JP3442620B2 - Three-dimensional molding apparatus and three-dimensional molding method - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention discharges a viscous liquid resin material from a nozzle and then cures the material.
A three-dimensional molding apparatus and a three-dimensional molding method for manufacturing a molded article having a desired three-dimensional shape by repeating the step of discharging a liquid resin material onto the cured resin material and laminating the resin material to laminate the resin material. It is about.

[0002]

2. Description of the Related Art FIG. 10 shows, for example, JP-A-2-307729.
1 shows a conventional molding device for forming a three-dimensional shape of this kind disclosed in Japanese Patent Laid-Open Publication No. This three-dimensional molding apparatus includes an inkjet head that ejects thermosetting resin into small droplets, a stage on which the thermosetting resin ejected from the inkjet head is laminated, a heat source that applies heat to the laminated resin, and a resin A control means for relatively changing the ejection direction and amount of resin is provided during ejection.

This three-dimensional molding apparatus basically comprises a control computer 51 for controlling the formation of a three-dimensional model and each part in accordance with the data, an XY direction movement control device 52 and a Z for controlling the ejection direction of the thermosetting resin. Directional movement control device 53, inkjet heads 54 to 59, resin tank 6
0, 61, pumps 62 to 67, a molding stage 68, and a resin curing heat source 69.

First, the shape of the object to be formed is input to the control computer 51. The control computer 51
Based on the information from the XY direction movement control device 52 and Z
The directional movement control device 53 operates to move the inkjet heads 54 to 59 and the molding stage 68 positioned thereabove to a predetermined position.

After the movement, a command is issued from the control computer 51 to the pump 64, and the thermosetting resin A contained in the resin tank 61 is jetted from the ink jet head 56 while moving in the X direction or the Y direction to form a molding stage. 68
Stack in the shape of "U" on top. Then, the irradiation of the heat source 69 cures the resin. FIG. 11 shows the state.

Next, from the control computer 51 to the pump 6
A command is issued to 3, 67, the inkjet head 55,
Similarly to the above, the thermosetting resin A contained in the resin tank 61 is jetted from 59 while moving in the X direction or the Y direction (in this example, the resin is discharged from the ink jet head 55 due to the shape of the molded object). (Not ejected),
Laminated on previously cured object. Then, the irradiation of the heat source 69 cures the resin. FIG. 12 shows the state.

Further, according to a command from the control computer 51, the molding stage 68 moves in the Z direction, and the ink jet heads 56, 57 move in the X direction or the Y direction. After that, the ink jet head 57 enters the resin tank 60. The thermosetting resin B present is jetted while moving in the X direction or the Y direction, and is laminated on the above-mentioned cured object. Then, the irradiation of the heat source 69 cures the resin. FIG. 13 shows the state.

Finally, from the computer 51 to the pump 62,
A command is issued to 66, and the inkjet heads 54, 58
From the above, the thermosetting resin B contained in the resin tank 60 is ejected while moving in the X direction or the Y direction.
(In this example, the resin is not ejected from the inkjet head 54 because of the shape of the molded object), and the resin is laminated on the previously cured object. Then, the resin is cured by the irradiation of the heat source 69, and the formation is completed. Figure 1
The state is shown in FIG.

As described above, a plurality of resins are jetted upward from the plurality of ink jet heads positioned lower than the stage onto the stage to be laminated and cured by heat irradiation, and the process is repeated to repeat three-dimensionally. Form a molded article.

[0010]

Since the conventional three-dimensional molding apparatus is constructed as described above, a thermosetting resin having a low viscosity is used to eject the thermosetting resin to be laminated from the ink jet head. I had a good problem to do. Further, since the thermosetting resin is ejected to be laminated, there is a problem that the layer for one lamination is thin and the lamination speed is slow.

The present invention has been made in order to solve the above problems, and provides an apparatus for discharging a liquid resin material having a relatively high viscosity in a line form from a nozzle,
And to provide a three-dimensional molding apparatus having a feature that the thickness of the laminate can be adjusted by changing the nozzle diameter, etc., and also by subjecting the surface of the molded article to a surface treatment during lamination, the strength, It is an object to provide a three-dimensional molding method excellent in dimensional accuracy and function.

[0012]

DISCLOSURE OF THE INVENTION In view of the above-mentioned object, the present invention laminates a delivery nozzle for continuously delivering a viscous liquid resin material in a line, and the delivered line-shaped liquid resin material. A work table for forming a desired three-dimensional molded product and a curing device are provided.
Emit from the delivery nozzle to the work table.
Laminating step for laminating the line-shaped liquid resin material
And a curing stage for curing the laminated materials,
An activation stage that activates the surface of the laminated material
The three-dimensional molding apparatus is characterized in that a plurality of stages including is provided .

Further, the present invention is characterized by further comprising a thickness adjusting means for changing the thickness of the linear liquid resin material.

Further, according to the present invention, the thickness adjusting means includes a nozzle diameter control means for changing the diameter of the delivery nozzle, and a liquid resin material flow rate control means for controlling the amount of the liquid resin material fed into the delivery nozzle. Consists of.

Further, the present invention is characterized by comprising a plurality of material supply means for supplying a plurality of materials including the liquid resin material to the delivery nozzle.

Further, the present invention is characterized in that the work table is rotated to switch the stage.

[0017]

Furthermore, the present invention is characterized in that the work table includes a smoothing stage for flattening the surface of the laminated materials.

Furthermore, the present invention is characterized in that the work table includes a coating stage for applying a conductive coating to the surfaces of the laminated materials.

Furthermore, the present invention is characterized in that tilting means for tilting the work table or the sending nozzle is provided in order to change the angle of the sending nozzle with respect to the three-dimensional molded product formed on the work table. .

Further, the present invention is a three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously feeding out a viscous liquid resin material in a line form from a delivery nozzle and laminating it. In order to increase the bonding strength of the resin material laminating step of discharging the liquid resin material from the nozzle to laminate one layer of the molded article, the resin material curing step of curing the laminated portion, and the surface of the cured molded article. A three-dimensional molding method is characterized in that the step of activating a resin material to be activated is sequentially repeated.

Furthermore, the present invention is a three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously feeding out a viscous liquid resin material in a line form from a delivery nozzle and laminating it. A resin material laminating step of discharging the liquid resin material from a nozzle to laminate one layer of a molded article, a resin material curing step of curing the laminated portion, a resin material smoothing for flattening the surface of the cured article The three-dimensional molding method is characterized in that the forming step is repeated in order.

Further, the present invention is a three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously feeding a viscous liquid resin material in a line form from a delivery nozzle and laminating the liquid resin material. A resin material laminating step of sending out the liquid resin material from a nozzle to laminate one layer of a molded article, a resin material curing step of curing the laminated portion, and applying a conductive paint to the surface of the cured molded article. A three-dimensional molding method is characterized in that a resin material coating step is sequentially repeated.

[0024]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below in accordance with each embodiment. Embodiment 1. FIG. 1A is a diagram showing the configuration of a three-dimensional molding apparatus according to an embodiment of the present invention. Figure 1 (a)
, 10 is a computer, 11 is a flow rate control unit, 1
2 is a nozzle position control unit, 13 is a work table position control unit, 14 is a delivery nozzle, 15 is a flow control valve, 16 is a pump, 17 is an electric motor, 18 is a material tank, 19 is a work table, 20 is a material hardening propulsion device. , 21 is a liquid resin material, 41 is a nozzle diameter control unit, and CAD is CAD.
System.

FIG. 1B shows an example of a mechanism for changing the nozzle diameter of the delivery nozzle 14. The member 14a is controlled to move in the direction of the arrow to change the nozzle diameter.

FIG. 2 is a perspective view showing a state in which the line-shaped liquid resin material 21 is delivered from the delivery nozzle 14 and the three-dimensional molded product 22 is formed on the work table 19.

The flow rate control unit 11 and the flow rate control valve 15 constitute liquid resin material flow rate control means, and the delivery nozzle 1
4. The nozzle diameter control unit 41 constitutes nozzle diameter control means,
The whole of them constitutes a liquid resin material thickness adjusting means.
Further, the flow rate control unit 11, the flow rate control valve 15, the pump 16,
The electric motor 17 and the material tank 18 constitute the material supply means.

Next, the operation will be described. After forming a three-dimensional model of the shape of a desired molded product to be formed by a three-dimensional CAD system CAD, data sliced into cross-sectional layers along each direction of the three-dimensional shape is input to the computer 10. The computer 10 sucks the liquid resin material 21 from the material tank 18 by the pump 16 while controlling the position of the delivery nozzle 14 or the work table 19 based on the input three-dimensional shape data. Pump 16
Is driven by an electric motor 17.

The thickness of one layer of the molded product formed of the liquid resin material 21 sent out in a line from the nozzle 14 is determined by the amount of the liquid resin material 21 sent into the nozzle 14 and the diameter of the nozzle 14, and is determined by the computer 10. Command, the amount of liquid resin material 21 fed into the nozzle 14 is controlled by the flow rate control unit 11 and the flow rate control valve 15, and the diameter of the nozzle 14 is controlled by the nozzle diameter control unit 41 and the member 14a shown in FIG. Controlled.

The liquid resin material 21 sucked from the material tank 18 is continuously sent in line form from the nozzle 14 onto the work table 19. The liquid resin material 21 delivered onto the work table 19 is cured by the material curing propulsion device 20 controlled by the computer 10. The material curing propulsion device 20 includes an ultraviolet irradiator, a heater, a humidifier, and the like.

After the liquid resin material 21 is hardened, the positions of the nozzles 14 or the work table 19 are set on the hardened surface by the nozzle position controller 12 and the work table position controller 1.
Molded product 22 cured as shown in FIG.
The liquid resin material 21 is newly sent on top and laminated.
After the liquid resin material 21 is laminated, it is cured to repeat the steps of laminating and curing the liquid resin material 21 to form the three-dimensional molded product 22 having a desired shape. A specific example of the liquid resin material 21 used is a one-liquid silicone compound.

Embodiment 2. FIG. 3 is a diagram showing the structure of a three-dimensional molding apparatus according to another embodiment of the present invention. In this embodiment, the flow rate control unit 11a and the flow rate control valve 15
a, a pump 16a, an electric motor 17a, and a material tank 18a are additionally provided as one set of material supplying means, and the liquid resin material 21 and the material 21a are controlled while being controlled by the computer 10.
It is also possible to form a three-dimensional molded product by using a two-component epoxy resin or the like as a material by mixing and sending out, and further, if the material 21a is used as a pigment and mixed, coloring can be easily performed.

Embodiment 3. In the above embodiment, an example in which the liquid resin material 21 is laminated and cured in one stage has been described, but in this embodiment, the liquid resin material 21 is laminated on the work table 19 as shown in FIG. A stacking stage 190 and a curing stage 191 for curing are provided. Then, after the liquid resin material 21 has been stacked on the stacking stage 190, the work table 19 is rotated about the rotary shaft 23, and the work table 19 is moved to the hardening stage 191 to carry out the hardening process.

While the curing process is being carried out at the curing stage 191, another molded product 2 is produced at the lamination stage 190 on the opposite side.
Lamination can be performed on the two. Work table 1
By configuring 9 as described above, it is possible to perform a laminating process on another molded article 22 while curing the molded article 22, so that curing and lamination of the molded article 22 can be performed at the same time. There is a merit that the property is improved. In the curing stage 191, as a means for curing the molded product 22, a method suitable for the material to be used such as natural standing, humidification, ultraviolet irradiation, and heating can be adopted.

Further, although the work table 19 which is rotated in the horizontal direction is shown in FIG. 4, as shown in FIG.
4 and the rotary link 25, the work table 19 may be configured to rotate in the vertical direction around the rotary shaft 24, and the same effect can be obtained. Further, in FIGS. 4 and 5, two stages 19 are provided on one work table 19.
Although 0 and 191 are provided, the number of stages of the work table may be three or more, and a considerable effect can be obtained. Other stages include a resin material activation stage for activating the surface of the cured molded article to increase the bonding strength, and a flattened surface of the cured molded article, as described in the fifth to seventh embodiments. Examples include a resin material smoothing stage, a resin material coating stage for applying a conductive coating material to the surface of a cured molded article, etc. (both not particularly shown).

Fourth Embodiment Further, in each of the above-described embodiments, the work table 19 and the nozzle 14 are always in a vertical positional relationship, but as shown in FIG. 6A, the work table 19 is provided with a tilting mechanism 26 which is a tilting means. By rotating the rotary shaft 26a of the above and tilting the work table 19 by a desired angle, it is possible to form the molded product 22 with a higher degree of freedom. Further, as shown in FIG. 6B, the nozzle 14 may be provided with an inclining mechanism 27 which is an inclining means, and the rotation shaft 27a of the inclining mechanism 27 may be rotated to incline the nozzle 14 by a desired angle. Can be obtained.

Embodiment 5. FIG. 7 is a diagram showing steps in a three-dimensional molding method according to another embodiment of the present invention. Conventionally, in order to obtain a desired molded article 22, a liquid resin material 21 is laminated on the molded article 22 and the laminated molded article 2
2 is cured, and then the step of laminating the liquid resin material 21 again on the cured molded article 22 is repeated to laminate the layers formed of the liquid resin material 21 one by one, but as shown in FIG. In this embodiment, a step of activating the material surface of the cured molding 22 is added. That is, the liquid resin material 21 is laminated on the molded article 22 (step S1), the laminated molded article 22 is cured (step S2), and the surface of the cured molded article 22 is activated (step S3), and thereafter. This is repeated by returning to the laminating step of step S1.

Conventionally, there was a problem in that the bonding strength between layers was weak when laminating, but the molded product 22
By activating the surface of (3), there is an effect that a strong bond is obtained between the layers and a three-dimensional molded product 22 excellent in material strength is obtained. Examples of the activation method include coating with a chemical agent called a primer, ultraviolet irradiation, corona discharge, flame radiation and the like.

Sixth Embodiment Although the activation step is provided in the fifth embodiment, in the three-dimensional molding method according to another embodiment of the present invention shown in FIG. 8, lamination (step S1) → curing
The process of (step S2) → smoothing (step S4) is repeated. In the smoothing step (step S4), the surface between the laminated layers of the molded product 22 is cut with a blade to smooth it, so that the three-dimensional molded product 22 having excellent shape accuracy can be formed.

Embodiment 7. In the three-dimensional molding method according to another embodiment of the present invention shown in FIG. 9, the process of stacking (step S1) → curing (step S2) → painting (step S5) is repeated. Resin material painting process
In (step S5), a three-dimensional molded article 22 having a conductive layer can be formed by applying a conductive coating material in which a metal powder is mixed into the coating material to the surface of the layers to be laminated.

[0041]

As described above, according to the present invention, a delivery nozzle for continuously delivering a viscous liquid resin material in a line shape and the fed line-shaped liquid resin material are laminated to obtain a desired shape. A work table for forming a three-dimensional molded article and a curing device are provided, and the work table
The line sent from the above-mentioned sending nozzle to the cable
Laminating stage, which laminates liquid resin material in the shape of
The curing stage that cures the materials
A plurality of stages including an activation stage that activates the surface.
Since over di is provided, it is sending a relatively high liquid resin material viscosity linearly from the nozzle, to provide a three-dimensional molding apparatus capable of forming a three-dimensional molded article of a desired shape which are laminated, further A strong bond between the layers is obtained, and the material strength is excellent.
We can provide 3D molding equipment that can form 3D molded products.
Effects such as that can be obtained.

Further, according to the present invention, since the thickness adjusting means for changing the thickness of the line-shaped liquid resin material is further provided, the thickness of the liquid resin material to be laminated can be adjusted, and the speed of forming a three-dimensional molded product can be increased. It is possible to obtain an effect that a three-dimensional molding apparatus capable of achieving the above can be provided.

Further, in the present invention, the thickness adjusting means includes a nozzle diameter control means for changing the diameter of the delivery nozzle, and a liquid resin material flow rate control means for controlling the amount of the liquid resin material fed into the delivery nozzle. Since it is made of, the liquid resin material having a relatively high viscosity is sent out in a line from the nozzle, and the thickness of the laminate can be adjusted by changing the feed amount of the resin material to the nozzle and the nozzle diameter of this nozzle, It is possible to obtain an effect such as providing a three-dimensional molding apparatus that can speed up the formation of a three-dimensional molded article.

Further, according to the present invention, since a plurality of material supplying means for supplying a plurality of materials including the above-mentioned liquid resin material to the above-mentioned delivery nozzles respectively are provided, a two-liquid epoxy resin or the like is used as a liquid resin material to form a tertiary resin. The original molded product can be formed, and if one material is a pigment, it is possible to provide a three-dimensional molding device that can be colored easily.

Further, according to the present invention, since the work table is rotated to switch the stages, it is possible to perform a plurality of processes at the same time, and it is possible to provide a three-dimensional molding apparatus with improved productivity. To be

[0046]

Further, according to the present invention, since the work table includes the smoothing stage for flattening the surfaces of the laminated materials, it is possible to provide a three-dimensional molding apparatus capable of forming a three-dimensional molded product having excellent shape accuracy. The effect of is obtained.

Further, in the present invention, since the work table includes a coating stage for conducting the conductive coating on the surfaces of the laminated materials, a three-dimensional molding apparatus capable of forming a three-dimensional molded product having a conductive layer is formed. Can be provided.

Further, according to the present invention, the inclination means for inclining the work table or the delivery nozzle is provided to change the angle of the delivery nozzle with respect to the three-dimensional formed article formed on the work table. It is possible to obtain an effect such that a three-dimensional molding apparatus having an improved degree of freedom in forming can be provided.

Further, according to the present invention, there is provided a three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously sending out a viscous liquid resin material in a line form from a sending-out nozzle and laminating it. From the above liquid resin material to laminate one layer of a molded article, a resin material curing step of curing the laminated portion, and an activity to increase the bonding strength of the surface of the cured molded article. Since the resin material activation step to be activated is sequentially repeated, it is possible to provide a three-dimensional molding method capable of forming a three-dimensional molded product having a strong bond between layers and excellent material strength. .

Further, according to the present invention, there is provided a three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously sending out a viscous liquid resin material in a line form from a sending nozzle and laminating the resinous material. From the above liquid resin material to laminate one layer of the molded article, a resin material curing step to cure the laminated portion, and a resin material smoothing to flatten the surface of the cured article Since the steps are repeated in order, it is possible to obtain an effect such as providing a three-dimensional molding method capable of forming a three-dimensional molded product having excellent shape accuracy.

Further, according to the present invention, there is provided a three-dimensional molding method in which a viscous liquid resin material is continuously fed in a line form from a delivery nozzle and laminated to form a three-dimensional molded product having a desired shape. A resin material laminating step of sending out the liquid resin material from the above to laminate one layer of a molded article, a resin material curing step of curing the laminated portion, and a resin for applying a conductive paint to the surface of the cured molded article. Since the material coating step is repeated in order, it is possible to provide an effect such as providing a three-dimensional molding method capable of forming a three-dimensional molded article having a layer having conductivity.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a three-dimensional molding apparatus according to an embodiment of the present invention.

FIG. 2 is a perspective view showing a state in which a three-dimensional molded product is formed on a work table by the three-dimensional molding apparatus of FIG.

FIG. 3 is a diagram showing a configuration of a three-dimensional molding apparatus according to another embodiment of the present invention.

FIG. 4 is a diagram showing a configuration of a work table of a three-dimensional molding apparatus according to another embodiment of the present invention.

FIG. 5 is a diagram showing a configuration of a work table of a three-dimensional molding apparatus according to another embodiment of the present invention.

FIG. 6 is a diagram showing a configuration of a work table and a nozzle of a three-dimensional molding apparatus according to another embodiment of the present invention.

FIG. 7 is a diagram showing steps of a three-dimensional molding method according to another embodiment of the present invention.

FIG. 8 is a diagram showing steps of a three-dimensional molding method according to another embodiment of the present invention.

FIG. 9 is a diagram showing steps of a three-dimensional molding method according to another embodiment of the present invention.

FIG. 10 is a diagram showing a configuration of a conventional three-dimensional molding apparatus.

FIG. 11 is a diagram showing a molding process of a conventional three-dimensional molding apparatus.

FIG. 12 is a diagram showing a molding process of a conventional three-dimensional molding apparatus.

FIG. 13 is a diagram showing a molding process of a conventional three-dimensional molding apparatus.

FIG. 14 is a diagram showing a molding process of a conventional three-dimensional molding apparatus.

[Explanation of symbols]

10 computer, 11 and 11a flow rate control unit, 12
Nozzle position control unit, 13 work table position control unit, 14 delivery nozzle, 14a member, 15, 15
a Flow control valve, 16, 16a Pump, 17, 17a
Electric motor, 18, 18a material tank, 19 work table, 20 material curing propulsion device, 21 liquid resin material,
21a material, 22 three-dimensional molded product, 23, 24, 26
a, 27a rotary shaft, 25 rotary link, 26, 27
Inclination mechanism, 41 nozzle diameter control unit, 190 laminating stage, 191 curing stage, CAD CAD system.

─────────────────────────────────────────────────── ─── Continuation of front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) B29C 67/00

Claims (11)

(57) [Claims] 1. A delivery nozzle for delivering a viscous liquid resin material continuously in a line shape, and a line-shaped liquid resin material thus delivered are laminated to form a three-dimensional molded product having a desired shape. Equipped with a work table and a curing device, and sent to the work table from the delivery nozzle
Stage for laminating the line-shaped liquid resin material
And a curing stage for curing the laminated materials,
And an activation stage for activating the surface of the processed material.
A three-dimensional molding apparatus having a plurality of stages . 2. The three-dimensional molding apparatus according to claim 1, further comprising thickness adjusting means for changing the thickness of the linear liquid resin material. 3. The thickness adjusting means comprises a nozzle diameter control means for changing the diameter of the delivery nozzle, and a liquid resin material flow rate control means for controlling the amount of the liquid resin material fed into the delivery nozzle. Item 3. The three-dimensional molding apparatus according to Item 2. 4. The three-dimensional structure according to claim 1, further comprising a plurality of material supply means for supplying a plurality of materials including the liquid resin material to the delivery nozzle. Molding equipment. 5. A stay is provided by rotating the work table.
5. The method according to any one of claims 1 to 4, characterized in that
The three-dimensional molding apparatus according to the above description. Wherein the work table, the three-dimensional molding apparatus according to claim 1 or 5, characterized in that it comprises a smoothing stage to flatten the laminated surface of the material. 7. The work table is a three-dimensional molding apparatus according to claim 1 or 5, characterized in that it comprises a coating stage for performing a conductive coating on the laminated surface of the material. 8. An inclination means for inclining the work table or the delivery nozzle to change an angle of the delivery nozzle with respect to a three-dimensional molded article formed on the work table.
7. The three-dimensional molding apparatus according to any one of 7 . 9. A three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously feeding a viscous liquid resin material in a line from a delivery nozzle and laminating the liquid resin material.
A resin material laminating step of delivering the liquid resin material from the delivery nozzle to laminate one layer of the molded article, a resin material curing step of curing the laminated portion, and a bonding strength of the surface of the cured article A three-dimensional molding method, characterized in that a resin material activation step of activating the resin material is repeatedly performed in order. 10. A three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously feeding a viscous liquid resin material in a line form from a delivery nozzle and laminating the liquid resin material from the delivery nozzle. A resin material laminating step of sending out a resin material to laminate one layer of a molded article, a resin material curing step of curing the laminated portion, and a resin material smoothing step of flattening the surface of the cured molded article. A three-dimensional molding method characterized in that it is carried out repeatedly in order. 11. A three-dimensional molding method for forming a three-dimensional molded product having a desired shape by continuously feeding a viscous liquid resin material in a line form from a delivery nozzle and laminating the liquid resin material from the delivery nozzle. A resin material laminating step of sending out a resin material to laminate one layer of a molded article, a resin material curing step of curing the laminated portion, and a resin material coating step of applying a conductive paint to the surface of the cured molded article. A three-dimensional molding method, characterized in that the steps 1 and 2 are repeated in order.