cooperation. Also serves as a department.

The stage 120 movably provided on the base 110 is a signal for controlling the start and stop of movement of the stage 120, the movement direction, the movement amount, the movement speed, and the like in the stage controller 410 based on the control signal from the control unit 400. Is sent to the driving device 111 provided in the base 110, and the stage 120 moves in the X, Y, and Z directions shown in the figure. The constituent material discharge unit 1230 provided in the head unit 1400 controls the material discharge amount from the discharge nozzle 1230a in the discharge drive unit 1230b provided in the constituent material discharge unit 1230 in the material supply controller 1500 based on the control signal from the control unit 400. And a predetermined amount of the constituent material is discharged from the discharge nozzle 1230a by the generated signal.
Similarly, in the support layer forming material discharge unit 1730 provided in the head unit 1900, the discharge nozzle in the discharge drive unit 1730 b provided in the support layer forming material discharge unit 1730 in the material supply controller 1500 based on the control signal from the control unit 400. A signal for controlling the material discharge amount and the like from the 1730a is generated, and a predetermined amount of the support layer forming material is discharged from the discharge nozzle 1730a by the generated signal.

  Further, as shown in FIGS. 1 and 3, the forming apparatus 2000 includes a magnetic field application unit 1000, and the direction D (lamination direction) toward the layers 501, 502, 503,... 50n. The magnetic field can be applied. The magnetic field application unit 1000 is also configured to be able to apply a magnetic field under the control of the control unit 400. In addition, although the formation apparatus 2000 (magnetic field application unit 1000) of the present embodiment is configured to be able to apply a magnetic field in the stacking direction, it is also inclined in the direction intersecting the stacking direction (inclined with respect to the stacking direction). It is configured to be able to apply a magnetic field (at an angle). The magnetic field application unit 1000 of the present embodiment is a superconducting magnet capable of applying a magnetic field of 5 Tesla or more, but the magnetic field application unit is not particularly limited as long as a desired magnetic field can be applied.

Next, the head unit 1400 will be described in more detail. The head unit 1900 has the same configuration as the head unit 1400. Therefore, a detailed description of the configuration of the head unit 1900 is omitted.
5 and FIGS. 6 to 8 show an example of a holding form of a plurality of head units 1400 and constituent material discharge units 1230 held by the head base 1100, among which FIGS. 6 to 8 are FIGS. 4 is an external view of the head base 1100 from the direction D shown in FIG.

As shown in FIG. 5, a plurality of head units 1400 are held on a head base 1100 by fixing means (not shown). As shown in FIGS. 6 to 8, in the head base 1100 of the forming apparatus 2000 according to this embodiment, the head unit 1401 in the first row, the head unit 1402 in the second row, A head unit 1400 in which four units of the head unit 1403 in the third row and the head unit 1404 in the fourth row are arranged in a staggered manner (staggered) is provided. Then, as shown in FIG. 6, the constituent material is discharged from each head unit 1400 while moving the stage 120 in the X direction with respect to the head base 1100, and the constituent layer constituent parts 50 (constituent layer constituent parts 50 a, 50 b). , 50c and 50d) are formed. A procedure for forming the constituent layer constituent unit 50 will be described later.
Although not shown, the constituent material discharge unit 1230 included in each of the head units 1401 to 1404 is connected to the constituent material supply unit 1210 via a supply tube 1220 via the discharge drive unit 1230b.

  As shown in FIG. 5, the constituent material discharge unit 1230 is a constituent material (paste-like fluid material) of the three-dimensional structure 500 from the discharge nozzle 1230 a toward the sample plate 121 placed on the stage 120. A certain material M is discharged. The head unit 1401 illustrates a discharge form in which the material M is discharged in the form of droplets, and the head unit 1402 illustrates a discharge form in which the material M is supplied in a continuous form. The discharge form of the material M may be either a droplet form or a continuous form, but in the present embodiment, the material M is described as a form discharged in the form of a droplet.

  The material M discharged in the form of droplets from the discharge nozzle 1230a flies in a substantially gravitational direction and lands on the sample plate 121. The stage 120 moves, and the constituent layer constituting part 50 is formed by the landed material M. An assembly of the constituent layer constituent portions 50 is formed as the constituent layer 310 (see FIG. 1) of the three-dimensional structure 500 formed on the sample plate 121.

Next, a procedure for forming the constituent layer constituent unit 50 will be described with reference to FIGS. 6 to 8 and FIGS. 9 and 10.
6 to 8 are plan views conceptually illustrating the relationship between the arrangement of the head unit 1400 of the present embodiment and the form of formation of the component layer constituting unit 50. FIG. 9 and 10 are side views conceptually showing the formation form of the constituent layer constituting unit 50.

First, when the stage 120 moves in the + X direction, the material M is discharged in droplets from the plurality of discharge nozzles 1230a, the material M is disposed at a predetermined position of the sample plate 121, and the constituent layer constituting unit 50 is formed. .
More specifically, first, as illustrated in FIG. 9, the material M is arranged at predetermined intervals from the plurality of discharge nozzles 1230 a to the predetermined positions of the sample plate 121 while moving the stage 120 in the + X direction. .

Next, as illustrated in FIG. 10, the material M is newly arranged so as to fill the space between the materials M arranged at a constant interval while moving the stage 120 in the −X direction.
However, a configuration in which the material M overlaps a predetermined position of the sample plate 121 from the plurality of discharge nozzles 1230a while moving the stage 120 in the + X direction (so as not to be spaced apart) (in the X direction of the stage 120). Instead of a configuration in which the constituent layer constituent unit 50 is formed by reciprocal movement, a configuration in which the constituent layer constituent unit 50 is formed only by moving one side of the stage 120 in the X direction may be employed.

  By forming the constituent layer constituting section 50 as described above, the head units 1401, 1402, 1403 and 1404 corresponding to one line in the X direction (the first line in the Y direction) as shown in FIG. A constituent layer constituent part 50 (constituent layer constituent parts 50a, 50b, 50c and 50d) is formed.

Next, in order to form the second layer constituent layer constituent unit 50 ′ (the constituent layer constituent units 50a ′, 50b ′, 50c ′, and 50d ′) in the Y direction of the head units 1401, 1402, 1403, and 1404, − The head base 1100 is moved in the Y direction. When the pitch between the nozzles is P, the movement amount is moved in the −Y direction by P / n (n is a natural number) pitch. In this embodiment, n is assumed to be 3.
By performing the same operation as described above as represented in FIG. 9 and FIG. 10, the constituent layer constituting unit 50 ′ (constituent layer constituting unit 50a) in the second line in the Y direction as represented in FIG. ', 50b', 50c 'and 50d') are formed.

Next, the third layer constituent layer constituent unit 50 ″ (the constituent layer constituent units 50a ″, 50b ″, 50c ″, and 50d ″) of each head unit 1401, 1402, 1403, and 1404 in the Y direction is inserted. In order to form, the head base 1100 is moved in the −Y direction. The movement amount is moved in the −Y direction by P / 3 pitch.
Then, by performing the same operation as described above as shown in FIG. 9 and FIG. 10, the constituent layer constituent unit 50 ″ (constituent layer) of the third line in the Y direction as shown in FIG. The components 50a ″, 50b ″, 50c ″ and 50d ″) are formed, and the component layer 310 can be obtained.

  Further, the material M discharged from the component material discharge unit 1230 can be discharged from one of the head units 1401, 1402, 1403, and 1404, or a component different from the other head units. Therefore, by using the forming apparatus 2000 according to the present embodiment, a three-dimensional structure 500 formed from different materials can be obtained.

  In the first layer 501, before or after the formation of the constituent layer 310 as described above, the support layer forming material is discharged from the support layer forming material discharge portion 1730, and the support layer is formed in the same manner. Layer 300 can be formed. When the layers 502, 503,... 50n are stacked on the layer 501, the constituent layer 310 and the support layer 300 can be similarly formed.

  The number and arrangement of the head units 1400 and 1900 included in the forming apparatus 2000 according to the above-described embodiment are not limited to the above-described number and arrangement. FIG. 11 and FIG. 12 schematically show examples of other arrangements of the head unit 1400 arranged on the head base 1100 as an example.

  FIG. 11 shows a form in which a plurality of head units 1400 are juxtaposed in the X-axis direction on the head base 1100. FIG. 12 shows a form in which the head units 1400 are arranged in a lattice pattern on the head base 1100. Note that the number of head units arranged in each case is not limited to the example shown.

Next, each of the three-dimensional modeling pastes as the constituent material and the support layer forming material of this example will be described in detail.
As the constituent material powder P of the constituent material and the support layer forming powder of the support layer forming material, a material having no ferromagnetism or soft magnetism is preferable. For example, magnesium (Mg), aluminum (Al), titanium (Ti) Copper (Cu) simple powder, or an alloy containing one or more of these metals and not having ferromagnetism or soft magnetism (titanium alloy, aluminum alloy, copper alloy) or the like can be used. In addition, even if it is a material having ferromagnetism or soft magnetism alone, the alloy does not have ferromagnetism or soft magnetism, such as hematite (α-Fe ₂ O ₃ ) or nonmagnetic stainless steel (17Cr-17Mn-7). .3Ni) and other alloys can be used.
In addition, general-purpose engineering plastics such as polyamide, polyacetal, polycarbonate, modified polyphenylene ether, polybutylene terephthalate, and polyethylene terephthalate can be used. In addition, engineering plastics (resins) such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and polyetheretherketone can also be used.
Thus, the constituent material powder P and the support layer forming powder may be any material that does not have ferromagnetism or soft magnetism, and metals other than the above metals, ceramics, resins, and the like can be used. In addition, titanium dioxide (TiO ₂ ), aluminum oxide (Al ₂ O ₃ ), zirconium oxide (ZrO) and the like can be preferably used.

However, although the details will be described later, the constituent material powder P is particularly preferably a powder having magnetic illegality.
For example, α-Al ₂ O ₃ , α-SiC, TiO ₂ , La _9.3 3Si ₆ O ₂₆ , Y ₂ O may be used as the powder whose orientation direction is parallel to the magnetic field (the c axis in the crystal axis is parallel). _3. Powders such as CeO ₂ can be preferably used. As the powder whose orientation direction is perpendicular to the magnetic field, powders such as AlN, ZnO, hydroxyapatite, α-Si ₃ N ₄ , PbTiO ₃ , CaBi ₄ Ti ₄ O ₁₅ , LiCoO ₂ can be preferably used. is there.
For example, when the three-dimensional structure 500 is used as a phosphor, a powder containing yttrium (Y), aluminum (Al), cerium (Ce), etc. capable of forming a YAG phosphor (Ce: YAG). Can be preferably used.

  As the magnetic anisotropic organic fiber F of the constituent material, the fully anisotropic polyester fiber, carbon fiber (carbon nanofiber, pencil, mechanical pencil, etc.) are oriented as the magnetic anisotropic organic fiber F whose orientation direction is parallel to the magnetic field. Core), polyparaphenylene benzoxazole (PBO) and the like can be preferably used. In addition, cellulose fibers and the like can be preferably used as the magnetic anisotropic organic fibers F whose orientation direction is perpendicular to the magnetic field.

  Examples of the solvent include water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether; ethyl acetate, n-propyl acetate, acetic acid Acetic acid esters such as iso-propyl, n-butyl acetate and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene and xylene; methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butyl ketone, diisopropyl ketone, acetylacetone Ketones such as ethanol; alcohols such as ethanol, propanol, butanol; tetraalkylammonium acetates; dimethyl sulfoxide, diethyl sulfoxide, etc. Phoxide solvents; pyridine solvents such as pyridine, γ-picoline, 2,6-lutidine, etc .; ionic liquids such as tetraalkylammonium acetate (for example, tetrabutylammonium acetate, etc.) can be used. These can be used alone or in combination of two or more.

  Examples of the binder include polyvinyl alcohol (Poval), polyvinyl butyral, acrylic resin, epoxy resin, silicone resin, cellulose resin, or other synthetic resins, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide). Alternatively, other thermoplastic resins can be used.

Next, an example of a manufacturing method of a three-dimensional structure performed using the forming apparatus 2000 will be described using a flowchart.
Here, FIG.13 and FIG.14 is a flowchart which concerns on one Example of the manufacturing method of a three-dimensional structure, respectively.
FIG. 15 is a schematic view showing the state of the magnetic anisotropic organic fiber F when no magnetic field is applied (when the magnetic field application step is not executed). On the other hand, FIG. 16 is a schematic diagram showing a state (orientation state) of the magnetic anisotropic organic fiber F when a magnetic field is applied (when a magnetic field application step is executed).
FIG. 17 is a schematic view showing the state of the constituent material powder P when no magnetic field is applied, and FIG. 18 is a schematic view showing the state (orientation state) of the constituent material powder P when the magnetic field is applied. is there.
FIG. 19 is a schematic diagram showing a magnetic field application method example (execution example of a magnetic field application step).

Initially, the Example of the manufacturing method of the three-dimensional structure represented by FIG. 13 is described.
As shown in FIG. 13, in the three-dimensional structure manufacturing method of the present embodiment, first, in step S <b> 110, data of the three-dimensional structure is acquired. Specifically, for example, data representing the shape of the three-dimensional structure 500 is acquired from an application program or the like executed on a personal computer.

  Next, in step S120, data for each layer is created (generated) under the control of the control unit 400. Specifically, in the data representing the shape of the three-dimensional structure 500, the data is sliced according to the modeling resolution in the Z direction, and bitmap data is generated for each cross section.

  Next, in the layer forming process of step S130, the control unit 400 controls to discharge the flowable material (component material) from the component material discharge unit 1230 based on the bitmap data generated in step S120 (note that the case Depending on the case, the support layer forming material discharge unit 1730 may also discharge the support layer forming material) to form the configuration layer configuration unit 50 (configuration layer 310) based on the bitmap data.

  Next, in the magnetic field application process of step S140, the magnetic field application unit 1000 is driven under the control of the control unit 400, and a magnetic field is applied in a state where the constituent material has fluidity. In addition, in the manufacturing method of the three-dimensional structure according to the present embodiment, since the forming apparatus 2000 is used, not only the stacking direction (direction along the direction D) toward the layers 501, 502, 503,. It is possible to apply a magnetic field also in a direction intersecting with the stacking direction. Here, the magnetic field application process of step S140 may be performed simultaneously with the layer formation process of step S130. In this embodiment, not only the magnetic anisotropic organic fiber F but also the constituent material powder P having magnetic illegality is oriented, so that the magnetic field application unit 1000 (superconducting magnet) capable of applying a magnetic field of 5 Tesla or more is provided. However, when only the magnetic anisotropic organic fiber F is oriented, the magnetic field application unit 1000 capable of applying a magnetic field of about 2 Tesla may be used.

  FIG. 15 schematically shows the state of the magnetic anisotropic organic fiber F before the execution of step S140, and FIG. 16 shows the magnetic anisotropic organic after the execution of step S140 (after applying the magnetic field in the direction D). The state of the fiber F is schematically represented. FIG. 17 schematically shows the state of the constituent material powder P having magnetic illegality before execution of step S140, and FIG. 18 shows the magnetism after execution of step S140 (after applying the magnetic field in the direction D). The state of the constituent material powder P having illegality is schematically shown. 15 and 16 show the case where the magnetic anisotropic organic fiber F whose orientation direction is parallel to the magnetic field is used. 17 and 18 show the case where the constituent material powder P having the magnetic illegality whose orientation direction is parallel to the magnetic field is used. However, a constituent material having magnetic illegality whose orientation direction is perpendicular to the magnetic field (magnetic anisotropic organic fiber F and constituent material powder P having magnetic illegality) may be used. It is not necessary to use the constituent material powder P having magnetic illegality.

Here, in the case of using a constituent material (magnetic anisotropic organic fiber and constituent material powder P having magnetic illegality) whose orientation direction is parallel to the magnetic field, the above-described forming apparatus 2000 is used to provide the magnetic difference. The orientation of the isotropic organic fiber F and the constituent material powder P can be made uniform. This is because the magnetic anisotropic organic fiber F and the constituent material powder P are oriented along the magnetic field direction.
On the other hand, when the constituent material (the magnetic anisotropic organic fiber F and the constituent material powder P having magnetic illegality) whose orientation direction is perpendicular to the magnetic field is used, the magnetic anisotropy is obtained even if the forming apparatus 2000 is used. In some cases, the orientation of the conductive organic fiber F and the constituent material powder P cannot be aligned. This is because the magnetic anisotropic organic fiber F and the constituent material powder P may be oriented with a 360 ° variation in a direction perpendicular to the magnetic field direction. For this reason, the orientation of the constituent materials can be made uniform by using, as the magnetic field application unit 1000, for example, a forming apparatus 2000 including the magnetic field application unit 1000 configured as shown in FIG.

  A magnetic field application unit 1000 shown in FIG. 19 includes a rotating unit 120a that can rotate in the rotation direction E on the stage 120 (can rotate about a direction orthogonal to the support surface 120b of the three-dimensional structure 500). The magnetic field in the direction G that is parallel to the support surface 120b can be applied. Then, the layers 501, 502, 503,... 50 n of the three-dimensional structure 500 are formed on the rotating part 120 a in a state where the rotation is stopped (Step S 130), and the rotating part 120 a is rotated in the rotating direction E and the direction G By applying the magnetic field (step S140), the orientation of the constituent material whose alignment direction is perpendicular to the magnetic field can be aligned (specifically, the alignment can be performed in the direction along the rotation axis).

  Next, in step S160, the control unit 400 determines whether or not the formation of the constituent layer constituent unit 50 based on the bitmap data generated in step S120 is completed. When it is determined that the formation of the constituent layer constituent unit 50 has not been completed, the process returns to step S130, and when it is determined that the formation of the constituent layer constituent unit 50 has been completed, the process proceeds to step S170. That is, under the control of the control unit 400, steps S130 to S160 are repeated until the formation of the laminate of the three-dimensional structure 500 based on the bitmap data corresponding to each layer generated in step S120 is completed.

  Next, in the void forming process in step S170, for example, in a thermostat (not shown), the laminate of the three-dimensional structure 500 formed in the above step is heated to perform degreasing. With the degreasing, the magnetic anisotropic organic fiber F is removed (vaporized), so that the portion where the magnetic anisotropic organic fiber F was located becomes a void.

And by the sintering process of step S180, for example, in the thermostat not shown, the laminate of the three-dimensional structure 500 formed in the above step is heated to sinter the constituent material powder P.
And the manufacturing method of the three-dimensional structure of a present Example is complete | finished with completion | finish of this step S180.

In the method of manufacturing a three-dimensional structure according to the present embodiment, a constituent material having the following composition was used as the three-dimensional structure 500 in order to create a YAG phosphor that can be used for a display or the like. Here, an appropriate amount of water was used as the solvent.
[Component material powder P]
Y ₂ O ₃ : 16.9 parts (56.41%)
Al ₂ O ₃ : 12.8 parts (42.72%)
CeO ₂ : 0.26 part (0.87%)
The elemental composition ratio is Y: Al: O: Ce = 2.97: 5: 12: 0.03.
The particle size of these powders was 0.1 μm to 3 μm (D50).
[Magnetic anisotropic organic fiber F]
Totally aromatic polyester fiber: diameter 0.5 μm to 10 μm, fiber length 20 μm to 150 μm
[binder]
Polyvinyl alcohol: DENKA POVAL B-05 (manufactured by DENKA)
[Component material composition]
Constituent material powder P: Magnetic anisotropic organic fiber F: Binder = 50: 15.33: 80

Next, the Example of the manufacturing method of the three-dimensional structure represented by FIG. 14 is described.
In addition, the manufacturing method of the three-dimensional structure according to the present embodiment is the same as the manufacturing method of the three-dimensional structure illustrated in FIG. 13 except that the orientation fixing step of Step S150 is included. For this reason, descriptions other than step S150 are omitted.

  As shown in FIG. 14, in the method for manufacturing a three-dimensional structure according to the present embodiment, the orientation fixing step in step S <b> 150 is performed after the magnetic field application step in step S <b> 140. Specifically, the solvent was volatilized from the layers 501, 502, 503,... 50n of the three-dimensional structure 500 by heating by a heating unit (not shown) in the forming apparatus 2000.

  In addition, in the manufacturing method of the three-dimensional structure according to the present embodiment, the constituent materials in the layers 501, 502, 503,. However, the present invention is not limited to such a method. For example, the constituent material may contain an ultraviolet curable resin or the like, and the orientation of the constituent material may be fixed by irradiating ultraviolet rays.

  As described above, the manufacturing method of the three-dimensional structure illustrated in FIG. 13 and FIG. 14 includes a constituent material (flow) including the constituent material powder P and the magnetic anisotropic organic fiber F that constitute the three-dimensional structure 500. Layer formation step (step S130) for forming the layers 501, 502, 503,... 50n using the conductive composition), and the layers 501, 502, 503,. A magnetic field applying step (step S140) for applying a magnetic field to 50n, a void forming step (step S170) for removing the magnetic anisotropic organic fiber F and forming voids in the layers 501, 502, 503,. , 50n, and heating the layers 501, 502, 503,... 50n to sinter the constituent powder P (step S180).

  Thus, the manufacturing method of the three-dimensional structure represented by FIG.13 and FIG.14 forms a layer using the fluid composition containing the constituent material powder P and the magnetic anisotropic organic fiber F, A magnetic field is applied to the layer to orient the magnetic anisotropic organic fibers F in a desired direction, and the magnetic anisotropic organic fibers F are removed to form voids in the layer. That is, a magnetic field is applied in a desired direction according to the magnetic anisotropic organic fiber F to be used to orient the magnetic anisotropic organic fiber F in a desired direction, and then the magnetic anisotropic organic fiber F is removed. By forming the voids, the three-dimensional structure 500 having the voids oriented in a desired direction can be manufactured.

  Here, it is preferable that not only the magnetic anisotropic organic fiber F but also the constituent material powder P has magnetic anisotropy. Not only the magnetic anisotropic organic fibers F that form voids but also the constituent material powder P has magnetic anisotropy, so that a three-dimensional structure 500 having voids oriented in a desired direction can be manufactured. Moreover, it is because it becomes possible to improve the characteristics of portions other than the voids of the three-dimensional structure 500 according to the use.

  Moreover, like the manufacturing method of the three-dimensional structure represented by FIG. 14, it has a composition in which the fluid composition is difficult to maintain the orientation by having an orientation fixing step of fixing the orientation state of the layer by the magnetic field application step. Even if there is (for example, when the application of the magnetic field is stopped, the orientation of the fluid composition immediately collapses to return to the original state as shown in FIGS. 15 and 17, for example), the orientation state of the layer is maintained. A void can be formed as it is.

As described above, the forming apparatus 2000 according to the present embodiment can apply a magnetic field not only in the stacking direction but also in a direction crossing the stacking direction toward the layers 501, 502, 503,. Is possible. And the direction which applies a magnetic field can be changed for every layer 501,502,503, ... 50n.
That is, the manufacturing method of the three-dimensional structure represented by FIGS. 13 and 14 repeats at least the layer formation step and the magnetic field application step, thereby stacking the layers 501, 502, 503,... 50n. The three-dimensional structure 500 can be manufactured, and the magnetic field direction in the magnetic field application process can be changed in a part of the layers 501, 502, 503,.
For this reason, for example, it is possible to create a longer gap (such as a zigzag-shaped gap) than to create a straight gap parallel to the stacking direction, and effectively widen the range of uses of the three-dimensional structure 500. In addition, it is possible to effectively improve the performance even in applications that have been used so far.

Further, as described above, the forming apparatus 2000 of the present embodiment can use a flexible film instead of the sample plate 121.
That is, the manufacturing method of the three-dimensional structure represented by FIGS. 13 and 14 can form the layers 501, 502, 503,... 50n on the flexible film in the layer forming step.
In general, it is difficult to manufacture a thin three-dimensional structure 500 (for example, composed of one layer or two layers). This is because it is difficult to remove the thin three-dimensional structure 500 from the support (stage 120 or sample plate 121) without damaging it. For this reason, when the thin three-dimensional structure 500 is manufactured, the thick three-dimensional structure 500 is manufactured once, and the thick three-dimensional structure 500 is often manufactured by cutting. However, since the layers 501, 502, 503,... 50 n are formed on the flexible film in the layer formation step by executing the manufacturing method of the three-dimensional structure shown in FIGS. 13 and 14. After the three-dimensional structure 500 is manufactured, the flexible film can be peeled while being deformed (bent), and can be easily detached from the support (flexible film) without damaging the thin three-dimensional structure 500. It is. For this reason, it can manufacture easily, without damaging the thin three-dimensional structure 500 which has the space | gap orientated in the desired direction by performing the manufacturing method of the three-dimensional structure represented by FIG.13 and FIG.14. .

  In the example of the method for manufacturing the three-dimensional structure represented in FIGS. 13 and 14, the YAG phosphor was prepared using powder containing yttrium (Y), aluminum (Al), cerium (Ce), and the like. In a display using a YAG phosphor, a thin three-dimensional structure is used. Thus, when using a YAG phosphor in a display or the like, irregular reflection of light or the like can be suppressed by aligning the direction of the air gap in a certain direction, and a highly accurate display can be obtained. Since the three-dimensional structure 500 (YAG phosphor) created by executing the method for manufacturing the three-dimensional structure shown in FIGS. 13 and 14 can align the direction of the gap in a certain direction, By using a YAG phosphor, a highly accurate display can be obtained.

  The present invention is not limited to the above-described embodiments, and can be realized with various configurations without departing from the spirit of the present invention. For example, the technical features in the embodiments corresponding to the technical features in the embodiments described in the summary section of the invention are intended to solve part or all of the above-described problems, or one of the above-described effects. In order to achieve part or all, replacement or combination can be appropriately performed. Further, if the technical feature is not described as essential in the present specification, it can be deleted as appropriate.

50, 50 a, 50 b, 50 c, 50 d ... constituent layer constituent part, 110 ... base,
111 ... Drive device, 120 ... Stage, 120a ... Rotating part, 120b ... Support surface,
121 ... Sample plate, 130 ... Head base support, 300 ... Support layer,
310 ... Constituent layer, 400 ... Control unit, 410 ... Stage controller,
500 ... three-dimensional structure, 501, 502, 503, ... 50n ... layer,
730 ... head base support, 1000 ... magnetic field application unit,
1100 ... head base, 1200 ... constituent material supply device,
1210 ... Constituent material supply unit, 1210a ... Constituent material container,
1220 ... Supply tube, 1230 ... Constituent material discharge part, 1230a ... Discharge nozzle,
1230b ... discharge driving unit, 1400 ... head unit, 1400a ... holding jig,
1401, 1402, 1403 and 1404 ... head unit,
1500 ... Material supply controller, 1600 ... Head base,
1700: Support layer forming material supply device, 1710: Support layer forming material supply unit,
1710a: Support layer forming material container, 1720: Supply tube,
1730: Material discharge part for forming a support layer, 1730a: Discharge nozzle,
1730b: Discharge drive unit, 1900: Head unit,
1900a ... holding jig, 2000 ... forming device (manufacturing device for three-dimensional structure),
F: Magnetic anisotropic organic fiber, M: Material, P: Constituent material powder

Claims (5)

A layer forming step of forming a layer using a flowable composition comprising a constituent material powder constituting the three-dimensional structure and a magnetic anisotropic organic fiber;
A magnetic field applying step of applying a magnetic field to the layer;
A void forming step of removing the magnetic anisotropic organic fibers to form voids in the layer;
A sintering step of sintering the constituent material powder by heating the layer;
The manufacturing method of the three-dimensional structure characterized by having. In the manufacturing method of the three-dimensional structure described in claim 1,
The method for producing a three-dimensional structure, wherein the constituent material powder has magnetic anisotropy. In the manufacturing method of the three-dimensional structure according to claim 1 or 2,
A method for producing a three-dimensional structure, comprising: an orientation fixing step of fixing the orientation state of the layer by the magnetic field application step. In the manufacturing method of the three-dimensional structure according to any one of claims 1 to 3,
By repeating at least the layer formation step and the magnetic field application step, it is possible to produce a three-dimensional structure by laminating the layers,
A method for producing a three-dimensional structure, wherein a magnetic field direction in the magnetic field application step is changed in a part of the layer. In the manufacturing method of the three-dimensional structure according to any one of claims 1 to 4,
In the layer forming step, the layer is formed on a flexible film.

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