JP6506926B2 - Three-dimensional model - Google Patents

Description

  The present invention relates to an arbitrary-shaped three-dimensional structure realized by combining the additive manufacturing technology and the thermal spraying technology.

  Lamination molding technology is known as a technology for producing a three-dimensional structure of arbitrary shape. The additive manufacturing technology processes three-dimensional shape data of an article into thin layered slice data, identifies the cross-sectional shape and relative position of each layer, and sequentially layers each layer to form an arbitrary three-dimensional shape. There are an optical molding method, a powder sintered lamination molding method (SLS method), a binder jet method (so-called 3D printing), a melt deposition method (FDM method), an inkjet method, a sheet lamination method and the like. It should be noted that the term 3D printer usually refers to devices that are specialized for relatively inexpensive model-building applications, regardless of these modeling methods.

  According to the additive manufacturing technology, it is also easy to produce a replica of an existing article of any shape. Therefore, in order to manufacture a lightweight replica, the external shape of the target article is faithfully copied by the SLS method of additive manufacturing technology, and the inside of the target article is hollowed out, as an internal structural pattern for weight reduction in the hollow. For example, a method of incorporating a honeycomb structure pattern or the like has been proposed (Patent Document 1).

JP 2004-34298 A

  According to the prior art, since metal powder is used as a laminate material by the SLS method, the laminate molding apparatus is expensive, and a cavity having an internal structure pattern is used to reduce the weight of the replica, so the cavity and the internal structure are reduced. There is a problem that special design steps for optimizing the pattern are indispensable and complicated.

  Therefore, in view of the problems of the prior art, an object of the present invention is to realize a good appearance and texture while being lightweight, by combining a lamination molding technology using a nonmetallic laminate material and a thermal spraying technology. An object of the present invention is to provide a three-dimensional structure which can easily realize durability, wear resistance, conductivity and the like as needed.

  The configuration of the present invention for achieving such an object comprises a three-dimensional base material formed by laminating and forming a nonmetallic laminated material, and a metal film formed by spraying zinc on the surface of the base material. The metal film has a film thickness of 100 to 200 μm that is equivalent to 1 to 2 times the lamination pitch of the base material, thereby enabling the finishing process by polishing as a metal film for decorating the surface layer, The gist of the invention is that it can also be used as an underlying metal film for forming a top coat of another thermal spray material on the upper surface by thermal spraying.

  According to the configuration of the invention, since the three-dimensional base material is formed by laminating and forming a non-metallic laminated material such as paper, resin, gypsum and the like, it realizes an arbitrary three-dimensional shape and itself It can be lightweight enough. On the other hand, the metal coating formed by spraying zinc on the surface of the base material may itself be used as a metal coating for decorating the surface layer, and is for forming a top coat of other thermal spray materials on the top surface You may utilize as a base metal film (undercoat). The film thickness of the metal film is preferably 100 to 200 μm. While filling the level difference of about 0.1 mm of the lamination pitch of the base material, it is possible to finish the metal film for decoration or to reduce the thermal influence on the base material when the top coat is sprayed. Even if the film thickness is more than 200 μm, no particular effect is obtained only by prolonging the spraying time.

  The top coat on the upper surface of the metal coating is formed by flame spraying a thermal spray material such as ceramic, metal such as aluminum, copper and tin, nylon resin, or thermal spray of a conductive metal wire such as stainless steel or aluminum The material is arc sprayed to form. In the case of flame spraying a ceramic or metal spray material, it is preferable to flame spray NiAl on the top surface of the metal film to form a bond coat prior to that. The film thickness of the top coat is preferably about 100 μm to 100 μm or more, and the film thickness of the bond coat is preferably about 50 μm.

  The surface finish of the top coat can be achieved by polishing with sand paper, brush, barrel, buff, etc. when the top coat is metal, and good metallic luster can be realized, and when the top coat is nylon resin, it can be a torch etc. Preferably, the resin film is melted and melted. When the top coat is ceramic or metal, a sealing agent such as an epoxy resin may be applied to improve the durability, or it may be finished by painting.

  When the top coat is omitted and the metal film of zinc is used as it is as the metal film for decoration, the same finishing treatment as the metal top coat can be applied. However, the metal coating for decorating zinc, or the top coat such as ceramic, metal, resin, etc. may be a sprayed coating as it is without a special finishing treatment.

  The three-dimensional structure according to the present invention can be easily manufactured. However, the metal coating formed on the surface of the base material does not have the possibility of burning or burning the surface of the base material by arc spraying zinc. A top coating can be formed by flame spraying a ceramic, metal, nylon resin, or other thermal spray material on the top surface of the metal coating, and arc thermal spray of a conductive metal wire to form a top coat. You can also.

  However, when flame-spraying a ceramic or metal as a thermal spray material for top coat, it is preferable to form a bond coat on the upper surface of the metal film prior to that. In addition, if the surface of the base material is subjected to a blast treatment to arc spray zinc, the anchor effect of the metal film can be enhanced.

  In addition, flame spraying is a kind of gas thermal spraying, and refers to a thermal spraying method that uses a gas flame such as a combustion flame of an oxygen / acetylene mixed gas as a heat source for thermal spraying, and jets of compressed air to accelerate thermal spray particles. The thermal spray material may be any of powder, linear, rod-like powder type, wire-type and rod-type flame spray, as well as high-speed flame spray to be used.

A schematic cross-sectional view of a three-dimensional object Explanation chart of finishing process Manufacturing process chart

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  The three-dimensional structure 10 comprises a three-dimensional base material 11, a zinc metal coating 12 formed on the surface of the base material 11, and a top coat 13 formed on the upper surface of the metal coating 12 (FIG. 1) .

  The base material 11 is formed into an arbitrary three-dimensional shape by laminating and modeling non-metallic laminated materials such as paper, resin, gypsum and the like. That is, the base material 11 is integrally solidified while sequentially laminating the layers 11a, 11a. However, the base material 11 may be solid or may have a hollow portion inside.

  The metal coating 12 is formed by arc spraying a thermal spray material of zinc on the surface of the base material 11. The metal film 12 has a thickness of 100 to 200 μm.

  The top coat 13 is formed on the upper surface of the metal coating 12 by flame spraying any thermal spraying material such as ceramic, metal, nylon resin or the like, or arc spraying a thermal spraying material of conductive metal wire. However, when flame spraying a ceramic or metal thermal spray material, Ni Al is flame sprayed on the top surface of the metal coating 12 prior to that, and a bond coat of about 50 μm thickness is formed on the metal coating 12 and the top coat 13. Be intervened between

  The surface of the top coat 13 may be a thermal spray coating as it is or may be subjected to an appropriate finishing treatment (FIG. 2). That is, when the thermal spray material of the top coat 13 is a metal, a good metallic luster can be realized by polishing treatment, and in the case of a ceramic or a metal, a sealing agent is applied and a paint finish is used as needed. Thus, the durability can be particularly improved outdoors, and in the case of a resin, sealing and fusion of the film can be achieved by a fusing process using a torch.

  On the other hand, in FIG. 1, the top coat 13 may be omitted, and the metal film 12 may be a metal film for decorating the surface layer. Also, the metal coating at this time may be a thermal spray coating as it is, as with the top coat 13, and may be subjected to an appropriate finishing treatment. Further, in FIG. 1, the metal film 12 and the top coat 13 may be formed only on a part of the surface of the base material 11 instead of forming the entire surface of the base material 11.

  The manufacturing procedure of the three-dimensional structure 10 is, for example, as shown in FIG.

  First, non-metallic laminated materials such as paper, resin, gypsum and the like are laminated and formed (step (1) in FIG. 3, hereinafter, simply described as (1)) to form a three-dimensional base material 11. In addition, the laminate molding in step (1) can be performed by a so-called 3D printer.

  Subsequently, the surface of the base material 11 is blasted (2), and zinc is arc sprayed on the surface of the base material 11 (3) to form a metal film 12. However, the blasting treatment in step (2) may be omitted.

  Thereafter, NiAl is flame-sprayed on the upper surface of the metal coating 12 (4) to form a bond coat, and flame-spraying of any thermal spray material such as ceramic, metal such as aluminum, copper, tin, nylon resin, etc. (5) The top coat 13 is formed on the upper surface of the metal film 12. However, in the case where a nylon resin is used as the thermal spray material in step (5), the formation of the bond coat of Ni 3 Al 4 in step (4) can be omitted.

  Subsequently, an appropriate finishing process is performed depending on the material of the top coat 13 ((6), FIG. 2), and the three-dimensional structure 10 is completed. However, the finishing process of step (6) may be omitted, and the top coat 13 may be a thermal spray coating.

  On the other hand, in FIG. 3, after the formation of the metal coating 12 according to the step (3), a thermal spray material of an electrically conductive metal wire such as stainless steel or aluminum is arc sprayed on the upper surface of the metal coating 12 (7). 13 may be formed. Further, in FIG. 3, the steps (4), (5) and (7) are omitted, and the metal film 12 on the base material 11 is used as a metal film for decoration of the surface layer without finishing or finishing Processing may be performed to obtain a three-dimensional structure 10.

  The present invention can be used as a prototype of an arbitrary three-dimensional shaped product, a replica, etc., as well as a nameplate, a signboard, a display plate, etc. for displaying arbitrary characters and marks in three dimensions, or any three-dimensional figurine or decoration The present invention can be widely and suitably applied to uses for producing articles and the like.

10: Three-dimensional object 11: Base material 12: Metal film 13: Top coat

Patent applicant Houmura Sangyo Co., Ltd.

Claims (1)

A three-dimensional base material formed by laminating and forming a nonmetallic laminate material, and a metal film formed by spraying zinc on the surface of the base material , the metal film being the base material By using a film thickness of 100 to 200 μm equivalent to 1 to 2 times the lamination pitch, it is possible to perform a finishing process by polishing as a metal film for decorating the surface layer, and topcoats of other thermal spray materials on top A three-dimensional structure characterized in that it can be used as a base metal film for forming by thermal spraying .

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