JP4128292B2 - Stereolithography method and apparatus manufactured by the processing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an optical modeling processing method and an apparatus manufactured by the processing method.
[0002]
[Prior art and problems]
For example, as a general method of constructing a mechanical device or a fluid device by incorporating a mechanical component such as a gear or a fluid element such as a turbine or a filter into a resin case, a split case that is pre-molded with resin is prepared. After a mechanical part or fluid element is assembled in the split mold case, the other split mold case is attached and fixed to one split mold case.
[0003]
However, in the case of such a method, when the split mold case, the machine part, or the like has a very complicated shape, the shape of the molding die becomes complicated and the cost increases. In addition, when the apparatus main body has a complicated shape that is difficult to assemble by the above method, the assembly by the above method cannot be performed.
[0004]
Furthermore, if the device itself is a small device that constitutes a micromachine, the mechanical parts and fluid elements are also very small, so a microscope must be used to assemble the device, and the order of microns Super-precision assembly work is required, and assembly is not easy. Further, when a gap is formed on the mating surface of each split case, there is a risk that the lubricant or fluid inside the case may leak out of the case through this gap during operation.
[0005]
The present invention has been made to solve such a conventional problem, and an object of the present invention is to make it possible to inexpensively manufacture a complicated shape in an apparatus in which an object is accommodated. Another object of the present invention is to make it possible to easily manufacture a device having a shape, structure, or size that is difficult to assemble in the apparatus. Another object of the present invention is to reliably prevent leakage of lubricant and fluid to the outside in the apparatus.
[0006]
[Means for Solving the Problems]
The optical modeling processing method according to the invention of claim 1 is an optical modeling processing method in which light is applied to a liquid photo-curing resin to cure the photo-curing resin into a desired shape. Then, the rotating body or sliding body for micromachine is placed on the cured photocuring resin, and the curing process is continued from this state, so that the rotating body or sliding body for micromachine is cured with the cured photocuring resin. It is characterized by being supported so as to be rotatable or slidable.
[0007]
According to a second aspect of the present invention, in the first aspect, the rotating body is a turbine or a gear.
[0008]
The optical modeling processing method according to the invention of claim 3 is an optical modeling processing method in which light is applied to a liquid photo-curing resin to cure the photo-curing resin into a desired shape. The micromachine sensor or circuit element is placed on the cured photo-curing resin, and the curing process is continued from this state, thereby fixing the micro-machine sensor or circuit element with the cured photo-curing resin. It is characterized by doing so.
[0009]
An apparatus according to the invention of claim 4 is an apparatus manufactured by using an optical modeling method for curing a photo-curing resin into a desired shape by irradiating the liquid photo-curing resin with light, and photo-curing During the resin curing process, the rotating body or sliding body for micromachine is placed on the cured photo-curing resin, and the curing process is continued from this state. It is characterized by being supported rotatably or slidably by a cured photo-curing resin .
[0010]
According to a fifth aspect of the present invention, in the fourth aspect, the rotating body is a turbine or a gear.
[0011]
The stereolithography method according to the invention of claim 6 is a stereolithography method in which light is applied to a liquid photocurable resin to cure the photocurable resin into a desired shape. The micromachine sensor or circuit element is placed on the cured photo-curing resin, and the curing process is continued from this state to fix the micro-machine sensor or circuit element with the cured photo-curing resin. It is characterized by having.
[0012]
In the present invention, during the curing process of the photo-curing resin, the irradiation of light is temporarily interrupted, or an object is placed on the cured photo-curing resin using the interval between the light irradiations, and the curing process is started from this state. The remaining portion of the photo-curing resin is cured. As a result, even if the entire apparatus has a complicated shape, it can be manufactured at low cost without the need for a molding die.
[0013]
Further, since an arbitrary portion of the photo-curing resin can be cured, it has a shape and structure that is difficult to assemble by a conventional method, and can be easily manufactured. Furthermore, since the size of the device to be manufactured is not limited, even a small device that constitutes a micromachine can be easily manufactured.
[0014]
In addition, since all of the cured photo-curing resin portion is integrally formed, it is possible to reliably prevent the internal lubricant and fluid from leaking to the outside.
[0015]
In the invention of claim 1 or 4, the object placed on the cured photo-curing resin is a rotating body or a sliding body for a micromachine. In the invention of claim 3 or 6, a sensor for a micromachine is used. Or circuit elements such as electric circuits and electronic circuits.
[0016]
The rotating body may be a turbine or a gear as described in the invention of claim 2 or 5 .
[0017]
DETAILED DESCRIPTION OF THE INVENTION
[First Embodiment]
The stereolithography method according to the first embodiment of the present invention will be described with reference to FIGS. Here, the case where the apparatus by which a turbine is arrange | positioned inside the resin-made case comprised by hardening photocuring resin is taken as an example. FIGS. 1 to 4 are diagrams for explaining the machining process of this stereolithography method, and FIG. 5 is an overall perspective view of an apparatus manufactured by this stereolithography method.
[0018]
In this first embodiment, as an example of the stereolithography processing method, a free liquid level method without a liquid level regulating plate is used, but a liquid level regulating method using a liquid level regulating plate is adopted. Alternatively, any other method may be adopted. This also applies to the following Reference Examples 1 and 2 .
[0019]
In this case, first, liquid photo-curing resin L is placed in a container (not shown), and the stage S provided so as to be movable up and down is moved upward to obtain liquid light between the stage upper surface Sa and the liquid surface. A thin layer of curable resin L is formed. From this state, the first hardened layer 1 is formed by irradiating the liquid surface with light U to cure the photo-curing resin L (see FIG. 1).
[0020]
Next, the stage S is moved down by one step, and a thin layer of the liquid photo-curing resin L is formed again between the cured layer 1 and the liquid surface. From this state, the liquid U is irradiated with light U. Then, the second hardened layer 2 is formed (see FIG. 1). Next, the third hardened layer 3 is formed by the same operation as that for forming the hardened layer 2. However, when the hardened layer 3 is formed, the irradiation position of the light U is controlled so that a circular hole 3a is formed at the center of the hardened layer 3 as shown in FIG.
[0021]
Next, as shown in FIG. 2, a fourth hardened layer 4 having a hole 4 a at the center is formed by the same operation as that for forming the hardened layer 3.
[0022]
Then, as shown in FIG. 3, the turbine 10 is disposed on the fourth hardened layer 4. At this time, the lower part of the shaft 10 a of the turbine 10 is inserted into the holes 3 a and 4 a of the hardened layers 3 and 4.
[0023]
Next, by curing the photo-curing resin L on the front side and the back side in FIG. 3, the cured layer is sequentially stacked on the cured layer 4 to form the cured layer 5 as illustrated in FIG. 5.
[0024]
Next, cured layers 6 to 9 as shown in FIG. 4 are formed on the cured layer 5 (see FIG. 5). In this case, when the hardened layers 6 and 7 are formed, by controlling the irradiation position of the light U, the holes facing the holes 3a and 4a formed in the hardened layers 3 and 4 are formed in the hardened layers 6 and 7, respectively. 7 and the upper part of the shaft 10a of the turbine 10 is disposed in these holes (see FIG. 4).
[0025]
In this way, as shown in FIG. 5, the device (fluid device) 1 including the turbine 10 inside the resin case 20 is completed. The apparatus 1 has a through hole 1a, and a turbine 10 is rotatably disposed in the through hole 1a. In this apparatus 1, by flowing a fluid through the through hole 1a, the turbine 10 can be rotated by the fluid flow.
[0026]
Here, when it is going to manufacture the apparatus 1 using the shaping | molding die which is the conventional method, after dividing the resin case 20 into two and arrange | positioning the turbine 10 in one split mold case, the other split is performed. It is necessary to attach the mold case to one of the split mold cases.
[0027]
However, in this case, when a gap is formed on the mating surface of each split case, the fluid inside the case may leak out of the case through the gap. Further, when the apparatus itself is a small apparatus that constitutes a micromachine, the internal turbine is also very small, so that the assembly of the apparatus is not easy.
[0028]
On the other hand, in this embodiment, since all the cured photocured resin portions are integrally formed, it is possible to reliably prevent fluid leakage to the outside of the case. Even in the case of a small apparatus such as a micromachine, it is only necessary to control the light irradiation range and the like, so that it can be easily manufactured.
[0029]
Furthermore, according to this embodiment, even if the case has a very complicated shape or structure, it is possible to cure any portion of the photo-curing resin using the above-described stereolithography method. Since it is possible, the case can be easily and inexpensively manufactured.
[0030]
In addition, you may make it comprise an apparatus using a gearwheel and another movable member instead of the turbine 10. FIG. In this case, as in the case of the above-described embodiment, a complicated shape and structure can be easily and inexpensively manufactured, an arbitrary size can be manufactured, and leakage of lubricant inside the case can be prevented. It can be surely prevented.
[0031]
[ Reference Example 1 ]
The stereolithography method according to the reference example of the present invention will be described with reference to FIGS. Here, the case where the apparatus by which a filter is arrange | positioned inside the resin-made case comprised by hardening photocuring resin is taken as an example. 6 to 9 are diagrams for explaining the processing process of this stereolithography method, and FIG. 10 is an overall perspective view of an apparatus manufactured by this stereolithography method. In these drawings, the same reference numerals as those in the first embodiment denote the same or corresponding parts.
[0032]
In this case, similarly to the case of the first embodiment, the stage S is moved upward in the liquid photo-curing resin L accommodated in a container (not shown), and the stage upper surface Sa and the liquid level are A thin layer of liquid photo-curing resin L is formed between them. And the hardened layer 31 of the 1st layer is formed by irradiating the liquid surface with the light U and hardening the photocurable resin L (refer FIG. 6). When the hardened layer 31 is formed, the irradiation range of the light U is controlled so that a hardened layer having a rectangular shape in plan view is formed as shown in FIG.
[0033]
Next, the stage S is lowered by one step to form a thin layer of the liquid photo-curing resin L between the first-layer cured layer 31 and the liquid surface, and from this state, the liquid surface is irradiated with light U. Thus, the second hardened layer 31 is formed (see FIGS. 6 and 7). In the same manner, the third to fifth hardened layers 31 are formed. In this way, the laminated body 30 of the hardened layer 31 is formed on the stage S.
[0034]
Next, as shown in FIG. 8, the filter F is placed on the fifth hardened layer 31. From this state, the laminated body 30 'of the hardened layer 32 is formed on the upper surface of the filter F by the same operation as that for forming the laminated body 30 composed of the plurality of hardened layers 31 (see FIGS. 9 and 10). .
[0035]
In this way, as shown in FIG. 10, a device (fluid device) 40 in which the filter F is fitted in the longitudinal center portion of the resin case 41 is manufactured. The device 40 has a through hole 40a, and the fluid can be filtered by flowing the fluid into the through hole 40a.
[0036]
Here, when the apparatus 40 is manufactured using a molding die which is a conventional method, two parts of the laminate 30 and the laminate 30 ′ are manufactured as the resin case 41, and a filter is formed in these parts. It is necessary to sandwich and fix F.
[0037]
However, in this case, as in the case of the first embodiment, when gaps are formed on the mating surfaces of the parts, the fluid inside the case may leak out of the case from the gaps. is there. Further, when the device itself is a small device constituting a micro machine, the filter is very small, and the assembly of the device is not easy.
[0038]
On the other hand, in this reference example , the laminates 30 and 30 ′ are integrally formed with the filter F interposed therebetween, so that fluid leakage to the outside of the case can be reliably prevented. Further, even in the case of a small apparatus such as a micromachine, it is only necessary to control the light irradiation range and the like, so that it can be easily manufactured.
[0039]
Furthermore, according to this reference example , even if the case has a very complicated shape or structure, it is possible to cure any portion of the photo-curing resin using the above-described stereolithography method. Since it is possible, the case can be easily and inexpensively manufactured.
[0040]
[ Reference Example 2 ]
The stereolithography method according to Reference Example 2 of the present invention will be described with reference to FIGS. Here, as in the case of Reference Example 1, a case where a device in which a filter is arranged inside a resin case configured by curing a photo-curing resin is taken as an example. Shows an example in which a cured layer of a photocurable resin is laminated in the longitudinal direction of the case, whereas in Reference Example 2 , the cured layer of the photocurable resin is laminated in a direction perpendicular to the longitudinal direction of the case. This is different from the reference example 1 in that an example to be performed is shown.
[0041]
FIGS. 11 to 13 are diagrams for explaining the machining process of this stereolithography method, and FIG. 14 is an overall perspective view of an apparatus manufactured by this stereolithography method. In these drawings, the same reference numerals as those in the reference example 1 denote the same or corresponding parts.
[0042]
In this case, first, the hardened layers 35 and 36 are formed on the upper surface Sa of the stage S by the same operation as the case of forming the hardened layers 1 to 4 in the first embodiment (see FIG. 11). At this time, when the hardened layer 36 is formed, the irradiation position of the light U is controlled so that a groove 36 a extending in the direction perpendicular to the paper surface is formed at the center of the hardened layer 36.
[0043]
Next, as shown in FIG. 12, the filter F is placed in the groove 36 a of the hardened layer 36. From this state, the hardened layers 37, 38, and 39 are formed by the same operation as that for forming the hardened layers 5 to 9 in the first embodiment (see FIGS. 13 and 14). At this time, when the hardened layer 38 is formed, by controlling the irradiation position of the light U, a groove facing the groove 36a formed in the hardened layer 36 is formed in the hardened layer 38, respectively. The upper part of the filter F is arranged in these grooves (see FIGS. 13 and 14).
[0044]
In this way, as shown in FIG. 14, a device (fluid device) 40 'in which the filter F is embedded in the resin case 41' is manufactured. The device 40 'has a through hole 40'a, and the fluid can be filtered by flowing a fluid through the through hole 40'a.
[0045]
Here, when the apparatus 40 'is manufactured using a conventional molding die, two split mold parts are manufactured as the resin case 41', and the filter F is set in one split mold part. Then, it is necessary to fix the other split mold part to one split mold part.
[0046]
However, in this case, when a gap is formed on the mating surface of each split mold portion, the fluid inside the case may leak out of the case from the gap portion. Further, when the device itself is a small device constituting a micro machine, the filter is very small, and the assembly of the device is not easy.
[0047]
On the other hand, in this reference example 2 , since all the parts of the cured photo-curing resin are integrally formed, it is possible to reliably prevent the leakage of fluid to the outside of the case. Further, even in the case of a small apparatus such as a micromachine, it is only necessary to control the light irradiation range and the like, so that it can be easily manufactured.
[0048]
Furthermore, according to this reference example 2 , even if the case has a very complicated shape or structure, any portion of the photo-curing resin is cured using the above-described stereolithography method. Therefore, the case can be easily and inexpensively manufactured.
[0049]
The filter mounting direction with respect to the case is not limited to the direction orthogonal to the fluid flow, as shown in Reference Examples 1 and 2, and may be arranged obliquely with respect to the fluid flow. Good.
[0050]
[Other Embodiments]
In the reference examples 1 and 2 , the case where a device including a filter is manufactured has been described as an example, but the device may be configured using a sensor instead of the filter. Further, the apparatus may be configured using circuit elements of an electric circuit or an electronic circuit instead of the filter.
[0051]
In this case, as in the case of Reference Examples 1 and 2 , a complicated shape and structure can be manufactured easily and inexpensively, and an arbitrary size can be manufactured. In addition, in this case, since the photo-curing resin is generally an insulating resin, it is particularly suitable as a holding member for the circuit element.
[0052]
Furthermore, the present invention can be similarly applied to the production of an apparatus including an arbitrary member in addition to a functional material and a chemical substance.
[0053]
【The invention's effect】
As described above in detail, according to the present invention, during the curing process of the photocurable resin, the object is placed on the cured photocurable resin, and the curing process is continued from this state. Accordingly, even if the apparatus itself has a complicated shape, there is an effect that it can be manufactured at low cost without requiring a molding die. In addition, since any portion of the photo-curing resin can be cured, it has a shape and structure that is difficult to assemble and can be easily manufactured. In addition, since the size of the device to be manufactured is not limited, an apparatus having an arbitrary size can be easily manufactured. Furthermore, since all the cured photo-curing resin portions are integrally formed, there is an effect that the internal lubricant and fluid can be surely prevented from leaking.
[Brief description of the drawings]
FIG. 1 is a view for explaining a machining process using an optical modeling method according to a first embodiment of the present invention.
FIG. 2 is a view for explaining a machining process using an optical modeling method according to the first embodiment of the present invention.
FIG. 3 is a view for explaining a processing process using an optical modeling processing method according to the first embodiment of the present invention.
FIG. 4 is a view for explaining a machining process using an optical modeling method according to the first embodiment of the present invention.
FIG. 5 is a view showing a manufacturing example of a turbine apparatus manufactured by using an optical modeling method according to the first embodiment of the present invention.
FIG. 6 is a view for explaining a machining process using an optical modeling method according to the second embodiment of the present invention.
FIG. 7 is a view for explaining a processing process using an optical modeling method according to the second embodiment of the present invention.
FIG. 8 is a view for explaining a machining process using an optical modeling method according to the second embodiment of the present invention.
FIG. 9 is a view for explaining a processing process using an optical modeling method according to the second embodiment of the present invention.
FIG. 10 is a view showing a manufacturing example of a filter device manufactured using an optical modeling method according to the second embodiment of the present invention.
FIG. 11 is a diagram for explaining a machining process using an optical modeling method according to the third embodiment of the present invention.
FIG. 12 is a diagram for explaining a machining process using an optical modeling method according to the third embodiment of the present invention.
FIG. 13 is a view for explaining a processing process using an optical modeling method according to the third embodiment of the present invention.
FIG. 14 is a view showing a manufacturing example of a filter device manufactured using an optical modeling method according to the third embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Apparatus 1a Through-hole 3a, 4a Circular hole 10 Turbine 10a Shaft 20 Case 31, 32 Hardened layer 35, 36 Hardened layer 37, 38, 39 Hardened layer 36a Groove 40, 40 'Device 40a, 40'a Through-hole 41, 41 'Case L Liquid photo-curing resin U Light S Stage F Filter (1) to (9) Cured layer

Claims (6)

In the optical modeling processing method of irradiating a liquid photocurable resin with light and curing the photocurable resin into a desired shape,
During the curing process of the photo-curing resin, the rotating body or sliding body for micromachine is placed on the cured photo-curing resin, and the curing process is continued from this state , whereby the rotating body or sliding body for the micromachine is used. , To be supported rotatably or slidable with a cured photo-curing resin ,
A stereolithography method characterized by that. The rotating body is a turbine or a gear;
The optical modeling processing method according to claim 1. In the optical modeling processing method of irradiating a liquid photocurable resin with light and curing the photocurable resin into a desired shape,
During the curing process of the photo-curing resin, the micro-machine sensor or circuit element is placed on the cured photo-curing resin, and the curing process is continued from this state. It was fixed with a cured photo-curing resin.
A stereolithography method characterized by that. An apparatus manufactured using an optical modeling method for curing a photo-curing resin into a desired shape by irradiating light to the liquid photo-curing resin,
During the curing process of the photo-curing resin, the rotating body or sliding body for micromachine is placed on the cured photo-curing resin, and the curing process is continued from this state , whereby the rotating body or sliding body for the micromachine is used. Is a device that supports a curable resin in a rotatable or slidable manner . The rotating body is a turbine or a gear;
The apparatus according to claim 4. In the optical modeling processing method of irradiating a liquid photocurable resin with light and curing the photocurable resin into a desired shape,
During the curing process of the photo-curing resin, the micro-machine sensor or circuit element is placed on the cured photo-curing resin, and the curing process is continued from this state. A device fixed with a cured photo-curing resin.

Images