JP2021050373A - Powder for manufacturing three-dimensional molded article, composition for manufacturing three-dimensional molded article and method for manufacturing three-dimensional molded article - Google Patents

Abstract

To provide a method for manufacturing a three-dimensional molded article, by which a three-dimensional molded article constituted by an amorphous soft magnetic alloy that is suitably prevented from crystallization can be manufactured, and to provide a powder for manufacturing a three-dimensional molded article and a composition for manufacturing a three-dimensional molded article, which can be suitably used for manufacturing the above three-dimensional molded article.SOLUTION: The powder for manufacturing a three-dimensional molded article of the present invention is a powder for manufacturing a three-dimensional molded article to be used for manufacturing a three-dimensional molded article by irradiating plurality of particles with a laser beam to join to form a layer and stacking the layers. The particle has a base particle constituted by a material comprising an amorphous soft magnetic alloy and a coating that coats at least a part of the surface of the base particle. The coating comprises a low melting point glass having a melting point lower than the melting point of the amorphous soft magnetic alloy and a laser beam absorbent having a high absorptivity for the laser beam than that of the amorphous soft magnetic alloy.SELECTED DRAWING: None

Description

The present invention relates to a powder for producing a three-dimensional model, a composition for producing a three-dimensional model, and a method for producing a three-dimensional model.

In general, amorphous soft magnetic alloy powder is excellent in corrosion resistance, abrasion resistance, strength, magnetic permeability, etc., for example, a magnetic material provided in an electric / electronic device, more specifically, a transformer, an inductor, etc. It is applied to molded bodies such as motors, generators, and relays.

The amorphous soft magnetic alloy powder is generally made into an amorphous state by being produced through a step of quenching the molten alloy.

A molded product as described above, which is made of a material containing an amorphous soft magnetic alloy, is generally manufactured by a method of heating and pressurizing using a mold (see, for example, Patent Document 1).

JP-A-2002-280224

However, in the method of heating and pressurizing using a mold, the amorphous soft magnetic alloy used as a raw material is easily crystallized, and sufficient characteristics may not be obtained in the manufactured molded product. Further, it is difficult to manufacture a small molded body by the method of heating and pressurizing using a mold, and it meets the demand for miniaturization, more specifically, for example, miniaturization and mobileization of communication equipment. It has been difficult to meet the demand for further miniaturization of the molded product.

On the other hand, in recent years, after dividing the model data of a three-dimensional object into a large number of two-dimensional cross-section layer data, the cross-section members corresponding to each two-dimensional cross-section layer data are sequentially modeled, and the cross-section members are sequentially laminated to form three-dimensional. The three-dimensional modeling method, which is a laminating method for forming a modeled object, is attracting attention. Such a three-dimensional molding method has an advantage that even a minute molded body or a molded body having a fine shape, which was difficult to manufacture with a conventional mold, can be suitably manufactured.

In the production of such a three-dimensional model, a composition containing a powder which is an aggregate of a plurality of particles and a solvent may be used, and the particles may be bonded by laser light. However, when a composition containing an amorphous soft magnetic alloy powder is used in such a three-dimensional modeling method, the crystallization of the amorphous soft magnetic alloy could not be sufficiently suppressed.

The present invention has been made to solve the above-mentioned problems, and can be realized as the following application examples.

The powder for producing a three-dimensional model according to an application example of the present invention forms a layer by irradiating a plurality of particles with laser light and joining them, and stacks the layers to produce a three-dimensional model. It is a powder for manufacturing three-dimensional shaped objects used.
The particles have a mother particle made of a material containing an amorphous soft magnetic alloy and a coating film that covers at least a part of the surface of the mother particle.
The coating film contains a low melting point glass having a melting point lower than the melting point of the amorphous soft magnetic alloy, and a laser light absorber having a higher absorption rate of the laser light than the amorphous soft magnetic alloy.

It is sectional drawing which shows typically the preferable embodiment of the powder for manufacturing a three-dimensional model. FIG. 5 is a cross-sectional view schematically showing a state in which particles constituting the three-dimensional model manufacturing powder are joined by irradiating the three-dimensional model manufacturing powder shown in FIG. 1 with a laser beam. It is sectional drawing which shows typically the state when the scraper of the apparatus used for manufacturing the powder for manufacturing a three-dimensional model is located at the lowermost part. It is sectional drawing which shows typically the state when the pressing member of the apparatus used for manufacturing the powder for manufacturing a three-dimensional model is located at the lowermost part. It is a vertical cross-sectional view which shows typically the layer formation process which is a process in a preferable embodiment of the manufacturing method of a three-dimensional modeled object. It is a vertical cross-sectional view which shows typically the solvent removal step which is the step in the preferable embodiment of the manufacturing method of a three-dimensional model. It is a vertical cross-sectional view which shows typically the joining process which is the process in a preferable embodiment of the manufacturing method of a three-dimensional model. It is a vertical cross-sectional view which shows typically the layer formation process which is a process in a preferable embodiment of the manufacturing method of a three-dimensional modeled object. It is a vertical cross-sectional view which shows typically the solvent removal step which is the step in the preferable embodiment of the manufacturing method of a three-dimensional model. It is a vertical cross-sectional view which shows typically the joining process which is the process in a preferable embodiment of the manufacturing method of a three-dimensional model. It is a vertical cross-sectional view which shows typically the process in a preferable embodiment of the manufacturing method of a three-dimensional model, in particular, the state after performing a layer formation process a plurality of times. It is a vertical cross-sectional view which shows typically the three-dimensional model obtained by the preferable embodiment of the manufacturing method of a three-dimensional model. It is a flowchart which shows the preferable embodiment of the manufacturing method of a three-dimensional model. It is a vertical sectional view schematically showing a preferable embodiment of a three-dimensional model manufacturing apparatus.

Hereinafter, preferred embodiments will be described in detail with reference to the accompanying drawings.
[1] Powder for Manufacturing a Three-Dimensional Model First, the powder for manufacturing a three-dimensional model of the present invention will be described.

FIG. 1 is a cross-sectional view schematically showing a preferred embodiment of a powder for producing a three-dimensional model, and FIG. 2 is a three-dimensional model obtained by irradiating the powder for producing a three-dimensional model shown in FIG. 1 with laser light. It is sectional drawing which shows typically the state which the particles which make up the powder for manufacturing thing are joined.

The powder 2'for producing a three-dimensional modeled object contains a plurality of particles 21', and is used for producing the three-dimensional modeled object 10 by laminating a plurality of layers 1. The powder 2'for producing a three-dimensional model is bonded by irradiation with a laser beam L in the production of the three-dimensional model 10. In other words, the powder 2'for producing a three-dimensional modeled object forms a layer 1 by irradiating a plurality of particles 21'with a laser beam L and joining them, and the layers 1 are laminated to form a three-dimensional modeled object 10. It is used for manufacturing. The particles 21'have a mother particle 211' made of a material containing an amorphous soft magnetic alloy and a coating film 212'that covers at least a part of the surface of the mother particle 211'. The coating film 212'is a low melting point glass 2121 having a melting point lower than the melting point of the amorphous soft magnetic alloy which is a constituent material of the mother particles 211', and the absorption rate of the laser beam L more than the amorphous soft magnetic alloy. It contains a high laser light absorber 2122.

As a result, the benefits of the three-dimensional modeling method for manufacturing the three-dimensional model 10 by laminating a plurality of layers 1, for example, a small member and fine particles that are difficult to manufacture by a conventional method using a mold. Manufacture of a three-dimensional model 10 made of an amorphous soft magnetic alloy in which crystallization is preferably prevented while enjoying benefits such as being able to suitably manufacture a member having a simple structure and a complicated structure. It is possible to provide a powder 2'for producing a three-dimensional modeled product, which can be suitably used for the above.

It is considered that such an excellent effect can be obtained for the following reasons. That is, the surface of the mother particles 211'composed of the material containing the amorphous soft magnetic alloy is coated with the low melting point glass 2121 and the coating film 212'containing the laser light absorber 2122, so that the laser light L is generated. Upon irradiation, the energy of the laser beam L is selectively absorbed by the coating 212'containing the laser light absorber 2122. The laser light L absorbed by the coating film 212'is converted into heat energy and heats the coating film 212'. Here, the coating film 212'contains low melting point glass 2121 having a melting point lower than the melting point of the amorphous soft magnetic alloy constituting the mother particles 211'. Therefore, as shown in FIG. 2, the coating film 212'softens and melts in a state where the softening and melting of the amorphous soft magnetic alloy constituting the mother particles 211'do not proceed. In other words, the coating film 212'can be selectively softened and melted while preventing the mother particles 211' from being softened and melted. The amorphous soft magnetic alloy generally does not crystallize even after being heated at such a temperature. Therefore, in the production of the three-dimensional modeled object 10 by the three-dimensional modeling method, when the particles 21'are bonded, the particles 21'can be suitably bonded to each other while preventing the crystallization of the amorphous soft magnetic alloy. Therefore, it is considered that the three-dimensional model 10 can be suitably manufactured.

[1-1] Mother particle Mother particle 211'is composed of a material containing an amorphous soft magnetic alloy.

The composition of the amorphous soft magnetic alloy constituting the mother particle 211'is not particularly limited as long as it is amorphous and exhibits soft magnetism. For example, Fe-B type, Fe-Si-B type, and the like. Fe-based amorphous alloys such as Fe-Si-B-C system, Fe-Si-BP system, Fe-Si-B-C-P system, Fe-P-B system, Fe-Ni group amorphous Examples thereof include quality alloys and Co-based amorphous alloys.

In particular, the amorphous soft magnetic alloy constituting the mother particles 211'preferably an alloy containing at least one selected from the group consisting of Fe, Si, Cr, B, C and Ni.

As a result, the properties generally required for amorphous soft magnetic alloys, such as corrosion resistance, abrasion resistance, strength, and magnetic permeability, can be made more excellent, and for example, electrical and electronic devices are provided. More preferably, it can be more preferably applied to the manufacture of magnetic materials, more specifically transformers, inductors, motors, generators, relays and the like. Further, such an amorphous soft magnetic alloy is generally a material in which crystallization is particularly unlikely to occur even when the low melting point glass 2121 is heated at a temperature at which it softens and melts, which will be described in detail later. is there. Further, such an amorphous soft magnetic alloy generally has a particularly low absorption rate of laser light L containing a wavelength component absorbed by the laser light absorber 2122, which will be described in detail later. Therefore, it is possible to more effectively prevent the temperature of the mother particles 211'when irradiated with the laser beam L from unintentionally rising. From the above, when the mother particle 211'is composed of the above-mentioned amorphous soft magnetic alloy, the effect of the present invention is more remarkably exhibited.

The melting point of the amorphous soft magnetic alloy constituting the mother particle 211'is preferably 620 ° C. or higher, more preferably 650 ° C. or higher, and even more preferably 700 ° C. or higher.

As a result, when the particles 21'are heated to a temperature at which the low melting point glass 2121 is softened and melted by irradiation with the laser beam L, the mother particles 211'can be softened and the mother particles 211' can be softened. Crystallization of the constituent amorphous soft magnetic alloy can be prevented more effectively.

The recrystallization temperature of the amorphous soft magnetic alloy constituting the mother particle 211'is preferably 500 ° C. or higher, more preferably 550 ° C. or higher, and even more preferably 600 ° C. or higher.

As a result, the amorphous soft magnetic alloy constituting the mother particles 211'when the particles 21'are heated to a temperature at which the low melting point glass 2121 softens and melts as described in detail later by irradiation with the laser beam L. Crystallization can be prevented more effectively.

In the present specification, the recrystallization temperature refers to the temperature at which the amorphous soft magnetic alloy bulk body is heated and then cooled at a constant rate, for example, a differential. It can be determined by scanning calorimetry (DSC) and measuring the energy input difference between the sample and the reference material as a temperature function while varying the temperature of the material according to a regulated temperature control program. Further, DSC404 manufactured by NETZSCH Co., Ltd. can be used for the measurement.

The average particle size of the mother particles 211'is preferably 20 μm or more and 100 μm or less, more preferably 25 μm or more and 90 μm or less, and further preferably 30 μm or more and 80 μm or less.

As a result, the fluidity and ease of handling of the three-dimensional model manufacturing composition 1'including the three-dimensional model manufacturing powder 2'and the three-dimensional model manufacturing powder 2'are improved. be able to. Further, when the laser beam L is irradiated, the coating film 212'can be softened and melted more efficiently, and the amorphous soft magnetic alloy constituting the mother particles 211'is unwillingly crystallized. The bonding of the particles 21'can proceed more efficiently while effectively preventing them. Therefore, the productivity of the three-dimensional model 10 can be made more excellent, and it is also preferable from the viewpoint of energy saving.

In the present specification, the average particle size means a volume-based average particle size. For example, a dispersion liquid obtained by adding a sample to methanol and dispersing it with an ultrasonic disperser for 3 minutes is a Coulter counter particle size distribution measuring device. It can be obtained by measuring with (TA-II type manufactured by COULTER ELECTRONICS INS) using an aperture of 50 μm.

The proportion of the mother particles 211'in the particles 21'is preferably 50% by volume or more and 99% by volume or less, more preferably 55% by volume or more and 98% by volume or less, and 60% by volume or more and 97% by volume or less. The following is more preferable.

As a result, the bonding strength between the particles 21'after irradiation with the laser beam L can be made more excellent, and the mechanical strength, reliability, etc. of the three-dimensional model 10 can be made more excellent. At the same time, the content of the amorphous soft magnetic alloy in the three-dimensional model 10 can be increased more effectively. Further, it is possible to prevent the temperature of the mother particles 211'due to heat conduction from unintentionally rising when the laser beam L is irradiated.

[1-2] The coating particle 21'has a coating 212'that covers at least a part of the surface of the mother particle 211'.

The coating film 212'is a low melting point glass 2121 having a melting point lower than the melting point of the amorphous soft magnetic alloy which is a constituent material of the mother particle 211', and the amorphous soft magnetic which is a constituent material of the mother particle 211'. It contains the laser light absorber 2122, which has a higher absorption rate of the laser light than the alloy.

The average thickness of the coating film 212'is preferably 1 μm or more and 5.0 μm or less, more preferably 1.2 μm or more and 4.5 μm or less, and further preferably 1.5 μm or more and 4.0 μm or less. ..

As a result, the bonding strength between the particles 21'after irradiation with the laser beam L can be made more excellent, and the mechanical strength, reliability, etc. of the three-dimensional model 10 can be made more excellent. At the same time, the content of the amorphous soft magnetic alloy in the three-dimensional model 10 can be increased more effectively. Further, it is possible to prevent the temperature of the mother particles 211'due to heat conduction from unintentionally rising when the laser beam L is irradiated.

In the illustrated configuration, the coating film 212'of uniform thickness is provided on the entire surface of the mother particle 211', but the coating film 212'may have portions having different thicknesses. It may cover only a part of the mother particle 211'. When the coating film 212'covers only a part of the mother particle 211', the average value of the thickness of the coating film 212'at the portion covering the mother particle 211' is adopted as the average thickness of the coating film 212'. can do.

The coverage of the coating 212'with respect to the total surface area of the mother particles 211'is preferably 30% or more, more preferably 50% or more, and even more preferably 80% or more.

As a result, when the laser light L is irradiated, the selective absorption of the energy of the laser light L by the coating film 212'can proceed more preferably, and the effect according to the present invention can be more remarkably exhibited.

The proportion of the coating film 212'in the particles 21'is preferably 1% by volume or more and 50% by volume or less, more preferably 2% by volume or more and 45% by volume or less, and 3% by volume or more and 40% by volume. It is more preferably% or less.

As a result, the bonding strength between the particles 21'after irradiation with the laser beam L can be made more excellent, and the mechanical strength, reliability, etc. of the three-dimensional model 10 can be made more excellent. At the same time, the content of the amorphous soft magnetic alloy in the three-dimensional model 10 can be increased more effectively. Further, it is possible to prevent the temperature of the mother particles 211'due to heat conduction from unintentionally rising when the laser beam L is irradiated.

[1-2-1] The low melting point glass 2121 constituting the low melting point glass coating 212'may have a melting point lower than the melting point of the amorphous soft magnetic alloy constituting the mother particles 211'.

The melting point of the low melting point glass 2121 is preferably 220 ° C. or higher and 500 ° C. or lower, more preferably 25 ° C. or higher and 480 ° C. or lower, and further preferably 280 ° C. or higher and 470 ° C. or lower.

As a result, when the laser beam L is irradiated, the coating film 212'can be softened and melted more efficiently, and the amorphous soft magnetic alloy constituting the mother particles 211' is unwillingly crystallized. The bonding of the particles 21'can proceed more efficiently while preventing more effectively. Therefore, the productivity of the three-dimensional model 10 can be made more excellent, and it is also preferable from the viewpoint of energy saving.

The low melting glass 2121, for example, lead glass, salt phosphate glass, telluride glass, vanadate glass, fluoride glass, chalcogenide glass, and the like, SiO ₂ based glass, P ₂ O ₅ system glass, ZnO-BaO-based glass or, _preferably a _ZnO-B 2 O 3 -SiO ₂ based glass.

As a result, the melting point of the low melting point glass 2121 can be made sufficiently low as described above, and the above-mentioned effect is more prominently exhibited. Further, the bonding strength between the particles 21'when irradiated with the laser beam L can be made more excellent, and the mechanical strength, reliability, etc. of the manufactured three-dimensional model 10 can be made more excellent. can do.

The content of the low melting point glass 2121 in the coating film 212'is preferably 50.0% by mass or more and 99.9% by mass or less, and more preferably 60.0% by mass or more and 99.5% by mass or less. , 65.0% by mass or more and 99.0% by mass or less is more preferable.

As a result, when the laser light L is irradiated, the absorption rate of the energy of the laser light L by the laser light absorber 2122 is made higher, and the ease of softening / melting of the coating film 212'is made better. , The bonding strength between the particles 21'can be made more excellent.

[1-2-2] Laser light absorber The laser light absorber 2122 constituting the coating film 212'may have a higher absorption rate of laser light L than the amorphous soft magnetic alloy constituting the mother particles 211'. Just do it.

The laser light absorber 2122 may be one or more selected from the group consisting of various dye compounds such as phthalocyanine compounds and cyanine compounds and diotyl metal complexes, although it depends on the wavelength of the laser light L and the like. Can be used in combination.

Among them, a dye compound is preferable as the laser light absorber 2122.
Thereby, the laser light L having a wavelength in the visible light region can be preferably used for joining the particles 21'together.

In particular, as the laser light absorber 2122, a phthalocyanine compound is preferable among various dye compounds.

When the laser light absorber 2122 is a phthalocyanine compound, the selectivity of absorption of the laser light L by the laser light absorber 2122, that is, the laser light by the laser light absorber 2122 with respect to the absorption ratio of the laser light L by the mother particle 211'. The ratio of the absorption ratio of L can be made higher, and the effect according to the present invention can be made more excellent. In addition, the chemical stability and thermal stability of the laser light absorber 2122 can be made more excellent.
Examples of the phthalocyanine compound include phthalocyanine copper and the like.

The laser light absorber 2122 may be contained in the coating 212'in any form. For example, in the coating film 212', the laser light absorber 2122 may be contained in a state of being dissolved in the low melting point glass 2121 or may be contained in a state of being dispersed in the low melting point glass 2121.

Further, the laser light absorber 2122 may be uniformly contained in the coating film 212'or may be unevenly distributed at a predetermined portion in the coating film 212', but as shown in FIG. 1, the coating film 212 may be unevenly distributed. It is preferable that the area on the outer surface side of'is unevenly distributed.

As a result, when the laser beam L is irradiated, the vicinity of the outer surface of the coating film 212', which is a particularly important region for joining the particles 21', can be softened and melted more effectively. In addition, the region near the outer surface of the coating 212'can be heated with higher selectivity, and the region near the inner surface of the coating 212', that is, the mother, is reached by the time the particles 21' are bonded to each other. It is possible to more effectively suppress the temperature rise of the region on the particle 211'side and the mother particle 211'. Therefore, the productivity, mechanical strength, and reliability of the three-dimensional model 10 can be made more excellent, and it is also preferable from the viewpoint of energy saving. Further, even when the content of the laser light absorber 2122 in the coating film 212'is lowered, the energy of the laser light L can be efficiently absorbed. Therefore, for example, the low melting point glass 2121 in the coating film 212' , The content of the low melting point glass 2121 in the particles 21', and the content of the amorphous soft magnetic alloy can be increased, and the functions of these components can be more effectively exhibited. Further, the powder 2'for producing a three-dimensional model can be preferably produced by a method as described in detail later.

The content of the laser light absorber 2122 in the coating film 212'is preferably 0.1% by mass or more and 50.0% by mass or less, and more preferably 0.5% by mass or more and 40.0% by mass or less. It is preferably 1.0% by mass or more and 35.0% by mass or less.

As a result, when the laser light L is irradiated, the absorption rate of the energy of the laser light L by the laser light absorber 2122 is made higher, and the ease of softening / melting of the coating film 212'is made better. , The bonding strength between the particles 21'can be made more excellent.

[1-2-3] Other Components The coating film 212'may contain at least components other than the low melting point glass 2121 and the laser light absorber 2122 described above.

When the coating film 212'contains other components, the content of the other components in the coating film 212'is preferably 5% by mass or less, more preferably 3% by mass or less, and 1% by mass or less. Is more preferable. When a plurality of components are included as other components, the sum of the contents of the plurality of components shall be adopted as the content rate.

The shape of the particle 21'is not particularly limited, and may be any shape such as spherical, spindle-shaped, needle-shaped, tubular, scaly-shaped, or irregular, but spherical. Is preferable.

The powder 2'for producing a three-dimensional model may contain particles having different conditions as a plurality of particles 21'. For example, particles 21'with different sizes, particles 21'with different compositions, particles 21'with different thicknesses of the coating 212', particles 21'with different sizes of the mother particles 211', and laser light absorbers. It may contain different particles 21'etc.

The average particle size of the particles 21'is preferably 21 μm or more and 105 μm or less, more preferably 26.2 μm or more and 94.5 μm or less, and further preferably 31.5 μm or more and 84 μm or less.

As a result, the fluidity and ease of handling of the three-dimensional model manufacturing composition 1'including the three-dimensional model manufacturing powder 2'and the three-dimensional model manufacturing powder 2'are improved. be able to. Further, for example, during the production of the three-dimensional model 10, the solvent, binder, and the like contained in the layer 1 can be efficiently removed, and the constituent materials other than the particles 21'are unwillingly used as the final three-dimensional model. It is possible to more effectively prevent it from remaining in 10. Therefore, it is possible to further improve the productivity, mechanical strength, reliability, and the like of the manufactured three-dimensional model 10 while further improving the productivity of the three-dimensional model 10.

The powder 2'for producing a three-dimensional model may contain components other than the above-mentioned particles 21'. Such components include, for example, particles composed of an amorphous soft magnetic alloy, which does not have at least one of a low melting point glass and a laser light absorber attached, and an amorphous soft magnetic alloy. Examples thereof include low melting point glass contained in a form in which the particles are not coated, and a laser light absorber contained in a form in which particles composed of an amorphous soft magnetic alloy are not coated. Further, for example, at least a part of the amorphous soft magnetic alloy may contain crystallized particles.

However, the content of the components other than the above-mentioned particles 21'in the three-dimensional model manufacturing powder 2'is preferably 10% by mass or less, more preferably 5% by mass or less, and 3% by mass. The following is more preferable.

[2] Method for Producing Powder for Manufacturing a Three-Dimensional Model Next, a method for producing a powder for producing a three-dimensional model of the present invention will be described.

FIG. 3 is a vertical cross-sectional view schematically showing an apparatus used for manufacturing powder for manufacturing a three-dimensional model, FIG. 3A is a state when the scraper is located at the lowermost position, and FIG. 3B is a pressing member at the lowest position. It shows the state when it is located at the bottom.

The three-dimensional model manufacturing powder 2'can be produced, for example, by using the device shown in FIG. 3, that is, the three-dimensional model manufacturing powder manufacturing device P100.

The powder manufacturing apparatus P100 for manufacturing a three-dimensional model has a cylindrical and sealable container P10, a rotating shaft P20 inserted into the container P10, a boss P11 fixed to the rotating shaft P20, and fixed to the boss P11. It has a first arm P12 and a second arm P16.

The first arm P12 projects in the radial direction of the container P10, and the second arm P16 projects in the radial direction opposite to the first arm P12.

A hog-backed pressing member P14 extending in the axial direction of the container P10 is provided at the tip of the first arm P12.

The pressing member P14 is a raw material for powder 2'for producing a three-dimensional model, for example, amorphous soft magnetic alloy particles corresponding to mother particles 211', glass particles composed of low melting point glass 2121, and a laser light absorber. It is installed so that a gap portion having a predetermined width is provided between the tip surface of the pressing member P14 and the inner surface of the container P10 so that the 2122 and the like can be efficiently pressed and compressed.

A scraper P18, which is a long plate material in the axial direction of the container P10, is provided at the tip of the second arm P16.

The scraper P18 can efficiently scrape the raw material of the three-dimensional model manufacturing powder 2', the intermediate product of the three-dimensional model manufacturing powder 2', and the three-dimensional model manufacturing powder 2'. , It is arranged so as to come into contact with the inner surface of the container P10.

At the time of producing the powder 2'for producing a three-dimensional model, for example, the inside of the container P10 is configured to have a vacuum or an inert gas atmosphere.

The rotation shaft P20 is connected to a rotation drive device (not shown), and the first arm P12 and the second arm P16 are configured to rotate together with the rotation shaft P20.

Using the powder manufacturing apparatus P100 for manufacturing a three-dimensional model as described above, the powder 2'for manufacturing a three-dimensional model can be manufactured, for example, as follows.

First, the raw material of the powder 2'for producing a three-dimensional model, for example, the amorphous soft magnetic alloy particles corresponding to the mother particles 211' and the glass particles composed of the low melting point glass 2121 are put into the container P10. To do.

In this state, the rotation shaft P20 is rotated by a rotation drive device (not shown). As the rotation shaft P20 rotates, the first arm P12 and the second arm P16 rotate. Here, the charged raw material is pressed against the inner peripheral surface of the container P10 and undergoes a strong compressive frictional action, and the raw material and the intermediate product of the powder 2'for producing a three-dimensional model obtained from the raw material are scraped. It is scraped and stirred by P18.

By repeating these actions, surface fusion occurs between the amorphous soft magnetic alloy particles and the glass particles, and the glass particles are welded to each other, resulting in amorphous soft magnetism corresponding to the mother particles 211'. Composite particles in which the surface of the alloy particles is coated with low melting point glass 2121 can be obtained.

Then, in a state where the composite particles and the laser light absorber 2122 are contained in the container P10, the laser light is applied to the surface of the composite particles by operating the powder manufacturing apparatus P100 for manufacturing a three-dimensional model in the same manner as described above. The absorbent 2122 adheres. As a result, a three-dimensional model manufacturing powder 2'containing a plurality of particles 21' having the above-mentioned constitution can be obtained.

[3] Composition for Manufacturing a Three-Dimensional Model Next, the composition for manufacturing a three-dimensional model of the present invention will be described.

The three-dimensional model manufacturing composition 1'is used to form the layer 1 of the three-dimensional model 10 formed by laminating a plurality of layers 1 by a discharge method. The three-dimensional model manufacturing composition 1'contains the above-mentioned three-dimensional model manufacturing powder 2', a binder, and a solvent.

As a result, the benefits of the three-dimensional modeling method for manufacturing the three-dimensional model 10 by laminating a plurality of layers 1, for example, a small member and fine particles that are difficult to manufacture by a conventional method using a mold. Manufacture of a three-dimensional model 10 made of an amorphous soft magnetic alloy in which crystallization is preferably prevented while enjoying benefits such as being able to suitably manufacture a member having a simple structure and a complicated structure. It is possible to provide a composition for producing a three-dimensional modeled product 1'that can be suitably used for the above.

In the present invention, the solvent is a liquid capable of dispersing the particles, that is, a dispersion medium. The solvent is preferably a volatile liquid, that is, a substance that has a predetermined boiling point by itself and does not substantially decompose at the boiling point.

[3-1] Powder for manufacturing a three-dimensional model The content of powder 2'for manufacturing a three-dimensional model in the composition 1'for manufacturing a three-dimensional model is 30% by volume or more and 50% by volume or less. It is more preferably 33% by volume or more and 47% by volume or less, and further preferably 35% by volume or more and 45% by volume or less.

As a result, the composition 1'for producing a three-dimensional model can be more stably discharged over a long period of time. Further, since it is possible to prevent the content of the component to be removed from becoming unnecessarily high in the manufacturing process of the three-dimensional modeled product 10, the time and energy required for removing the component can be saved, and the tertiary can be obtained. It is advantageous from the viewpoints of improving the productivity of the original modeled object 10, reducing the production cost of the three-dimensional modeled object 10, saving energy, and the like.

[3-2] Binder The binder has a function of temporarily binding the particles 21'to each other in a state where the solvent is removed.

By including the binder in the three-dimensional model manufacturing composition 1', for example, the shape stability of the layer 1 formed by using the three-dimensional model manufacturing composition 1'can be improved. It is possible to effectively prevent unintentional deformation of the layer 1.

Further, it is possible to effectively prevent the particles 21'and their melts from being unintentionally scattered when the laser beam L is irradiated in the joining step described later. As a result, it is possible to effectively prevent the occurrence of undesired irregularities on the surface of the layer 1 on which the joint region 7 described later is formed.
From the above, the dimensional accuracy of the three-dimensional model 10 can be improved.

The binder may have a function of temporarily fixing the particles 21'in the composition 1'for producing a three-dimensional model before being subjected to the joining step, and is, for example, a thermoplastic resin, a curable resin, or the like. Various resin materials and the like can be used.

When the curable resin is contained, the curable resin may be cured at a timing after the discharge of the three-dimensional model manufacturing composition 1'and before the joining step described later.

Specific examples of the binder include cyclic cellulose derivatives such as acrylic resin, epoxy resin, silicone resin, polyvinyl alcohol, polylactic acid, polyamide, polyphenylene sulfide, alginate, pectin, methyl cellulose, nanocellulose, and cyclodextrin. And one or a combination of two or more selected from these can be used.

The content of the binder in the composition 1'for producing a three-dimensional model is preferably 1.5% by volume or more and 10% by volume or less, and preferably 1.6% by volume or more and 5.0% by volume or less. More preferably, it is 1.7% by volume or more and 4.0% by volume or less.

As a result, the function of the binder as described above is more effectively exhibited, and the binder and its decomposition products and modified products are more effectively prevented from remaining in the final three-dimensional model 10. Can be done.

[3-3] Solvent The composition 1'for producing a three-dimensional model contains a solvent having a function of dispersing the particles 21'.

Thereby, for example, the composition 1'for producing a three-dimensional modeled object can be stably discharged by a dispenser or the like.

Examples of the solvent constituting the composition 1'for producing a three-dimensional model include water, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, propylene glycol monoethyl ether, diethyl diglycol, and diethylene glycol monobutyl ether. Ethers such as acetate and diethylene glycol monoethyl ether; Acetate esters such as ethyl acetate, n-propyl acetate, iso-propyl acetate, n-butyl acetate and iso-butyl acetate; Carbitols such as carbitol and its ester compounds Cerosolobs such as cellosolves and ester compounds thereof; aromatic hydrocarbons such as benzene, toluene and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone and acetyl acetone; ethanol and propanol , Butanol, 2-ethyl-1-hexanol and other monohydric alcohols, and alcohols such as ethylene glycol, propylene glycol, butanediol, glycerin and other polyhydric alcohols; dimethylsulfoxide, diethylsulfoxide and other sulfoxide solvents; Examples thereof include volatile liquids such as pyridine solvents such as picolin and 2,6-rutidine, ionic liquids such as tetraalkylammonium acetate such as tetrabutylammonium acetate, and one or a combination of two or more selected from these. Can be used.

Above all, the solvent preferably contains water.
As a result, the solvent can be easily removed from the layer 1 during the production of the three-dimensional model 10 as compared with the case where a solvent containing no water, particularly an organic solvent having a relatively high boiling point, is used. It is advantageous in increasing the productivity of the three-dimensional model 10. Further, it is possible to more effectively prevent abrupt volatilization of the solvent in the joining step described in detail later, for example, unintentional deformation due to sudden boiling, etc., and further improve the dimensional accuracy of the three-dimensional modeled object 10. be able to.

The ratio of water to the total solvent constituting the composition for producing a three-dimensional model 1'is preferably 50% by mass or more, more preferably 80% by mass or more, and 90% by mass or more. Is even more preferable.
As a result, the above-mentioned effect is more prominently exhibited.

The content of the solvent in the composition 1'for producing a three-dimensional model is preferably 43% by volume or more and 68% by volume or less, more preferably 50% by volume or more and 65% by volume or less, and 51% by volume. It is more preferably 63% by volume or less.

Thereby, for example, the composition 1'for producing a three-dimensional modeled object can be discharged more stably for a longer period of time.

[3-4] Other Components The composition 1'for producing a three-dimensional model may contain components other than those described above. Such components include, for example, polymerization initiators; dispersants; surfactants; thickeners; anti-aggregation agents; defoamers; leveling agents; dyes; polymerization inhibitors; polymerization accelerators; penetration promoters; moisturizers. Agents; fixers; fungicides; preservatives; antioxidants; UV absorbers; chelating agents; pH adjusters and the like.

However, the sum of the contents of these components in the composition for producing a three-dimensional model is preferably 5% by mass or less, and more preferably 3% by mass or less.

The composition 1'for producing a three-dimensional model is preferably discharged by a dispenser when forming the layer 1.

As a result, the composition 1'for producing a three-dimensional model can be discharged more stably, and unintentional variation in the thickness of the formed layer 1 can be suppressed more effectively.

[4] Method for Producing a Three-Dimensional Model Next, a method for producing a three-dimensional model using the above-mentioned composition for producing a three-dimensional model of the present invention will be described.

4 to 10 are vertical cross-sectional views schematically showing a process in a preferred embodiment of a method for manufacturing a three-dimensional model. FIG. 11 is a vertical cross-sectional view schematically showing a three-dimensional model obtained by a preferred embodiment of a method for manufacturing a three-dimensional model. FIG. 12 is a flowchart showing a preferred embodiment of a method for manufacturing a three-dimensional model. In the following description, a case where an inductor is manufactured as a three-dimensional model will be typically described.

The method for producing the three-dimensional model 10 of the present invention includes a layer forming step of forming the layer 1 using the three-dimensional model manufacturing composition 1'as described above, and a laser beam L on the layer 1 in a predetermined pattern. A series of steps including a joining step of joining the particles 21'by irradiating the particles 21'is repeated a plurality of times to manufacture the three-dimensional modeled product 10.

As a result, for example, while enjoying the benefits that it is difficult to manufacture by the conventional method using a mold, it is possible to suitably manufacture a member having a small member, a fine structure, and a complicated structure. It is possible to provide a method for producing a three-dimensional model 10 capable of preferably producing a three-dimensional model 10 made of an amorphous soft magnetic alloy in which crystallization is preferably prevented.

In particular, as shown in FIGS. 4 and 7, the method for manufacturing the three-dimensional model 10 of the present embodiment includes the above-mentioned three-dimensional model manufacturing composition 1'and other three-dimensional model manufacturing compositions 9. A layer forming step of forming the layer 1 using ′, a solvent removing step of removing the solvent contained in the layer 1 as shown in FIGS. 5 and 8, and a layer as shown in FIGS. 6 and 9. 1 is irradiated with laser light L to form a bonding region 7 and a bonding region 9 in the layer 1. Then, as shown in FIG. 10, a series of steps including a layer forming step, a solvent removing step, and a joining step are repeated.

As a result, while obtaining the above-mentioned effects, it is possible to more effectively prevent unfavorable components from remaining in the finally obtained three-dimensional model 10, and the mechanical strength and dimensions of the three-dimensional model 10. The accuracy, reliability, etc. can be improved. In addition, the productivity of the three-dimensional model 10 as a whole can be made more excellent.

Hereinafter, each step will be described in detail.
[4-1] Layer forming step

In the first layer forming step, for example, the composition 1'for producing a three-dimensional model is supplied from the composition supplying means M3 on the plane M410 of the stage M41 to form the layer 1.

The layer forming step may be performed by any method as long as the composition 1'for producing a three-dimensional model can be supplied to the target site, but the layer forming step may be performed by the composition supply means M3 having a nozzle for three-dimensional modeling. It is preferably carried out by discharging the composition for producing a product 1'.

Thereby, a three-dimensional model 10 having a fine structure, a three-dimensional model 10 having a portion formed by using different compositions in the same layer 1, and the like can be more preferably produced.

The method of discharging the composition 1'for producing a three-dimensional model is not particularly limited, but it is preferably discharged by a dispenser.

As described above, by using the dispenser, the composition 1'for producing a three-dimensional model as described above can be discharged more stably, and a good layer 1 can be formed. Further, as compared with the case of using a method other than the dispenser, it is possible to effectively suppress the undesired variation in the thickness of the layer 1, and it is also possible to improve the dimensional accuracy of the three-dimensional model 10 to be manufactured. It is advantageous. In addition, the layer 1 having a relatively large thickness can be easily formed, which is advantageous in further improving the productivity of the three-dimensional modeled object 10.

In this step, the composition 1'for producing a three-dimensional model may be ejected in a continuous form or as a plurality of droplets, but in the illustrated configuration, it is ejected as a plurality of droplets. It shows the case to do.

In the production of the three-dimensional modeled object 10, a plurality of types of compositions may be used as the composition for producing the three-dimensional modeled object 1'.

Further, in the illustrated configuration, in the second and subsequent layer forming steps, the composition 1'for producing a three-dimensional model is discharged from the composition supply means M3, and another three-dimensional structure is discharged from the other composition supply means M3'. The composition 9'for manufacturing a modeled object is discharged.

As a result, the three-dimensional modeling has a bonding region 7 composed of the constituent materials of the three-dimensional model manufacturing composition 1'and a bonding region 9 composed of a material other than the three-dimensional model manufacturing composition 1'. The object 10, especially in the present embodiment, can suitably manufacture the joint region 9 as a winding portion made of a conductive material.

The other three-dimensional model manufacturing composition 9'may be any composition, and is appropriately selected depending on the three-dimensional model 10 to be manufactured.

When an inductor is manufactured as a three-dimensional model 10 as in the present embodiment, a composition containing conductive particles made of a conductive material is preferably used as a constituent material of a conductive winding portion. be able to.

Examples of the conductive material constituting the conductive particles include magnesium, iron, gold, silver, copper, cobalt, titanium, chromium, nickel, aluminum, and alloys containing at least one of these. Examples of the alloy include maraging steel, stainless steel, cobalt-chromium molybdenum, titanium alloy, nickel-based alloy, aluminum alloy and the like. Of these, copper and copper alloys having a relatively low melting point and excellent conductivity are preferably used.

The other three-dimensional model manufacturing composition 9'preferably contains conductive particles instead of the above-mentioned particles 21', but other components are used for the above-mentioned three-dimensional model manufacturing. It is preferable to contain the same components as described as the components of the composition 1'.

[4-2] Solvent removal step In the solvent removal step, the solvent contained in the layer 1 is removed.

As a result, the fluidity of the layer 1 is reduced, and the stability of the shape of the layer 1 is improved. Further, by performing this step, it is possible to effectively prevent sudden volatilization of the solvent in the subsequent joining step, for example, unintentional deformation due to sudden boiling or the like. From the above, it is possible to more reliably obtain the three-dimensional model 10 having excellent dimensional accuracy, further improve the reliability of the three-dimensional model 10, and produce the three-dimensional model 10. The sex can be further improved.

The solvent may be removed by natural drying, but in the illustrated configuration, the solvent removing means M9 is used. As a result, the productivity of the three-dimensional model 10 can be made more excellent.

Specific methods for removing the solvent by the solvent removing means M9 include, for example, heating the layer 1, irradiating the layer 1 with infrared rays, placing the layer 1 under reduced pressure, and liquid components such as dry air. For example, supplying a gas having a low content rate. Further, two or more kinds selected from these may be combined. When a method of supplying a gas having a low content of liquid components is adopted, a gas having a relative humidity of 30% or less can be preferably used as the gas.

In addition, this step may be performed simultaneously with the above-mentioned layer forming step, for example. More specifically, for example, a process of removing the solvent from the discharged three-dimensional model manufacturing composition 1'before the layer 1 is completed by discharging the three-dimensional model manufacturing composition 1'. May be given.

Further, in this step, it is not necessary to completely remove the solvent contained in the layer 1.
The content of the solvent in the layer 1 after this step is preferably 0.1% by mass or more and 25% by mass or less, and more preferably 0.5% by mass or more and 20% by mass or less.

As a result, it is possible to effectively prevent sudden volatilization of the solvent in a later step, for example, unintentional deformation due to sudden boiling, etc., and to reliably obtain a three-dimensional model 10 having excellent dimensional accuracy. The reliability of the three-dimensional model 10 can be further improved, and the productivity of the three-dimensional model 10 can be further improved.

[4-3] Joining step In the joining step, the layer 1 is irradiated with laser light L by the laser light irradiating means M6 to heat at least the surface of the film 212'of the particles 21'contained in the layer 1 and the conductive particles. Melt. More specifically, in each layer 1, the portion to be the actual part of the three-dimensional model 10 is selectively irradiated with the laser beam L.

As a result, the particles 21'contained in the three-dimensional model manufacturing composition 1'are joined to each other to form the bonding region 7, and are also contained in the other three-dimensional model manufacturing composition 9'. The conductive particles are bonded to each other to form a bonded region 9. By forming the bonding region 7 and the bonding region 9 in this way, the subsequent unintentional movement of the particles 21'and the conductive particles can be prevented, and the dimensional accuracy of the three-dimensional model 10 can be improved. Further, in the bonding region 7 formed as described above, the particles 21'are generally bonded to each other with sufficient bonding strength, and in the bonding region 9, the conductive particles are generally bonded to each other with sufficient bonding strength. are doing. Further, in this step, when the layer 1 in which the bonding region 7 and the bonding region 9 are formed is provided below the layer 1 irradiated with the laser beam L, generally, the bonding of the lower layer 1 is performed. The region 7 and the joining region 9 and the newly formed joining region 7 and the joining region 9 are joined. From such a thing, it is possible to improve the mechanical strength, reliability and the like of the finally obtained three-dimensional modeled object 10.

Further, by using the laser beam L, energy can be applied to a desired portion with high selectivity, which is advantageous in improving the dimensional accuracy of the three-dimensional model 10 and the three-dimensional model 10. It is also advantageous in improving the productivity of the laser. In addition, energy efficiency can be improved, which is advantageous from the viewpoint of energy saving.

Further, in this step, the particles 21'and the conductive particles can be bonded by irradiating the laser beam L, and unnecessary components other than the particles 21' and the conductive particles can be removed. For example, the binder, the remaining solvent, and the like can be removed, and it is possible to effectively prevent these components from remaining in the bonding region 7 and the bonding region 9.

In particular, as the particles 21', the mother particles 211' made of a material containing an amorphous soft magnetic alloy have a low melting point glass 2121 having a melting point lower than the melting point of the amorphous soft magnetic alloy, and amorphous soft Since it is coated with a coating film 212'composed of a material containing a laser light absorber 2122, which has a higher absorption rate of laser light L than a magnetic alloy, the amorphous soft magnetic alloy crystallizes due to the energy of the laser light L. It is preferably prevented from forming.

Examples of lasers that can be used in this step include solid lasers such as ruby lasers, YAG lasers, Nd: YAG lasers, titanium sapphire lasers, and semiconductor lasers; liquid lasers such as dye lasers; neutral atoms such as helium neon lasers. Ion lasers such as lasers, argon ion lasers, molecular lasers such as carbon dioxide lasers and nitrogen lasers, gas lasers such as metal vapor lasers such as excima lasers and helium cadmium lasers; free electron lasers; oxygen-iodine chemical lasers, hydrogen fluoride lasers Chemical lasers such as; fiber lasers and the like.

By adjusting the irradiation time, intensity, and the like, the laser light L can promote the bonding between the particles 21'more efficiently while suppressing the influence of the laser light L on the mother particles 211'.

Above all, it is preferable that the laser beam L is irradiated by a pulse-oscillating solid-state laser.

As a result, while more effectively preventing the temperature rise of the mother particles 211', the coating 212', in particular, in the configuration shown in FIG. 1, on the outer surface side of the coating 212'where the laser light absorber 2122 is unevenly distributed. The region can be heated more efficiently. In addition, the total amount of energy required for the joining process can be reduced.

This step is preferably performed in an inert atmosphere such as nitrogen gas, helium gas, neon gas, or argon gas, or in a reduced pressure atmosphere. As a result, it is possible to effectively prevent an undesired chemical reaction of the constituent materials of the conductive particles.

The thickness of the layer 1 having the bonding region 7 and the bonding region 9 is not particularly limited, but is preferably 5 μm or more and 300 μm or less, and more preferably 10 μm or more and 200 μm or less.

As a result, the productivity of the three-dimensional model 10 can be improved, and the dimensional accuracy of the three-dimensional model 10 can be further improved.

For example, the irradiation conditions of the laser light L such as the type of the laser light L and the irradiation intensity may be adjusted to be different in each part of the layer 1.

[4-4] Completion of the three-dimensional model After that, a plurality of layers 1 are laminated as shown in FIG. 10 by repeating a series of steps including the above-mentioned layer forming step, solvent removing step and joining step. The laminated body 50 is obtained. The laminated body 50 includes a three-dimensional model 10 having a joint region 7 and a joint region 9 provided over a plurality of layers 1.

After that, as shown in FIG. 11, the three-dimensional model 10 is taken out from the laminated body 50 by removing the portions of the layer 1 other than the joint region 7 and the joint region 9.

FIG. 12 summarizes the manufacturing method of the three-dimensional model 10 as described above in a flowchart.

As shown in FIG. 12, in the production of the three-dimensional modeled product 10, a series of steps including a layer forming step, a solvent removing step, and a joining step are repeated a predetermined number of times, and a laminated body 50 in which a plurality of layers 1 are laminated is repeated. To get.

That is, it is determined whether or not a new layer 1 should be formed on the already formed layer 1, and if there is a layer 1 to be formed, a new layer 1 is formed, and there is no layer 1 to be formed. To obtain the target three-dimensional model 10 by performing a post-treatment on the laminated body 50 to remove unnecessary parts of the layer 1 other than the joint region 7 and the joint region 9.

In the illustrated configuration, in order to facilitate understanding, the above-mentioned steps are described as being sequentially performed, but different steps are simultaneously performed in each part of the space on the stage, which is a modeling area. May be good. For example, while forming the layer 1, a solvent removing step or a joining step may be performed at another portion of the layer 1 before completion.

[5] Three-dimensional model manufacturing device Next, a three-dimensional model manufacturing device will be described.
FIG. 13 is a vertical cross-sectional view schematically showing a preferred embodiment of the three-dimensional model manufacturing apparatus.

The three-dimensional model manufacturing apparatus M100 is used to manufacture the three-dimensional model 10 by forming the layer 1 a plurality of times. The three-dimensional model manufacturing apparatus M100 includes a composition supply means M3 for discharging the three-dimensional model manufacturing composition 1'and another composition supply means for discharging another three-dimensional model manufacturing composition 9'. Formed by M3', a three-dimensional model manufacturing composition 1'discharged from the composition supply means M3, and another three-dimensional model manufacturing composition 9'discharged from another composition supply means M3'. The layer 1 is provided with a laser light irradiating means M6 for irradiating the laser light L. The three-dimensional model manufacturing apparatus M100 having such a configuration stacks the layers 1 to manufacture the three-dimensional model 10.

More specifically, the three-dimensional model manufacturing apparatus M100 includes a control unit M2, a composition supply means M3 provided with a nozzle capable of discharging the three-dimensional model manufacturing composition 1'in a predetermined pattern, and the like. Another composition supply means M3'provided with a nozzle capable of ejecting another three-dimensional model manufacturing composition 9'in a predetermined pattern, and another three-dimensional model manufacturing composition ejected from the composition supply means M3. With the solvent removing means M9 for removing at least a part of the solvent from the layer 1 formed by the composition 1'and the other composition for producing a three-dimensional model 9'ejected from the other composition supplying means M3'. The layer 1 from which at least a part of the solvent has been removed is provided with the particles 21'and the laser light irradiating means M6 for irradiating the laser light L for joining the conductive particles.

As a result, the effect of the three-dimensional model manufacturing composition 1'of the present invention as described above can be more preferably exhibited.

The control unit M2 includes a computer M21 and a drive control unit M22.
The computer M21 is a general desktop computer or the like having a CPU, a memory, or the like inside. The computer M21 converts the shape of the three-dimensional model 10 into data as model data, slices it into parallel thin cross-sectional bodies, and outputs the cross-sectional data, that is, the slice data to the drive control unit M22. To do.

The drive control unit M22 included in the control unit M2 serves as a control means for driving the composition supply means M3, the other composition supply means M3', the layer forming unit M4, the solvent removing means M9, the laser light irradiation means M6, and the like. Function. Specifically, for example, the composition supply means M3 is driven, the composition 1'for producing a three-dimensional modeled product is discharged by the composition supply means M3, the other composition supply means M3'is driven, and the other composition is supplied. Discharge of another three-dimensional model manufacturing composition 9'by means M3', lowering and lowering amount of stage M41 movable in the Z direction in FIG. 13, driving solvent removing means M9, laser light irradiation means M6. The irradiation pattern, irradiation, scanning speed, etc. of the laser beam L are controlled. Examples of the drive of the composition supply means M3 include movement on the XY plane, and examples of the drive of the other composition supply means M3 ′ include movement on the XY plane.

The composition supply means M3 is connected to a pipe M8 from the composition storage unit M7 in which the composition 1'for producing a three-dimensional model is stored and stored. The above-mentioned three-dimensional model manufacturing composition 1'is stored in the composition storage unit M7, and is discharged from the composition supply means M3 under the control of the drive control unit M22.

The composition supply means M3 can move independently in the X direction and the Y direction in FIG. 13 along the guide M5.

The other composition supply means M3'is connected to a pipe M8'from the composition storage unit M7' in which the other three-dimensional model manufacturing composition 9'is stored and stored. The other three-dimensional model manufacturing composition 9'described above is stored in the composition storage unit M7', and is discharged from the other composition supply means M3'under the control of the drive control unit M22.

The composition supply means M3 and the other composition supply means M3'can move independently in the X direction and the Y direction in FIG. 13 along the guide M5.

The layer forming portion M4 is a three-dimensional model manufacturing composition 1'discharged from the composition supply means M3 and another three-dimensional model manufacturing composition 9'discharged from the other composition supply means M3'. A stage M41 that supports the layer 1 formed by using the three-dimensional model manufacturing composition 1'and another three-dimensional model manufacturing composition 9', and a frame M45 that surrounds the stage M41. have.

When a new layer 1 is formed on the previously formed layer 1, the stage M41 is sequentially lowered by a predetermined amount according to a command from the drive control unit M22.

The stage M41 has a flat flat surface M410 on the upper surface to which at least the three-dimensional model manufacturing composition 1'and the other three-dimensional model manufacturing composition 9'are applied. Thereby, the layer 1 having high thickness uniformity can be easily and surely formed.

The stage M41 is preferably made of a high-strength material. Examples of the constituent material of the stage M41 include various metal materials such as stainless steel.

Further, the flat surface M410 of the stage M41 may be surface-treated. As a result, for example, it is more effective that the constituent material of the three-dimensional model manufacturing composition 1', the constituent material of another three-dimensional model manufacturing composition 9', and the like firmly adhere to the stage M41. It is possible to prevent this, improve the durability of the stage M41, and achieve stable production of the three-dimensional model 10 over a longer period of time. Examples of the material used for the surface treatment of the flat surface M410 of the stage M41 include a fluorine-based resin such as polytetrafluoroethylene.

The composition supply means M3 is configured to move according to a command from the drive control unit M22 and discharge the three-dimensional model manufacturing composition 1'to a desired portion on the stage M41.

The composition supply means M3 is configured to discharge the composition 1'for producing a three-dimensional model.

Examples of the composition supplying means M3 include an inkjet head, various dispensers, and the like, and a dispenser is preferable.

As described above, by using the dispenser, the above-mentioned three-dimensional model manufacturing composition 1'can be discharged more stably, and a good layer 1 can be formed. Further, as compared with the case of using a method other than the dispenser, it is possible to effectively suppress the undesired variation in the thickness of the layer 1, and it is also possible to improve the dimensional accuracy of the three-dimensional model 10 to be manufactured. It is advantageous. In addition, the layer 1 having a relatively large thickness can be easily formed, which is advantageous in further improving the productivity of the three-dimensional modeled object 10.

The nozzle diameter, which is the size of the discharge portion of the composition supply means M3, is not particularly limited, but is preferably 10 μm or more and 100 μm or less.

As a result, the productivity of the three-dimensional model 10 can be further improved while further improving the dimensional accuracy of the three-dimensional model 10.

The other composition supply means M3'is configured to move according to a command from the drive control unit M22 and discharge the other three-dimensional model manufacturing composition 9'to a desired portion on the stage M41. ..

The other composition supply means M3'is configured to discharge another composition 9'for producing a three-dimensional model.

Examples of the other composition supplying means M3' include an inkjet head, various dispensers, and the like, but a dispenser is preferable.

As described above, by using the dispenser, the other three-dimensional model manufacturing composition 9'can be discharged more stably, and a good layer 1 can be formed. Further, as compared with the case of using a method other than the dispenser, it is possible to effectively suppress the undesired variation in the thickness of the layer 1, and it is also possible to improve the dimensional accuracy of the three-dimensional model 10 to be manufactured. It is advantageous. In addition, the layer 1 having a relatively large thickness can be easily formed, which is advantageous in further improving the productivity of the three-dimensional modeled object 10.

The nozzle diameter, which is the size of the discharge portion of the other composition supply means M3', is not particularly limited, but is preferably 10 μm or more and 100 μm or less.

As a result, the productivity of the three-dimensional model 10 can be further improved while further improving the dimensional accuracy of the three-dimensional model 10.

The solvent removing means M9 is a three-dimensional model manufacturing composition 1'discharged by the composition supply means M3, and another three-dimensional model manufacturing composition 9'discharged by the other composition supply means M3'. It has a function of removing at least a part of the solvent contained in the layer 1 formed by.

Examples of the solvent removing means M9 include a line heater for heating the layer 1, a heating roller, an infrared irradiation means for irradiating the layer 1 with infrared rays, a gas supply means having a low content of liquid components such as dry air, and the like. And may be a combination of two or more selected from these.

The laser light irradiation means M6 is a composition for producing a three-dimensional model 1'discharged by the composition supply means M3, and another composition for producing a three-dimensional model 9 ejected by the other composition supply means M3'. The layer 1 formed by', in particular, in the present embodiment, the particles 21'contained in the layer 1 from which at least a part of the solvent has been removed by the solvent removing means M9, and the laser beam L for joining the conductive particles. Has the function of irradiating.

As a result, the particles 21'contained in the layer 1 are bonded to each other to form a bonding region 7, and the conductive particles are bonded to each other to form a bonding region 9. In particular, by scanning the laser beam L on the layer 1, energy can be selectively applied to a desired portion of the layer 1, and the energy efficiency of forming the bonding region 7 and the bonding region 9 can be further improved. it can. Thereby, the productivity of the three-dimensional model 10 can be further improved. In addition, energy efficiency can be improved, which is advantageous from the viewpoint of energy saving. Further, by irradiating the laser light L, the low melting point glass 2121 having a melting point lower than the melting point of the amorphous soft magnetic alloy and the laser light absorption having a higher absorption rate of the laser light L than the amorphous soft magnetic alloy Crystallization of the amorphous soft magnetic alloy coated with the coating film 212'composed of the material containing the agent 2122 is preferably prevented.

In the present invention, the three-dimensional model 10 may be manufactured in a chamber in which the composition of the atmosphere and the like are controlled. Thereby, for example, the joining step can be performed in an inert gas, and unintentional denaturation of particles can be prevented more effectively.

[6] Three-dimensional model The three-dimensional model according to the present invention uses the powder 2'for producing a three-dimensional model of the present invention and the composition for producing a three-dimensional model 1'of the present invention as described above. Can be manufactured. In particular, it can be suitably manufactured by applying the method for manufacturing the three-dimensional modeled object 10 as described above and the three-dimensional modeled object manufacturing apparatus M100.

Thereby, it is possible to provide a three-dimensional model 10 made of an amorphous soft magnetic alloy in which crystallization is preferably prevented. In particular, it is possible to preferably provide a small three-dimensional model 10, a fine structure, and a three-dimensional model 10 having a complicated structure.

In the above description, the case where the three-dimensional model 10 is an inductor has been mainly described, but the three-dimensional model 10 according to the present invention may be any, for example, a transformer, a motor, a generator, and the like. It may be a magnetic component other than an inductor such as a relay, particularly a magnetic component provided in an electric / electronic device.

Further, the three-dimensional model 10 may be an article other than the magnetic parts provided in the electric / electronic device. For example, watch cases, eyeglass frames, medals, pendant heads, other accessories, tableware, dolls, figures and other ornaments / exhibits; implants, stents, artificial bones and other medical devices; bolts, nuts, screws, arms, etc. It may be a ring, a pipe, or a part of various industrial products.

Further, the three-dimensional model may be applied to any of a prototype, a mass-produced product, and a custom-made product.

Although preferred embodiments of the present invention have been described above, the present invention is not limited thereto.

For example, in the three-dimensional model manufacturing apparatus, the configuration of each part can be replaced with an arbitrary configuration that exhibits the same function, or an arbitrary configuration can be added.

For example, in the above-described embodiment, the configuration in which the stage moves up and down has been described, but the stage may not move up and down, and the composition supply means may move up and down.

Further, in the above-described embodiment, the configuration in which the laser light irradiating means moves on the XY plane to change the irradiation site of the laser light on the layer is illustrated, but the laser light irradiating means is on the XY plane. It may be the one that does not move. More specifically, for example, the laser light irradiation means is a galvano laser having a laser light irradiation unit, a plurality of mirrors for positioning the laser light from the laser light irradiation unit, and a lens for converging the laser light. May be good. This makes it possible to scan the laser beam at high speed and over a wide range.

Further, in the above-described embodiment, the case where the layer is directly formed on the surface of the stage has been typically described. For example, a modeling plate is arranged on the stage, and the layers are laminated on the modeling plate for three-dimensional modeling. You may manufacture things. In such a case, in the manufacturing process of the three-dimensional model, the model plate and the particles constituting the lowermost layer may be joined, and then the model plate may be removed from the target three-dimensional model by post-treatment. .. As a result, for example, it is possible to more effectively prevent the occurrence of warpage of the layers in the process of laminating a plurality of layers, and it is possible to further improve the dimensional accuracy of the finally obtained three-dimensional model. it can.

Further, in the above-described embodiment, the case where the bonding region is formed in all the layers has been typically described, but the laminated body in which a plurality of layers are laminated includes, for example, a layer having no bonding region. You may. Further, a layer on which the body portion is not formed may be formed on the contact surface with the stage, and the layer may function as a sacrificial layer.

Further, in the method for manufacturing a three-dimensional model, a pretreatment step, an intermediate treatment step, and a posttreatment step may be performed as necessary.

Examples of the pretreatment step include a stage cleaning step and the like.
Examples of the post-treatment step include a cleaning step, a shape adjusting step of performing deburring, polishing, and the like, a coloring step, a coating layer forming step, a heat treatment step for improving the bonding strength of particles, and the like.

Further, in the above-described embodiment, the case where the region to be the actual part of the three-dimensional model and the other regions of the layer are produced by using the same composition has been described, but for example, it is unnecessary. The region to be removed in the portion removing step may be formed by using a composition different from the region to be the actual portion of the three-dimensional modeled object.

Further, in the above-described embodiment, a case where a composition obtained by mixing a powder for producing a three-dimensional model with another component such as a solvent is used for producing a three-dimensional model has been typically described. The manufacturing powder may be used, for example, as a powder for manufacturing a three-dimensional model without mixing with other components.

Further, the composition for producing a three-dimensional model of the present invention may be any composition used for producing a three-dimensional model by laminating a plurality of layers, and the composition for producing a three-dimensional model as described above may be produced. It may be applied to a manufacturing method other than the method, or an apparatus other than the above-mentioned three-dimensional model manufacturing apparatus.

Further, in the above-described embodiment, in the production of the powder for producing a three-dimensional model, after the amorphous soft magnetic alloy powder and the low melting point glass are mixed to form composite particles, the composite particles and the laser light absorber are used. Although the case of mixing the two is typically described, the method for producing the powder for producing a three-dimensional model is not limited to this, and for example, the amorphous soft magnetic alloy powder, the low melting point glass, and the laser light absorber are used. The order of mixing may be changed. For example, the amorphous soft magnetic alloy powder, the low melting point glass, and the laser light absorber may be mixed at the same time. Further, when mixing the composite particles and the laser light absorber, low melting point glass may be additionally used.

The present invention will be described in more detail with reference to specific examples below, but the present invention is not limited to these examples. In the following description, the treatment not particularly indicating the temperature condition was performed at 25 ° C. Further, as for various measurement conditions, those that do not particularly indicate the temperature conditions are the values at 25 ° C.

[7] Production of powder for producing a three-dimensional model (Example A1)
First, particles made of an amorphous soft magnetic alloy composed of Fe, Si, Cr, B and the like which are amorphous soft magnetic alloys, glass particles composed of phosphate glass which is a low melting point glass, and a laser. A phthalocyanine copper, which is a phthalocyanine compound, was prepared as a light absorber.

The Fe-Si-Cr-B metal particles, which are amorphous soft magnetic alloys constituting the amorphous soft magnetic alloy particles, have a melting point of 1170 ° C. and a recrystallization temperature of 500 ° C. there were. The softening point of the phosphate-based glass, which is a low-melting point glass, was around 200 ° C., and the melting point of the low-melting point glass was lower than that of the amorphous soft magnetic alloy.

Next, the above-mentioned amorphous soft magnetic alloy particles and glass particles were put into the container of the powder manufacturing apparatus for manufacturing a three-dimensional model shown in FIG.

In this state, the rotation shaft was rotated by the rotation drive device, and the first arm and the second arm fixed to the rotation shaft were rotated via the boss.

By the rotation of the first arm and the second arm, the raw material is pressed and compressed by the pressing member provided at the tip of the first arm, the raw material is pressed and compressed by the scraper provided at the tip of the second arm, and the raw material is three-dimensional. The intermediate products of the powder for producing a modeled product were repeatedly scraped off to obtain an aggregate of composite particles in which the surface of the amorphous soft magnetic alloy particles was coated with low melting point glass.

After that, the composite particles and the laser light absorber were put into the container of the powder manufacturing apparatus for producing a three-dimensional model, and the powder manufacturing apparatus for producing a three-dimensional model was operated in the same manner as described above. As a result, the laser light absorber adhered to the surface of the composite particles, and a powder for producing a three-dimensional modeled product containing a plurality of particles as shown in FIG. 1 was obtained.

The average particle size of the particles constituting the powder for producing a three-dimensional model thus obtained was 30 μm. The coating film covering the mother particles had an average thickness of 2 μm and a coverage ratio of 80% on the entire surface of the mother particles. In addition, the proportion of the mother particles in the particles constituting the powder for producing a three-dimensional model was 40% by volume.

(Comparative Example A1)
The same treatment as in Example A1 was carried out except that the treatment for adhering the laser light absorber to the aggregate of the composite particles was omitted. In other words, the constituent particles of the powder for producing a three-dimensional model of this comparative example are a mother particle made of a material containing an amorphous soft magnetic alloy and a film of low melting point glass that covers the surface of the mother particle. It is composed of, and does not contain a laser light absorber.

[8] Production of composition for producing three-dimensional modeled product (Example B1)
The powder for producing a three-dimensional model obtained in Example A1, water as a solvent, and PVA as a binder were mixed at a predetermined ratio to obtain a composition for producing a three-dimensional model. The content of the powder for producing a three-dimensional model in the composition for producing a three-dimensional model thus obtained is 40% by volume, the content of the solvent is 56% by volume, and the content of the binder is It was 4% by volume.

(Comparative Example B1)
A composition for producing a three-dimensional model was produced in the same manner as in Example B1 except that the powder obtained in Comparative Example A1 was used as the powder for producing a three-dimensional model.

[9] Production of Three-Dimensional Model Using the three-dimensional model production compositions of the above Examples and Comparative Examples, an inductor as a three-dimensional model was manufactured as follows.

First, along with the three-dimensional model manufacturing compositions of the above-mentioned Examples and Comparative Examples, other three-dimensional model manufacturing compositions used for forming the winding portion were prepared. The other composition for producing a three-dimensional model was prepared by mixing conductive particles composed of copper, water as a solvent, and PVA as a binder in a predetermined ratio.

Next, a three-dimensional model manufacturing apparatus as shown in FIG. 13 is prepared, the composition for manufacturing the three-dimensional model of the above embodiment is discharged from the composition supplying means, and the other composition supplying means. These compositions were stored in separate composition reservoirs so as to discharge the compositions for producing three-dimensional shaped objects.

Next, as described above, a series of steps including the layer forming step, the solvent removing step, and the joining step are repeated a plurality of times, and then the unnecessary portion removing step is performed to obtain the three-dimensional model according to the present invention. I got an inductor. The size of the obtained inductor was 1.5 mm × 1.5 mm.

The thickness of the layer formed in the layer forming step was 50 μm.
The solvent removing step was carried out by performing a heat treatment at 200 ° C. using a line heater as the solvent removing means.

The joining step was performed by scanning the laser beam of a YAG laser having a maximum peak wavelength of 1064 nm, which is a pulse-oscillating solid-state laser.

Further, in the same manner as described above, as the three-dimensional model of the comparative example, except that the composition for producing the three-dimensional model of the comparative example was used instead of the composition for producing the three-dimensional model of the example. I got an inductor.

In the three-dimensional model according to the present invention, the crystallization of the amorphous soft magnetic alloy is effectively prevented, the inductance value, the DC superimposition characteristic, the temperature characteristic, etc. are excellent, and the magnetic flux leakage is also effectively prevented. It was confirmed that the function required as an inductor was excellent. On the other hand, in the three-dimensional model according to the comparative example, the crystallization of the amorphous soft magnetic alloy was progressing, and the function required as an inductor was inferior.

Further, except that a cyanine-based pigment was used instead of phthalocyanine copper as the laser light absorber, a powder for producing a three-dimensional model and a composition for producing a three-dimensional model were produced in the same manner as described above, and the tertiary was produced. When a three-dimensional model was produced in the same manner as described above using the original composition for producing a model, the same results as described above were obtained.

Further, as the low-melting glass, in place of the phosphate type glass, except for using SiO ₂ -based glass, ZnO-BaO-based _glass, a _ZnO-B 2 O 3 -SiO ₂ based glass, three-dimensional in the same manner as above When a powder for manufacturing a modeled object and a composition for producing a three-dimensional modeled product were produced, and the three-dimensional modeled product was produced in the same manner as described above using the composition for producing the three-dimensional modeled object, the same result as described above was obtained. was gotten.

Further, except that the average thickness of the coating film was changed within the range of 1 μm or more and 5 μm or less, a powder for producing a three-dimensional model and a composition for producing a three-dimensional model were produced in the same manner as described above, and the three-dimensional structure was produced. When a three-dimensional model was produced in the same manner as described above using the composition for producing a model, the same result as described above was obtained.

Further, except that the average particle size of the mother particles was changed within the range of 20 μm or more and 100 μm or less, a powder for producing a three-dimensional model and a composition for producing a three-dimensional model were produced in the same manner as described above, and the tertiary was produced. When a three-dimensional model was produced in the same manner as described above using the original composition for producing a model, the same results as described above were obtained.

Further, the three-dimensional model is the same as described above except that the content of the powder for producing the three-dimensional model in the composition for producing the three-dimensional model is changed within the range of 30% by volume or more and 50% by volume or less. When a manufacturing powder and a composition for manufacturing a three-dimensional model were manufactured, and the three-dimensional model was manufactured in the same manner as above using the composition for manufacturing the three-dimensional model, the same result as described above was obtained. Was done. Further, except that the content of the binder in the composition for producing a three-dimensional model was changed within the range of 1.5% by volume or more and 10% by volume or less, the powder for producing a three-dimensional model was obtained in the same manner as described above. When a composition for producing a three-dimensional model was produced, and the composition for producing the three-dimensional model was used to produce a three-dimensional model in the same manner as described above, the same results as described above were obtained. Further, except that the content of the solvent in the three-dimensional model manufacturing composition was changed within the range of 43% by volume or more and 68% by volume or less, the three-dimensional model manufacturing powder and three-dimensional When a composition for producing a modeled product was produced and a three-dimensional modeled product was produced in the same manner as described above using the composition for producing a three-dimensional modeled object, the same result as described above was obtained.

10 ... 3D model, 50 ... Laminate, 1 ... Layer, 1'... Composition for 3D model production, 2'... Powder for 3D model production, 21'... Particles, 211' ... Mother particles, 212'... coating, 2121 ... low melting point glass, 2122 ... laser light absorber, 7 ... bonding region, 9 ... bonding region, 9'... other three-dimensional model manufacturing composition, P100 ... for three-dimensional model manufacturing Powder manufacturing equipment, P10 ... Container, P20 ... Rotating shaft, P11 ... Boss, P12 ... First arm, P14 ... Pressing member, P16 ... Second arm, P18 ... Scraper, M100 ... Three-dimensional model manufacturing equipment, M2 ... Control unit, M21 ... Computer, M22 ... Drive control unit, M3 ... Composition supply means, M3'... Other composition supply means, M4 ... Layer forming unit, M41 ... Stage, M410 ... Plane, M45 ... Frame, M5 ... guide, M6 ... laser light irradiation means, M7 ... composition storage part, M7'... composition storage part, M8 ... piping, M8' ... piping, M9 ... solvent removing means, L ... laser light

Claims (14)

A three-dimensional model manufacturing powder used for forming a layer by irradiating a plurality of particles with laser light and joining them, and laminating the layers to produce a three-dimensional model.
The particles have a mother particle made of a material containing an amorphous soft magnetic alloy and a coating film that covers at least a part of the surface of the mother particle.
The coating film contains a low melting point glass having a melting point lower than the melting point of the amorphous soft magnetic alloy and a laser light absorber having a higher absorption rate of the laser light than the amorphous soft magnetic alloy. A powder for manufacturing three-dimensional alloys, which is characterized by. The powder for producing a three-dimensional model according to claim 1, wherein the laser light absorber is a dye compound. The powder for producing a three-dimensional model according to claim 2, wherein the laser light absorber is a phthalocyanine compound. Wherein the low melting glass, SiO _{2 glass,} P 2 _{O 5} based glass, ZnO-BaO-based glass, _or, in any one of claims 1 to 3 is a _ZnO-B 2 O 3 -SiO ₂ based glass The described three-dimensional model manufacturing powder. The powder for producing a three-dimensional model according to any one of claims 1 to 4, wherein the laser light absorber is unevenly distributed in a region on the outer surface side of the coating film. The powder for producing a three-dimensional model according to any one of claims 1 to 5, wherein the average thickness of the coating film is 1 μm or more and 5.0 μm or less. The powder for producing a three-dimensional model according to any one of claims 1 to 6, wherein the average particle size of the mother particles is 20 μm or more and 100 μm or less. The three-dimensional according to any one of claims 1 to 7, wherein the amorphous soft magnetic alloy is an alloy containing at least one selected from the group consisting of Fe, Si, Cr, B, C and Ni. Powder for manufacturing shaped objects. The powder for producing a three-dimensional model according to any one of claims 1 to 8.
With a binder
A composition for producing a three-dimensional model, which comprises a solvent. The composition for producing a three-dimensional model according to claim 9, wherein the content of the powder for producing a three-dimensional model is 30% by volume or more and 50% by volume or less. The composition for producing a three-dimensional model according to claim 9 or 10, wherein the composition for producing a three-dimensional model is discharged by a dispenser when forming the layer. A layer forming step of forming a layer using the composition for producing a three-dimensional model according to any one of claims 9 to 11.
A three-dimensional model characterized by producing a three-dimensional model by irradiating the layer with a laser beam in a predetermined pattern and repeating a series of steps including a bonding step of joining the particles a plurality of times. Production method. The method for producing a three-dimensional model according to claim 12, wherein the layer forming step is performed by discharging the composition for producing the three-dimensional model from a composition supply means having a nozzle. The method for manufacturing a three-dimensional model according to claim 12 or 13, wherein the laser light is irradiated by a pulse-oscillating solid-state laser.

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