JP2022506320A - 層状の材料塗布によって三次元の成形品を製造するための方法 - Google Patents
層状の材料塗布によって三次元の成形品を製造するための方法 Download PDFInfo
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Abstract
Description
a)雌型層を形成するために、流動性の第1の材料の材料ポーションを、幾何学データに相応して、基礎面に、かつ/または三次元の成形品の、基礎面の上に位置している硬化した材料層に塗布し、雌型層が、この雌型層の、基礎面とは反対側の表面に、成形品の製造すべき材料層の雌型を有する少なくとも1つのキャビティを有するようにし、
b)雌型層を硬化させ、
c)成形品層を形成するために、キャビティを第2の材料によって満たし、雌型が雄型として成形品層に転写されるようにし、
d)キャビティ内に充填された第2の材料の主成分を、エネルギを用いた処理によって部分架橋させて硬化させ、
e)硬化した雌型層および/または硬化した成形品層の、基礎面に対して予め設定された間隔を置いて配置された平面を越えて突出している領域を、材料除去によって取り除き、
f)ステップa)~e)を少なくとも1回繰り返し、
g)成形品層から形成された成形品の主成分を、熱処理によってさらに架橋させて、第2の材料が、硬化した第1の材料および/または部分架橋した第2の材料よりも高い強度を有するように硬化させ、
h)雌型層を、熱処理の実施前、実施中かつ/または実施後に成形品から取り除く、
方法が提案されている。
Claims (15)
- 層状の材料塗布によって三次元の成形品(1)を製造するための方法であって、
前記成形品(1)のための幾何学データと、
前記三次元の成形品(1)を載せるための基礎面(3)を備える支持部材(2)と、
硬化可能な液状のまたは流動性の第1の材料(4)と、
硬化可能な液状の、流動性の、ペースト状の、または粉末状の第2の材料(5)であって、硬化した前記第1の材料(4)を溶解することができる第2の材料(5)と
を準備し、
前記第2の材料(5)は、エネルギを用いた処理によって架橋可能な少なくとも1つの主成分と、熱によって活性可能な潜伏性硬化剤とを含み、前記硬化剤によって、熱作用により前記主成分の化学的な架橋を引き起こすことができ、
a)雌型層(12)を形成するために、前記流動性の第1の材料(4)の材料ポーションを、前記幾何学データに相応して、前記基礎面(3)に、かつ/または前記三次元の成形品(1)の、前記基礎面(3)の上に位置している硬化した材料層に塗布し、前記雌型層(12)が、該雌型層(12)の、前記基礎面(3)とは反対側の表面に、前記成形品(1)の製造すべき材料層の雌型を有する少なくとも1つのキャビティ(13)を有するようにし、
b)前記雌型層(12)を硬化させ、
c)成形品層(16)を形成するために、前記キャビティ(13)を前記第2の材料(5)によって満たし、前記雌型が雄型として前記成形品層(16)に転写されるようにし、
d)前記キャビティ(13)内に充填された前記第2の材料(5)の前記主成分を、エネルギを用いた処理によって部分架橋させて硬化させ、
e)硬化した前記雌型層(12)および/または硬化した前記成形品層(16)の、前記基礎面(3)に対して予め設定された間隔を置いて配置された平面を越えて突出している領域を、材料除去によって取り除き、
f)ステップa)~e)を少なくとも1回繰り返し、
g)前記成形品層(16)から形成された前記成形品(1)の前記主成分を、熱処理によってさらに架橋させて、前記第2の材料(5)が、硬化した前記第1の材料(4)および/または部分架橋した前記第2の材料(5)よりも高い強度を有するように硬化させ、
h)前記雌型層(12)を、前記熱処理の実施前、実施中かつ/または実施後に前記成形品(1)から取り除く、
方法。 - 前記第1の材料(4)の前記材料ポーションを、好ましくはインクジェット印刷法または粉末塗布法によって、前記基礎面に、かつ/または前記基礎面の上に位置している硬化した前記雌型層(12)に、かつ/または硬化した成形品層(16)に塗布し、前記第1の材料(4)は、エネルギの作用によって硬化可能な材料であり、該材料に、前記雌型層(12)の硬化のために、前記エネルギを加える、請求項1記載の方法。
- 前記第2の材料の前記主成分は、少なくとも1つのエポキシド、少なくとも1つのオキセタン、少なくとも1つの機能性(メタ)アクリレート、少なくとも1つのビニルエーテル、またはこれらの材料のうちの少なくとも2つの材料から成る混合物を含む、請求項1または2記載の方法。
- 前記潜伏性硬化剤は、ジシアンジアミドおよび/または酸無水物および/または少なくとも1つのブロックイソシアネートおよび/または少なくとも1つのカルボジイミドを含有する、請求項1から3までのいずれか1項記載の方法。
- 前記硬化剤の濃度は、前記第2の材料の0.2~5%の体積パーセント、特に1.2~4%の体積パーセント、好ましくは2.2~3%の体積パーセントである、請求項1から4までのいずれか1項記載の方法。
- 流動性の、ペースト状の、または粉末状の前記第2の材料(5)を、前記幾何学データに関連して、部分選択的な被覆法によって前記雌型層(12)に塗布し、前記第2の材料の少なくとも1回の材料ポーションを、前記少なくとも1つのキャビティ(13)内に完全充填するように放出し、好ましくは、前記雌型層の、前記キャビティの外に位置している少なくとも1つの箇所を、前記第2の材料(5)に接触させないようにする、請求項1から5までのいずれか1項記載の方法。
- 前記第2の材料(5)は、流体および少なくとも1つの添加剤を含む複合材であり、前記流体は、作業温度時に少なくとも50mPa・sの粘度、好ましくは少なくとも1000mPa・sの粘度を有し、前記添加剤は、前記流体内に配置されている固形粒子を有する、請求項1から6までのいずれか1項記載の方法。
- 前記第2の材料(5)に圧力を加え、こうして圧力下にある前記第2の材料(5)を少なくとも1つの弁(30)を介して少なくとも1つのノズル(27)に案内し、前記ノズルの流出開口を前記基礎面(3)に沿って前記支持部材(2)に対して位置決めし、前記弁(30)を、製造すべき前記成形品(1)のために準備された前記幾何学データと、前記ノズル(27)と前記支持部材(2)との間の相対位置とに関連して制御し、前記流出開口が、前記第2の材料(5)を前記ノズル(27)から前記キャビティ(13)に放出することができるように前記キャビティ(13)に位置決めされている場合には、材料流を解放し、前記流出開口が、前記第2の材料(5)を前記ノズル(27)から前記キャビティ(13)内に放出することができないように位置決めされている場合には、前記材料流を遮断する、請求項1から7までのいずれか1項記載の方法。
- 前記第2の材料(5)を、フレキソ印刷法、凹版印刷法、オフセット印刷法、スクリーン印刷法、レーザ転写法、マイクロ調量法によって、かつ/またはドクタ(24)および/またはチャンバドクタおよび/または粉末塗布法によって、非選択的にまたは部分選択的に前記キャビティ(13)内に充填する、請求項1から6までのいずれか1項記載の方法。
- 前記キャビティ(13)内に充填された前記第2の材料(5)をその主成分の部分架橋前に固形粒子、特に繊維と接触させ、前記固形粒子を、前記キャビティ(13)内に位置している前記第2の材料(5)内に完全にかつ/または部分的に押し込む、請求項1から9までのいずれか1項記載の方法。
- 前記固形粒子を固形粒子層として転写ローラの周面に被着し、その後、被覆された前記周面を、前記固形粒子層が前記第2の材料(5)と接触しかつ前記転写ローラの前記周面が前記第2の材料(5)から間隔を置いて配置されるように、前記キャビティ(13)内に充填された前記第2の材料(5)の表面に密に位置決めする、請求項10記載の方法。
- 硬化した一番上側の前記雌型層(12)および/または硬化した一番上側の前記成形品層(16)を、材料除去時に発生した除去物に対してクリーニングする、請求項1から11までのいずれか1項記載の方法。
- 前記基礎面(3)を有する前記支持部材(2)を前記材料塗布中にかつ場合によっては前記材料(4,5)の硬化中に回転軸線(11)を中心にして回転させ、好ましくは前記回転軸線(11)に沿って移動させる、請求項1から12までのいずれか1項記載の方法。
- 硬化した前記第1の材料(4)を溶解することができる溶剤(33)を準備し、前記雌型層(12)を前記熱処理の実施前、実施中かつ/または実施後に前記溶剤(33)と接触させ、硬化した前記第1の材料(4)を前記溶剤(33)内で溶解する、請求項1から13までのいずれか1項記載の方法。
- 前記雌型層(12)を前記熱処理の実施前、実施中かつ/または実施後に、硬化した前記第1の材料(4)の相転移によって前記成形品(1)から取り除く、請求項1から13までのいずれか1項記載の方法。
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