TW202408785A - Optical shaping apparatus,reduction projection optical component for optical shaping apparatus, and method for manufacturing optical shaping object - Google Patents

Abstract

The optical forming device of the present invention comprises: a liquid tank storing liquid photocurable resin, a light source device in which a plurality of single pixels having partition walls and light-emitting elements accommodated in the partition walls are arranged in a regular matrix and the maximum width of the single pixel is less than 200 μm, an optical element arranged between the light source device and the liquid tank, which uses light emitted from the single pixel to form a point light irradiated to the photocurable resin and forms an exposure image in a formation area in the liquid tank through the plurality of point lights, and a resin curing layer of the photocurable resin cured through the exposure image, and a stage that supports the resin curing layer and moves in the vertical direction.

Description

Light shaping device, reduced projection optical component for light shaping device, and method for manufacturing light shaping object

The present invention relates to a light shaping device, a reduced projection optical component used in the light shaping device, and a method for manufacturing a light shaping object.

A conventional light shaping device such as International Publication No. 2018/154847 is known as a device for shaping a three-dimensional structure with a three-dimensional shape. The light shaping device of International Publication No. 2018/154847 has a light source device and an optical element that collects light emitted from the light source device. Furthermore, a container storing a liquid photocurable resin that reacts to ultraviolet rays is provided as a liquid tank.

In International Publication No. 2018/154847, a light source device has a plurality of light-emitting elements that emit ultraviolet rays, and a partition wall that serves as a partition wall to separate adjacent light-emitting elements. The partition wall and the light-emitting elements contained in the area surrounded by the partition wall form a single pixel.

In addition, in International Publication No. 2018/154847, the optical element collects ultraviolet light emitted from a single pixel to form a point light that irradiates the photocurable resin. The point light irradiates the liquid surface from the upper side of the liquid tank in a direction perpendicular to the liquid surface of the liquid tank. In addition, in this specification, the direction perpendicular to the liquid surface is also simply referred to as the "irradiation direction".

By irradiating with multiple point lights, an exposure image designed with a desired two-dimensional shape pattern is formed in the formation area in the liquid tank. By irradiating with ultraviolet rays, the photocurable resin in the formation area formed with the exposure image undergoes a photocuring reaction. As a result, a resin cured layer having a predetermined thickness and the same two-dimensional shape pattern as the exposure image is formed in the formation area.

Furthermore, the light shaping device disclosed in International Publication No. 2018/154847 is provided with a stage that supports the formed resin hardened layer from the lower side. The stage sinks into the liquid tank while maintaining the state of supporting the resin hardened layer, and at the same time, the liquid photocurable resin on the upper side of the resin hardened layer is irradiated with ultraviolet rays. By repeatedly carrying out the stage sinking and ultraviolet irradiation, a plurality of resin hardened layers are stacked in the up and down direction. As a result, a three-dimensional molded object with a desired three-dimensional shape can finally be obtained.

Patent Document 1: International Publication No. 2018/154847

[Problems to be solved by the invention]

Here, according to the research results of the inventors of this case, it is found that when the power supplied to the light-emitting element emitting ultraviolet rays is the same, the wider the maximum width of a single pixel when viewed along the irradiation direction, the lower the directivity of the irradiation light irradiating the photocurable resin in the center of the width direction of the single pixel.

In other words, the wider the maximum width of a single pixel, the more light that is directed in directions other than the irradiation direction and does not contribute to exposure increases. Therefore, in the light shaping device of International Publication No. 2018/154847, there is a concern that the efficiency of light utilization is reduced due to the maximum width of a single pixel.

In addition, in the optical forming device, if the light energy density of the exposure image in the forming area, i.e., the forming image, becomes smaller, the exposure time of the optical forming must be extended, which results in a decrease in the forming speed. In other words, there is still room for improvement in the efficiency of light utilization. In addition, in this specification, light energy density means light energy per unit area.

The present invention is made with the above situation in mind and can improve the efficiency of light utilization. [Methods for solving the problem]

Means used to solve the above problems include the following aspects.

<1> A light shaping device, including: a liquid tank that stores liquid photocurable resin; and a light source device that arranges a plurality of single pixels having partition walls and light-emitting elements accommodated in the partition walls into a regular matrix shape , the maximum width of a single pixel is less than 200 μm; the optical element is arranged between the light source device and the liquid tank, and uses the light emitted from a single pixel to form point-like light that is irradiated to the photocurable resin, and passes through a plurality of points The exposure image is formed in the area where the light-like light is formed in the liquid tank; and the stage supports the resin cured layer of the photocurable resin that is cured through the exposure image, and moves in the up and down direction.

<2> The light shaping device as described in <1> above, wherein the optical element has a microlens for collecting light emitted from a single pixel, and the distance between the microlenses is greater than the wavelength [nm] of the light source of the light-emitting element and less than the distance between the single pixels.

<3> The light shaping device according to the above <1> or <2>, wherein the optical element has a microlens that collects light emitted from a single pixel, and a plurality of microlenses are arranged for a single pixel.

<4> The light shaping device according to the above <2> or <3>, wherein the microlenses are circular in plan view, and the distance between the microlenses is at least twice the wavelength [nm] of the light source of the light-emitting element.

<5> The light shaping device as described in <1> above, wherein the optical element is an aperture having a plurality of slits for narrowing light emitted from a single pixel, and the slits are used to form point-shaped light that irradiates the photocurable resin.

<6> The light shaping device according to any one of the above <1> to <5>, wherein the light source device is disposed below the liquid tank, the resin hardened layer is supported on the bottom side of the stage, and the stage can be placed on It rises while supporting the resin hardened layer.

<7> The light shaping device according to any one of the above <1> to <6>, wherein switching elements respectively corresponding to the plurality of light-emitting elements are provided.

＜8＞A photoforming device comprises: a liquid tank storing liquid photocurable resin; a light source device having a projection surface formed by a plurality of single pixels, and projecting a forming image of N times (where N>1) the area of the photoformed object to be formed from the projection surface; a reduction projection optical component arranged between the projection surface of the light source device and the bottom surface of the liquid tank, reducing the area of the forming image to 1/M (where M>1) and projecting it onto the forming surface in the liquid tank; and a carrier supporting a resin hardening layer of the photocurable resin hardened by the forming image on the forming surface, and moving in the up-down direction.

<9> The light shaping device according to the above <8>, wherein the reduction projection optical component includes a first light condensing member disposed on the side of the light source device, and an optical axis direction of the light concentrated by the first light condensing member. An optical axis correction member for correcting the direction perpendicular to the molding surface.

<10> The light shaping device according to the above <9>, wherein the reduction projection optical component includes a second light focusing member having a refractive index greater than that of air between the first light focusing member and the optical axis correction member.

<11> The optical shaping device according to any one of the above <8> to <10>, wherein N is 3 or more.

<12> The light shaping device according to any one of the above <8> to <11>, wherein the light source device is arranged below the liquid tank; the resin hardened layer is supported on the bottom side of the stage, and the stage can be placed on It rises while supporting the resin hardened layer.

＜13＞A method for manufacturing a light-shaped object comprises the following steps: a step of projecting a shaping image with an area N times (where N＞1) of the area of the light-shaped object to be shaped from a projection surface formed by a plurality of single pixels of a light source device; and a step of reducing the area of the shaping image to 1/M (where M＞1) by using a reduction projection optical component, and projecting the reduced shaping image onto a shaping surface in a liquid tank containing liquid photocurable resin, thereby curing the photocurable resin.

<14> A reduced projection optical component for a light shaping device is used in a light shaping device, the light shaping device comprising: a liquid tank storing liquid photocurable resin; a light source device having a projection surface formed by a plurality of single pixels, and projecting a shaping image of N times (where N>1) the area of the light shaping object to be shaped from the projection surface; and a stage supporting a resin hardening layer of the photocurable resin hardened by the shaping image and moving in the up-down direction; the reduced projection optical component is arranged between the projection surface of the light source device and the bottom surface of the liquid tank, and it reduces the area of the shaping image to 1/M (where M>1) and projects it onto the shaping surface in the liquid tank. [Effect of the invention]

The present invention can improve the light utilization efficiency.

The embodiments of the present invention will be described below using the first to third embodiments. In the description of the following drawings, the same parts or similar parts are designated with the same symbols or similar symbols. However, the drawings are only schematic diagrams, and the relationship between thickness and plane size, the ratio of the thickness of each device and each member, etc. are different from reality. Therefore, the specific thickness and size should be determined with reference to the following description. In addition, each drawing also includes parts with different dimensional relationships and ratios. In addition, unless otherwise specified in the specification, the number of each component of the present invention is not limited to one, and a plurality may exist.

[First Implementation] <Light Shaping Device> First, the light shaping device 10 according to the first implementation is described with reference to FIGS. 1 to 11. As shown in FIG. 1, the light shaping device 10 includes a liquid tank 12, a stage 14, a hanging member 16 for hanging the stage 14, and a light irradiation device 20.

(Liquid tank) The liquid tank 12 has a bottom and a side wall, and is generally made of a light-transmitting material. The liquid tank 12 stores a liquid photocurable resin 18. In the present invention, it is not necessary to make the entire liquid tank light-transmitting. In the present invention, at least the portion of the bottom or side wall through which the light irradiated by the light irradiation device passes is light-transmitting.

(Carrier) The carrier 14 supports the resin hardening layer of the photocurable resin 18 hardened by the exposure image, and moves in the up and down direction in FIG. 1. That is, the carrier 14 can rise and fall while supporting the resin hardening layer. In addition, in the first embodiment, the hardened resin hardening layer is supported on the bottom side of the carrier 14 via the support pins 32. That is, in the first embodiment, the optical shaping device 10 is a hanging type 3D printer.

(Light irradiation device) The light irradiation device 20 is disposed below the liquid tank 12 in FIG. 1 and irradiates light to the bottom side of the carrier 14 through the bottom of the liquid tank 12 which is light-transmissive. In the first embodiment, the light shaping of the surface exposure method, i.e., the DLP (Digital Light Processing) method, is exemplified, but the light shaping of the present invention is not limited to the DLP method, as long as it is a surface exposure method.

The light irradiation device 20 includes a frame 22 , a light source device 24 provided inside the frame 22 , and an optical element 26 disposed between the light source device 24 and the liquid tank 12 inside the frame 22 . When manufacturing a photo-shaped object, pre-created image data for modeling is input to the light irradiation device 20 . The image data for modeling is produced by, for example, CAD software or CAM software. The light irradiation device 20 selectively irradiates the underside of the stage 14 immersed in the liquid tank 12 with light of a predetermined wavelength required for light modeling, such as ultraviolet light, based on the input image data for modeling.

(Light source device) As shown in FIG. 2 , the light source device 24 includes a substrate 24A, a partition wall 24B, a light-emitting element 24C, a sealing material 24D, and a protective layer 24E. The light source device 24 emits light from a plurality of single pixels 23 together with respect to the formation area 18A of the photocurable resin 18. In FIG. 2 , for the convenience of explanation, the illustration of the frame 22 illustrated in FIG. 1 is omitted.

(Substrate) The substrate 24A is, for example, a glass substrate or a resin substrate. The substrate 24A is provided with various circuits for driving the light-emitting element 24C, switch elements such as TFT (Thin Film Transistor), scanning lines, signal lines, power lines and other wiring. The illustrations of various circuits are omitted. In addition, FIG. 5 illustrates the switch element 36, X electrode components X1, X2 and Y electrode components Y1, Y2 described later.

(Next door to the area) The partition wall 24B is formed of, for example, a resin material or a metal material. As shown in FIG. 3 , a plurality of partition walls 24B are provided along the X direction and the Y direction. The X direction and the Y direction are orthogonal to each other. Therefore, in a plan view, the partition walls 24B in the X direction and the partition walls 24B in the Y direction present a grid shape. One light-emitting element 24C is provided in the space inside the grid surrounded by the partition wall 24B.

(Light-emitting element) The light-emitting elements 24C are arranged in a regular matrix in a top view. The light-emitting element 24C is, for example, a micro light emitting diode (microLED). The light-emitting element 24C is accommodated between the partition walls 24B and the partition walls 24B. The light-emitting element 24C emits ultraviolet light having a wavelength of about 400nm. In addition, in the present invention, the light-emitting element is not limited to a microLED, and for example, an element that emits light of a wavelength that can cure the photocurable resin 18, such as an organic LED, can be appropriately used.

In addition, the micro-LED used as the light-emitting element in the present invention is not electrically controlled. In other words, the micro LED is the light source itself that emits the light for exposure, and the emitted light of the micro LED is directly used as the light for exposure. In this regard, for example, micro-LEDs used as backlights for liquid crystal displays electrically control the amount of light passing through the liquid crystal by applying a voltage to the liquid crystal. That is to say, the use purpose and use state of the light of the light-emitting element of the present invention are different from the use purpose and use state of the light of the micro LED of the liquid crystal display.

In the first embodiment, the plurality of light emitting elements 24C arranged in a matrix are arranged to face the photocurable resin 18 in the liquid tank 12. FIG3 shows a matrix arrangement of 4 elements in the X direction and 2 elements in the Y direction, but the number and arrangement pattern of the light emitting elements in the present invention can be set arbitrarily.

(Sealing material) The sealing material 24D may be made of a light-transmissive resin such as epoxy resin or silicone resin. As shown in FIG. 2 , the sealing material 24D seals the light-emitting element 24C inside the partition wall 24B.

(Protective layer) The protective layer 24E is provided on the partition wall 24B in FIG. 2 . The protective layer 24E protects the light-emitting element 24C. The protective layer 24E can be made of, for example, a light-transmitting resin film or the like.

(Single pixel) As shown in FIG. 2 , the "single pixel 23" in the first embodiment is composed of a region including a light-emitting element 24C on the inner side and surrounded by partition walls 24B. Therefore, like the light-emitting element 24C, the single pixel 23 is arranged in a regular matrix shape in a top view.

The distance between single pixels 23 is, for example, the center distance between adjacent single pixels 23 . In addition, the distance between single pixels 23 is equal to the center distance between adjacent partition walls 24B. Furthermore, in the first embodiment, the single pixel 23 has a square shape in plan view, so the distance between the single pixels 23 is equal to the maximum width W1 of the single pixel 23 . In the first embodiment, the maximum width W1 of a single pixel 23 is set to 5 μm or more and 200 μm or less.

When the maximum width W1 of the single pixel 23 is less than 5 μm, the single pixel 23 is too small and the manufacturing cost increases. In addition, when the maximum width W1 of a single pixel 23 exceeds 200 μm, the resolution of the exposed image will be reduced. Especially from the viewpoint of improving resolution, the maximum width W1 of a single pixel 23 is preferably 100 μm or less. Furthermore, in the present invention, the maximum width W1 of a single pixel may be less than 5 μm. Furthermore, in the present invention, the maximum width W1 of a single pixel may also exceed 200 μm.

Furthermore, in the first embodiment, the maximum width W1 in the X direction is equal to the maximum width W1 in the Y direction, but the present invention is not limited thereto, and the maximum width in the X direction may be different from the maximum width in the Y direction. That is, in the present invention, the shape of a single pixel in a top view may also be a rectangle. Furthermore, the shape of a single pixel is not limited to a rectangle, and may be any geometric shape such as a circle or other polygonal shape.

(Optical element) As shown in FIG. 2 , the optical element 26 has a base 26A and a microlens 26B disposed on one side of the base 26A. In the first embodiment, the optical element 26 is disposed between the light source device 24 and the liquid tank 12 at the lower side of the liquid tank 12. The optical element 26 uses light emitted from a single pixel 23 to form a point light irradiated to the photocurable resin 18. Through a plurality of point lights, an exposure image is formed in the formation area 18A in the liquid tank 12.

(Base) The base 26A is a plate-shaped member. The base 26A can be made of a light-transmitting glass or resin material.

(Microlens) The microlens 26B can be made of a light-transmitting glass or resin material. The microlens 26B of the first embodiment serves as an optical element to collect light emitted from a single pixel 23 and form a point light that irradiates the photocurable resin 18. In addition, in the present invention, the optical element can also be other light-collecting devices such as lenses and reflectors other than microlenses.

In the first embodiment, the base 26A and the microlens 26B are integrally formed. Furthermore, in the present invention, the microlens 26B may be formed separately from the base 26A, and may be bonded to the base 26A.

As shown in FIG. 3 , the microlens 26B has a circular shape in plan view. Furthermore, as shown in FIG. 2 , the microlens 26B has a hemispherical shape protruding upward. In the first embodiment, the diameters of the microlenses 26B are all the same. Furthermore, in the present invention, the shapes and sizes of the plurality of microlenses 26B may also be different. In addition, the shapes and sizes of the plurality of microlenses 26B corresponding to a group of single pixels may also be different from each other.

The microlenses 26B are arranged in a matrix on the base 26A in a top view. In the optical element 26 illustrated in FIG3 , four microlenses 26B are arranged as one microlens array for a single pixel 23. In the present invention, the number of microlenses 26B corresponding to a single pixel can be one, or any number. In the first embodiment, as shown in FIG2 , the width W2 of one microlens array is substantially equal to the width W3 of the sealing material.

(distance between microlenses) Next, the distance between microlenses will be described. In the first embodiment, the distance between the microlenses 26B in a single pixel 23 (for example, the center distance) is set to be greater than the light source wavelength [nm] of the light-emitting element 24C and less than the distance between the single pixels 23 . If the distance between the microlenses 26B is less than the wavelength of the light source, it will be difficult to properly perform the light collecting function of the lens. On the other hand, if the distance between microlenses exceeds the distance between single pixels, the size of the microlenses will be too large, thus increasing the manufacturing cost burden.

In the first embodiment, the spacing of the microlenses 26B is set to be at least twice the wavelength [nm] of the light source of the light emitting element 24C, which is more preferable from the perspective of suppressing interference fringes. For example, if the wavelength of the light source is about 400nm, the spacing of the microlenses 26B can be set to be within a range of about 800nm or more and 1μm or less.

Furthermore, in the first embodiment, the microlenses 26B are arranged without gaps in the single pixel 23. Therefore, as shown in FIG. 3, the distance between the microlenses 26B in the single pixel 23 is substantially equal to the diameter D of the microlenses 26B. . That is, in the first embodiment, the distance between the microlenses 26B in the so-called single pixel 23 is greater than the wavelength of the light source, which is equivalent to the diameter D of the microlens 26B being greater than the wavelength of the light source.

However, when there is a gap between the microlenses 26B, it is preferable that the distance between the microlenses in a single pixel 23 accounts for a larger proportion of the diameter of the microlenses. Specifically, the proportion of the diameter D of the microlens 26B in a single pixel 23 to the distance between the microlenses 26B is preferably more than 70%, more preferably more than 80%, and still more preferably more than 90%. Even better is above 95%. Especially when the length of the distance between microlenses 26B in a single pixel 23 is equal to the wavelength of the light source, the proportion of the diameter D of the microlenses 26B in one pitch is preferably in the range of more than 70% as mentioned above.

Furthermore, in the present invention, even if the diameter of the microlens is less than the wavelength of the light source, as long as the distance between the microlenses in a single pixel is greater than the wavelength. Even if the diameter of the microlenses is less than the wavelength of the light source, as long as the gap between the microlenses is small, the emitted light from a single pixel of the light source device can still be collected. In other words, as long as the gap between microlenses is small enough to collect the emitted light from a single pixel, the distance formed between adjacent microlenses in a single pixel can be set to be greater than the wavelength of the light source.

(light for exposure) Next, the exposure light formed through the microlens will be described. As shown in FIG. 4A , when only one microlens 26B is configured for a single pixel 23 including one light-emitting element 24C inside, the exposure image of the imaging bottom surface of the forming area 18A, that is, the molding forming surface 19, can be divided into a central area. RC and peripheral area RP.

The central region RC has a shape such that the outer edge of the lens is directly projected onto the molding surface 19 . Furthermore, the peripheral area RP is located on the periphery of the central area RC. The light energy irradiated to the peripheral area RP does not contribute to the exposure.

On the other hand, as shown in FIG. 4B , when four microlenses 26B are arranged for a single pixel 23 , among the light irradiated from the microlens 26B on the left, part of the light eccentric from the optical axis C reaches the adjacent microlens 26B on the right. The overlapping area RO inside the exposed image on the lens 26B side. In addition, two microlenses 26B are shown in the cross-sectional view of FIG. 4B. The optical axis C of the microlens 26B is parallel to the up-down direction in FIGS. 4A and 4B. Therefore, compared with the case where only one microlens 26B is arranged as shown in FIG. 4A , the amount of point light that does not contribute to exposure is suppressed from decreasing.

(switching element) As shown in FIG. 5 , in the first embodiment, switching elements 36 respectively corresponding to the plurality of light-emitting elements 24C are provided. Specifically, each of the plurality of single pixels 23 is connected to the X electrode members X1 and X2 and the Y electrode members Y1 and Y2 respectively set in each single pixel 23 via a corresponding switch element 36 . The X electrode members X1 and X2 and the Y electrode members Y1 and Y2 are orthogonal to each other.

The upper section of FIG. 5 illustrates two single pixels 23 adjacently arranged in the left-right direction and connected to the 1X electrode member X1. The lower section of FIG. 5 illustrates two single pixels 23 adjacently arranged in the left-right direction connected to the 2X The case of electrode member X2. In addition, the left side of FIG. 5 illustrates two single pixels 23 that are adjacently arranged in the vertical direction and are connected to the first Y electrode member Y1. The right side of FIG. 5 illustrates that the two single pixels 23 that are adjacently arranged in the vertical direction are connected to the first Y electrode member Y1. The case of the second Y electrode member Y2. Through the switching element 36, the accuracy of switching between light irradiation and light non-irradiation can be improved for each single pixel 23 as the object. In addition, in the present invention, the switching element 36 is not essential.

＜Method of manufacturing light sculpture＞ Next, a method of manufacturing the light-shaped object according to the first embodiment will be described. As shown in FIG. 1 , through light irradiation from the light irradiation device 20 , the photocurable resin 18 can be irradiated by the light irradiation device 20 in the formation region 18A that includes the liquid surface of the photocurable resin 18 on the lower side of the stage 14 and has a fixed thickness. Selectively hardened by photopolymerization. As a result, a resin cured layer of the photo-modelled object is formed. Furthermore, as the hanging member 16 moves upward in FIG. 1 , the stage 14 rises in accordance with the set thickness of the resin cured layer.

After the stage 14 is raised, the light irradiation device 20 irradiates light to deposit a subsequent resin hardening layer under the previously formed resin hardening layer. As shown in FIG6 , in the first embodiment, the light-emitting structure 30 is formed by liquid tank photopolymerization. The light-emitting structure 30 can be any industrial product.

In the first embodiment, FIG. 6 shows a state where the optical object 30 being formed is suspended downward by the support pins 32 extending from the bottom surface of the stage 14, but in the present invention, the support pins 32 are not necessary. By repeating the lifting of the stage 14 and the light irradiation of the light irradiation device 20, the optical object 30 is finally formed in a state of being suspended from the lower side of the stage 14.

Furthermore, in the present invention, for example, while the photo-modelled object is supported on the upper side of the stage 14 in FIG. 1 , the stage 14 is lowered into the liquid tank 12 to stack the resin cured layer in the up and down direction. way. However, when the stage 14 is lowered into the liquid tank 12 and the resin cured layer is stacked in the vertical direction, light is irradiated from the upper side of the liquid tank 12 toward the top surface of the stage 14 . The formation area 18A for forming the exposure image is located between the top surface of the stage 14 and the liquid surface of the liquid tank 12 . Therefore, the top surface of the photocurable resin 18 forming the region 18A is in contact with oxygen in the air. Oxygen makes it difficult for the photocurable resin 18 to harden.

On the other hand, as in the first embodiment, when the resin curing layer is deposited in the vertical direction by raising the stage 14 in FIG1 , light is irradiated from the lower side of the liquid tank 12 to the bottom surface of the stage 14. The photo-curable resin 18 of the formation area 18A is located below the bottom surface of the stage 14 in FIG1 . That is, the stage 14 shields the air, so the photo-curable resin 18 of the formation area 18A does not come into contact with oxygen in the air.

(First modification) As shown in FIG. 7 , the width W2 of the microlens array corresponding to a single pixel 23 can be greater than the width W3 of the sealing material 24D in the single pixel 23 . FIG. 7 illustrates a case where four microlenses 26B are arranged in a matrix for a single pixel 23 to form one microlens array. In addition, FIG. 7 illustrates a case where the width W2 of one microlens array is the same as the distance between single pixels 23, that is, the maximum width W1 of a single pixel 23.

The width W2 of the microlens array is preferably set to be less than the pitch of a single pixel 23. If the width W2 of the microlens array exceeds the pitch of a single pixel 23, there is a concern that light may reach the position corresponding to the exposure image of the adjacent single pixel 23 even if the adjacent single pixel 23 is in a non-irradiated state.

(Second modification) As shown in FIG. 8 , the microlens 26B may be square in plan view. That is, the microlens 26B of the second modification example has a rectangular parallelepiped shape. In addition, in the present invention, the shape of the microlens can be a rectangular shape in plan view or any other geometric shape.

(Third modification) As shown in FIGS. 9 and 10 , the microlens array may be composed of nine microlenses 26B arranged in a 3×3 matrix in a plan view. In the third modification example, nine microlenses 26B correspond to a single pixel 23.

(4th modification) As shown in FIG. 11 , when the microlens array is composed of nine microlenses 26B, the shape of one microlens 26B can be any geometric shape. FIG. 11 illustrates a case in which a microlens 26B having a square shape in plan view is provided similarly to the case described in the second modification example.

(Effect) In the first embodiment, the maximum width W1 of a single pixel 23 is set to 200 μm or less, thereby suppressing the decrease in light directivity. Therefore, compared with the case where the maximum width W1 exceeds 200 μm, the reduction in light utilization efficiency in the photohardening reaction can be suppressed. As a result, light utilization efficiency can be improved.

Furthermore, in the first embodiment, by setting the upper limit value and the lower limit value of the distance between the microlenses 26B, it is possible to achieve both the formation of the irradiation light required for exposure and the suppression of the manufacturing cost burden of the optical element 26 .

In the first embodiment, linearized point light can be irradiated through the microlens 26B. In addition, a plurality of microlenses 26B are arranged for light from a single pixel 23. Therefore, a portion of the light eccentric from the optical axis C among the light irradiated from one microlens 26B reaches the overlapping area RO inside the exposure image on the microlens 26B side adjacent to one microlens 26B. As a result, the reduction in the amount of point light can be suppressed compared to the case where only one microlens 26B is arranged. Therefore, the resin hardening layer can be finely shaped.

Furthermore, in the first embodiment, the microlenses 26B have a circular shape, and the distance between the microlenses 26B is more than twice the light source wavelength [nm] of the light emitting element 24C. Therefore, the light emitted from the microlens 26B does not interfere, and as a result, a ripple pattern is not generated on the surface of the optical sculpture.

In the first embodiment, the resin hardened layer is deposited in the vertical direction by raising the stage 14. Therefore, compared with the case where the stage 14 is lowered into the liquid tank 12, the energy required to form the resin hardened layer having a thickness of one layer can be reduced.

Furthermore, in the first embodiment, light can be irradiated through the switching element 36 in an active matrix driving mode. Therefore, compared with the point matrix driving method, the resolution of the design pattern is improved, and as a result, the shaping accuracy of the three-dimensional shaped object can be improved.

[Second implementation mode] Next, the light shaping device 10 according to the second embodiment will be described with reference to FIGS. 12 and 13 . The light shaping device according to the second embodiment includes a liquid tank, a light source device, an aperture 38 and a stage. In the second embodiment, similarly to the first embodiment, the maximum width W1 of a single pixel 23 of the light source device is set to 200 μm or less.

According to the light shaping device 10 of the second embodiment, the aperture 38 is disposed as an optical element between the light source device and the liquid tank in place of the microlens 26B as the optical element 26 described in the first embodiment. It is different from the first embodiment. That is, light collecting devices such as microlenses and aperture devices such as diaphragms are included in the "optical element" of the present invention. The components other than the aperture 38 in the second embodiment have the same structure and function as the components with the same name in the first embodiment. Therefore, below, the aperture 38 will be mainly described, and repeated descriptions of the structures of other components will be omitted.

As shown in Fig. 12 and Fig. 13, the aperture 38 is a plate-shaped aperture device having a plurality of slits 38A. The aperture 38 can be made of resin, etc. In the second embodiment, the slits 38A are rectangular in a plan view, but the shape of the slits in the present invention is not limited thereto, and can be any other shape such as an oblong shape.

In the method of manufacturing a light-shaped object according to the second embodiment, the aperture 38 passes through the slit 38A, and uses the light emitted from the single pixel 23 to form point-shaped light including linear light that is irradiated to the photocurable resin 18 . Through the formed plural point-shaped lights, an exposure image is formed in the formation area 18A in the liquid tank 12 . The other steps in the method of manufacturing the light-shaped object according to the second embodiment are the same as the method of manufacturing the light-shaped object according to the first embodiment, so repeated explanations are omitted.

(Effect) In the second embodiment, the maximum width W1 of a single pixel 23 is set to less than 200 μm as in the first embodiment, thereby suppressing the reduction of the directivity of light. Therefore, compared with the case where the maximum width W1 exceeds 200 μm, the reduction of the light utilization efficiency in the photocuring reaction can be suppressed. As a result, the light utilization efficiency can be improved.

In the second embodiment, an aperture 38 having a slit 38A is used as an optical element to form a point light irradiated to the photocurable resin 18. The aperture 38 can be manufactured more cheaply than a light collecting device such as a lens, so the cost can be reduced. The other effects of the second embodiment are the same as those of the first embodiment, so repeated description is omitted.

[Third Implementation] ＜Light Shaping Device＞ Next, the light shaping device 11 according to the third implementation will be described with reference to FIG. 14 and FIG. 15 . As shown in FIG. 14 , the light shaping device 11 includes a liquid tank 12, a stage 14, a hanging member 16 for hanging the stage 14, and a light irradiation device 50.

In addition, in the light shaping device 11 according to the third embodiment, the members with the same names as those in the first embodiment and the second embodiment have the same structure and function. In the third embodiment, the points that are different from the first embodiment and the second embodiment will be mainly described, and repeated descriptions of the same configurations and functions and effects will be appropriately omitted.

(Carrier) The carrier 14 supports the resin hardening layer of the photocurable resin 18 which is hardened by the image for forming, i.e., the exposure image, which is formed by reducing the area of the light-shaped object to be formed to 1/M, and moves in the up and down directions in FIG. 14. M is a positive real number greater than 1, i.e., M>1. The carrier 14 can rise and fall while supporting the resin hardening layer.

In this specification, "the area of the optical object to be formed" means the target area of the forming surface of each layer of the optical object. In addition, "each layer" means "each layer in the optical object formed by curing through light irradiation layer by layer and stacking in sequence". That is, the "optical object" used in this specification can be used to represent the entire three-dimensional object finally obtained, and can also be used to represent each layer of the multiple resin cured layers included in the optical object being formed.

(Light irradiation device) The light irradiation device 50 is disposed below the liquid tank 12 in FIG. 14 and irradiates light to the bottom side of the carrier 14 through the bottom of the light-transmitting liquid tank 12. In addition, in the third embodiment, the surface exposure method, i.e., the light forming of the DLP method, is exemplified, but the light forming of the present invention is not limited to the DLP method.

Furthermore, in the present invention, the light irradiation device and the liquid tank can move relatively along the surface direction of the molding surface 19 . For example, the light irradiation device can be moved two-dimensionally in a plane parallel to the exposure surface to perform light scanning.

The light irradiation device 50 includes a light source device 54 and an optical element 56 arranged between the light source device 54 and the liquid tank 12 . The light source device 54 and the optical element 56 are integrated through the sealing box 58 . When manufacturing a photo-shaped object, preliminarily created image data for modeling is input to the light irradiation device 50 .

The light irradiation device 50 is the same as the light irradiation device 20 of the first embodiment. Based on the input image data for forming, the light of a predetermined wavelength required for light forming is selectively irradiated to the lower side of the carrier 14 immersed in the liquid tank 12 through a light-emitting element not shown.

(light source device) The light source device 54 has a projection surface 55 formed by a plurality of single pixels 53 . The light source device 54 projects a shaping image that is N times the area of the light sculpture 31 to be shaped from the projection surface 55 . N is a positive real number greater than 1, that is, N>1. The expansion of the area can be achieved, for example, by respectively expanding the areas of the plurality of pixels used, or by increasing the number of the plurality of pixels used. In addition, the area and number of single pixels that can be used in combination can also be expanded.

FIG. 14 illustrates a state in which a plurality of single pixels 53 included in the light source device 24 are arranged along the X direction (ie, the left-right direction in FIG. 14 ) on the bottom 58A of the sealed box 58 . In addition, in FIG. 14 , for easy recognition, a dotted arrow is used to illustrate a state in which only a part of the plurality of single pixels 53 emits light. However, during actual light shaping, the light source device 24 is controlled so that a single pixel 53 corresponding to a desired shaping image emits light appropriately. The light source device 24 emits light from a plurality of single pixels 53 together.

(Single pixel) The single pixel 53 of the third embodiment has a light-emitting element arranged on an unpatterned substrate. In addition, each of the plurality of light-emitting elements is sealed by an unpatterned sealing material on the substrate inside a region surrounded by unpatterned partition walls. In the third embodiment, the single pixel 53 is square in a plan view. An unpatterned protective layer is provided on the upper side of the partition wall in FIG. 14 which is the opposite side to the substrate.

(Partition walls) Although not shown, multiple partition walls are provided along the X direction in FIG. 14 and along the Y direction extending through the paper surface of FIG. 14. Therefore, in a top view, the partition walls in the X direction and the partition walls in the Y direction appear in a lattice shape. Although not shown, a protective layer is provided on the partition walls in FIG. 14.

The wavelength of light emitted by the light emitting element can be set arbitrarily within the range of about 365 nm in the ultraviolet region to about 1770 nm in the infrared region. For example, when the light emitting element is a sub-millimeter LED or a micro LED, light in the ultraviolet region of 365 nm can be irradiated.

Here, when the transparency of the photocurable resin is high, sufficient curing reaction may not occur with light of wavelengths other than the ultraviolet range. Light with a wavelength in the ultraviolet range is advantageous in that it is easy to harden the photocurable resin even if the transparency of the photocurable resin is high.

(Optical element) As shown in FIG. 14 , in the third embodiment, the optical element 56 is disposed between the light source device 24 and the liquid tank 12 at the lower side of the liquid tank 12. In addition, in the present invention, the optical element may also be disposed at the upper side of the liquid tank 12.

(Reduced projection optical component) The optical element 56 has a reduced projection optical component 57 for a light shaping device. The reduced projection optical component 57 has a sealing box 58, a first light focusing component 57A, a second light focusing component 57B, and an optical axis correction component 57C. The reduced projection optical component 57 focuses the light of the shaping image 41.

The reduction projection optical component 57 is arranged between the projection surface 55 of the light source device 24 and the bottom surface of the liquid tank 12 . The reduction projection optical component 57 reduces the area of the modeling image to N times the area of the light modeling object 31 (where N > 1), so that the area of the modeling image is reduced to 1/M (where M > 1). It is projected onto the shaping surface 19 in the liquid tank 12 . In the third embodiment, N is 3 or more and M is 3 or more. That is, the area of the modeling image is set to 3 times or more, and the reduction ratio of the reduction projection optical component 57 is set to 1/3 or less.

Therefore, in the third embodiment, compared with the case where the area of the image for forming the light forming object 31 is not changed and the original area, i.e., 1 times the area, is directly projected, the light energy density can be increased to more than 9 times. In addition, from the perspective of increasing the light energy density, the reduction ratio is preferably 1/4 or less. In addition, from the perspective of increasing the light energy density, the reduction ratio is more preferably 1/5 or less.

On the other hand, if the reduction ratio exceeds 1/3, it is difficult to obtain the effect of increasing the light energy density. In addition, in the present invention, the reduction ratio of the reduced projection optical component to the image for shaping is arbitrary. That is, in the present invention, the value of N greater than 1 can be less than 3.

In addition, in the present invention, N and M may be the same or different. In addition, N<M may also be satisfied, for example, N=3 and M=4. In the case of N<M, the area of the modeling image that is reduced and projected onto the formation area is smaller than the area of the initial light modeling object before area expansion, that is, the target area. In other words, in the present invention, the area of the sculpting image of the exposed image in the sculpting area can be smaller than the initial target area.

When N < M, the number of single pixels per unit area in the image for shaping, i.e., the pixel density, increases compared to the case of M ≦ N. In addition, in this specification, "pixel density" means the number of single pixels of the light-emitting element contained in a unit area of a square area whose sides are defined by two mutually orthogonal axes on the projection plane and the length of one side is 1 inch.

(sealed box) Inside the sealing box 58, the first light focusing member 57A, the second light focusing member 57B and the optical axis correction member 57C are sealed respectively. The sealing box 58 can be made of resin, for example. The sealed box 58 has a bottom portion 58A, a peripheral wall portion 58B, and a top cover portion 58C. The top cover part 58C has translucency.

The shape of the peripheral wall portion 58B can be appropriately changed under the condition that the members constituting the reduction projection optical component 57 can be integrally sealed inside. For example, the side wall of the first light condensing member 57A may be used as a part of the peripheral wall portion 58B of the sealing box 58 . Alternatively, the bottom 58A of the first light focusing member 57A may be used as part or all of the bottom of the sealing box 58 . That is, in the present invention, the sealed box is not essential.

(First light focusing component) The first light focusing component 57A is disposed on the side of the light source device 24 on the opposite side of the liquid tank 12 and sandwiching the top cover 58C in the inner side of the sealing box 58. The first light focusing component 57A of the third embodiment is, for example, a concave focusing lens. In addition, in the present invention, the first light focusing component 57A is not limited to a focusing lens. In the present invention, other components or devices that are light-transmissive and can focus the light of the image 41 for forming can also be used as the first light focusing component.

(Second light condensing member) The second light focusing member 57B is arranged between the first light focusing member 57A and the optical axis correction member 57C. The second light focusing member 57B of the third embodiment has a refractive index greater than that of air. Furthermore, in the present invention, the refractive index of the second light condensing member may be lower than the refractive index of air. In addition, in the present invention, the second light condensing member is not essential.

The second light concentrating member 57B of the third embodiment is, for example, an acrylic or epoxy hardened material, that is, a solid material. The second light focusing member 57B has a refractive index different from that of the first light focusing member 57A. The refractive index of the second light focusing member 57B is about 1.5, for example. Furthermore, in the present invention, the second light condensing member 57B is not limited to the acrylic cured material. In the present invention, other members or devices that are light-transmissive and can concentrate the light for forming images can also be used as the second light-concentrating member.

Furthermore, in the present invention, the second light condensing member 57B may be solid, or may be a liquid without photocurability. In the present invention, as the second light condensing member 57B, for example, pure water, lubricating oil, diiodomethane (CH ₂ I ₂ ), organic halide, acryl-based hardening material, etc. can be used. Acrylic hardened materials are advantageous in that they are generally easy to obtain and relatively easy to handle.

In the third embodiment, the first light focusing member 57A and the second light focusing member 57B are closely connected inside the sealing box 58 . Therefore, compared with the case where the first light focusing member 57A and the second light focusing member 57B are not in close contact and a gap is formed between the first light focusing member 57A and the second light focusing member 57B, the refractive index for light can be reduced. the influence. Furthermore, in the present invention, the close contact between the first light focusing member 57A and the second light focusing member 57B is not essential.

In the third embodiment, the case where both the first light focusing member 57A and the second light focusing member 57B are included in the reduced projection optical component 57 is exemplified. However, in the present invention, the reduced projection optical component may be constituted by only one of the first light focusing member 57A and the second light focusing member 57B.

(Optical axis correction member) The optical axis correction member 57C corrects the optical axis of the light input from the second light focusing member 57B so that the optical axis of the light concentrated by the first light focusing member 57A is along the direction perpendicular to the shaping surface 19 of the formation region 18A. That is, in the present invention, the optical axis of the concentrated light does not have to be strictly orthogonal to the shaping surface 19 . As the optical axis correction member 57C, for example, any optical device such as a convex lens can be used. In addition, in the present invention, the optical axis correction member is not essential.

Furthermore, in the third embodiment, the first light focusing member 57A and the optical axis correcting member 57C are exemplified as different members. However, in the present invention, the first light focusing member and the optical axis correcting member may also be composed of one member. .

<Production method of optically formed objects> (Overview of optical forming) Next, referring to FIG. 14 and FIG. 16 to FIG. 19, the production method of optically formed objects according to the third embodiment is described. First, before optical forming, image data 40A for forming N times the area of the optically formed object 31 is prepared in advance by a forming image data preparation device such as CAM software. The prepared forming image data 40A is input to the optical forming device 11.

As shown in FIG. 14 , similarly to the first embodiment, the light irradiation device 50 selectively hardens the photocurable resin 18 by photopolymerization in the formation area 18A having a fixed thickness and a liquid surface of the photocurable resin 18 on the lower side of the carrier 14. As a result, a resin hardening layer of the photo-shaped object is formed. Then, by moving the hanging member 16 to the upper side in FIG. 14 , the carrier 14 is raised by the set thickness of the resin hardening layer. Again, similarly to the first embodiment, after the carrier 14 is raised, the light irradiation device 50 is used to irradiate light, and a subsequent resin hardening layer is deposited under the previously formed resin hardening layer.

(Formation of resin hardened layer) Next, the formation of each resin cured layer in the optical modeling of the third embodiment will be described in detail. As shown in FIG. 17 , when the first resin hardened layer 31A is photo-shaped, the area of the modeling image data 40A (in other words, the size of the outer shape) is substantially the same as the area of the modeling image 41A projected from the projection surface 55 of the light source device 24 .

On the other hand, the area of the molding image 42A on the molding surface 19 in the liquid tank 12 in which the photocurable resin 18 is stored is reduced by the reduction projection using the reduction projection optical component 57, compared to the area on the projection surface 55. The area is reduced to 1/N. That is, in the third embodiment, the case where the reduction ratio and the expansion ratio are equal, that is, M=N, is exemplified. In addition, in the present invention, the reduction ratio is not limited to the case of M=N. That is, the area of the image for modeling can be reduced to 1/M (where N≠M).

Next, as shown in FIG. 18 , when the second resin cured layer 31B laminated on the first resin cured layer 31A is photo-shaped, the area of the modeling image data 40B is the same as the area projected from the projection surface 55 of the light source device 24 The area of the modeling image 41B is also approximately the same. On the other hand, the area of the molding image 42B on the molding surface 19 in the liquid tank 12 in which the photocurable resin 18 is stored is reduced by the reduction projection using the reduction projection optical component 57, compared to the area on the projection surface 55. The area is reduced to 1/N.

As shown in FIGS. 17 and 18 , in the third embodiment, the pattern of the subsequent second resin cured layer 31B is different from the pattern of the preceding first resin cured layer 31A. In FIG. 19 , a part of the photo-sculpture in which the first resin cured layer 31A having a fixed thickness and the second resin cured layer 31B having a fixed thickness are laminated is illustrated.

Through the above-mentioned series of steps including reducing the projection, a method for manufacturing a light-shaped object using the light-shaping device 11 according to the third embodiment is constructed. In addition, the shape of the resin cured layer in FIGS. 17 to 19 is an illustration. In the present invention, the shape of the resin cured layer is arbitrary and is not limited thereto. In addition, the support pin 32 in FIG. 16 of the third embodiment is not essential in the present invention as described in the first embodiment.

In addition, as described in the first embodiment, in the present invention, for example, the stage 14 can be lowered into the liquid tank 12 while the photo-shaped object is supported on the upper side of the stage 14 in FIG. 14 , whereby the resin cured layer is laminated in the up and down direction. However, as described in the first embodiment, when the stage 14 is lowered into the liquid tank 12 and the resin cured layer is laminated in the up and down direction, oxygen will make it difficult for the photocurable resin 18 to harden.

On the other hand, as in the third embodiment, when the stage 14 is raised and the resin cured layer is laminated in the up and down direction, the stage 14 blocks the air, so that the light in the area 18A is formed, as in the first embodiment. The curable resin 18 does not come into contact with oxygen in the air.

(Effect) In the third embodiment, modeling images 41A and 41B having an area N times the area of the light modeling object 31 are projected from the projection surface 55 of the light source device 24 . Therefore, compared to a device that projects a shaping image with an area that is twice the area of the light sculpture 31 from the projection surface of the light source device, the number of single pixels 53 used is increased to N times. Furthermore, in the third embodiment, by reducing the projection optical component 57 , the areas of the modeling images 41A and 41B are reduced to 1/N and projected onto the modeling forming surface 19 in the liquid tank 12 .

Therefore, compared with the case where a patterning image having an area twice the area of the optical patterning object 31 is directly projected onto the patterning forming surface 19 in the liquid tank 12, the light energy density in the patterning area 18A as the patterning area can be increased. As a result, the light utilization efficiency can be improved.

Furthermore, when the pixel density of the patterning images 41A and 41B on the patterning forming surface 19 in the liquid tank 12 is increased by n times, the light energy density increases by n squared (n ² ) times. As a result, the patterning speed of the light patterning can be increased.

Furthermore, when the object of optical shaping is, for example, a dental object for a human, the shaping area generally requires a rectangular shaping surface with a diagonal length of about 5.6 inches (i.e., about 70 mm×124 mm) in terms of the size of a general oral cavity. Here, when preparing a light source device that can form exposure light with an actual fine pixel pitch of about 50 μm, such as the SLA (Stereo lithography) method, additional components such as micro-reflectors may be added to achieve a fine pixel pitch. Therefore, the structure of the device becomes complicated, which results in an increase in cost.

On the other hand, in the third embodiment, the area of the shaping image on the projection surface of the light source device 24 is enlarged to N times. Therefore, for example, the size of the projection surface 55 in the light source device 24 is about 25 inches and the actual pixel pitch is about 250 μm, but in the reduced shaping image 42, for the formation area with a diagonal length of about 5.6 inches, a pixel pitch of about 50 μm can still be obtained. As a result, there is no need to add additional components, etc., and a single pixel with a larger area can be used as a unit pixel, so the device can be constructed at a lower price. Therefore, the optical shaping device 11 according to the third embodiment is suitable for optical shaping of dental shapes.

Furthermore, in the third embodiment, the number of single pixels that project the modeling images 41A and 41B whose area is expanded to N times may be increased. As the number of single pixels that project the shaping images 41A and 41B increases, the pixel density of the shaping images 42A and 42B on the shaping forming surface 19 can be further increased.

Furthermore, in the third embodiment, the area of the modeling images 41A and 41B can be reduced to 1/N through the first light condensing member 57A. In addition, the optical axis of the light can be corrected in a direction perpendicular to the molding surface 19 through the optical axis correcting member 57C.

Furthermore, in the third embodiment, the refractive index of the entire projection optical component 57 is reduced by a combination of two light focusing members, the first light focusing member 57A and the second light focusing member 57B. Therefore, compared with the case where the reduction projection optical component 57 has only one first light focusing member 57A, it is easier to adjust the refractive index of the entire reduction projection optical component 57 . In addition, compared with the case where the reduced projection optical component 57 has only one first light concentrating member 57A, the modeling images 41A and 41B with reduced area are less likely to be deformed.

Furthermore, in the third embodiment, the value of N of the expansion ratio and the reduction ratio is greater than 3, so even if the value of N is greater than 3 for a mass-produced light-emitting element LED, the light energy density can be improved.

Furthermore, in the third embodiment, the stage 14 is raised to stack the resin cured layer in the up and down direction. Therefore, compared with the case where the stage 14 is lowered into the liquid tank 12, the thickness of one layer can be reduced. The energy required for the resin hardened layer. Other functions and effects of the third implementation aspect are the same as those of the first implementation aspect and the second implementation aspect, so repeated descriptions are omitted.

(Fifth variant) For example, in the present invention, the optical element 56 in the light forming device can rotate relative to the forming surface 19. As shown in FIG20, the light forming device 11A according to the fifth variant has a rotating support portion 34 for rotating the light irradiation device 50 including the optical element 56. In addition, the rotating support portion 34 can rotate not only in the X direction extending along the left-right direction in FIG20, but also in the Y direction extending along the direction passing through the paper surface of FIG20.

In the third embodiment, the light irradiation device 50 including the light source device 24 and the optical element 56 is supported by the rotation support portion 34 as a whole, but the present invention is not limited thereto, and only the optical element 56 may be supported in a rotatable state. The other components of the light shaping device 11A according to the fifth variation are the same as those of the light shaping device 11 according to the third embodiment, and thus repeated descriptions are omitted.

In the fifth variation, the light energy density of the light shaping can be increased as in the third embodiment. Furthermore, by rotating the light irradiation device 50, for example, the irradiation range of the light can be expanded compared to the case where the light irradiation device 50 irradiates only the light perpendicular to the shaping forming surface 19. The other effects of the fifth variation are the same as those of the third embodiment, so repeated descriptions are omitted.

(Applicability to other light shaping methods) In the third embodiment, the case of implementing light shaping through the DLP method is exemplified, but the present invention is not limited to the DLP method, and can also be applied to other methods such as the LCD (Liquid Crystal Display) method and the micro LED method.

Here, the DLP method generally requires the components constituting the light irradiation device to have higher durability to withstand higher light energy. Therefore, it is easy to increase the cost. On the other hand, in the present invention in which the modeling image on the modeling forming surface is shrunk compared to the modeling image projected from the projection surface, there is no need to improve the durability of the light irradiation device to the level of the DLP method. Therefore, for example, the cost of the light shaping device can be suppressed by combining the present invention with the LCD method and the micro-LED method.

Especially in the light shaping device using the general LCD method, the transmittance loss from the light source is large, so the light energy required for light shaping may not be obtained. For example, in a general LCD method, the light energy density may stay at about 2mJ/cm ² . On the other hand, the DLP method can achieve a light energy density of approximately 16mJ/ ^cm2 .

Therefore, by combining the present invention that shrinks the image for shaping on the shaping surface compared to the image for shaping projected from the projection surface with the light shaping device of the general LCD method, the light irradiation intensity equal to or higher than that of the DLP method can be obtained. For example, when the reduction ratio is 1/2.8, that is, when the area ratio is about 8 times, assuming that no light loss occurs, the light energy density of about 16mJ/ ^cm2 can be obtained, which is the same as the DLP method.

＜Other implementation forms＞ The present invention has been described based on the above-mentioned embodiments, but the present invention is not limited by the discussion and drawings that form part of the above content. A person of ordinary skill in the art to which this invention pertains should be able to contemplate various alternative implementations, examples, and application techniques from this invention.

For example, the present invention can be constituted by combining the components illustrated in Figures 1 to 20. As described above, the present invention includes various embodiments not described above, and the technical scope of the present invention is limited only by the essential technical features of the invention in the appropriate patent application scope from the above description.

The entire contents of Japanese Patent Application No. 2022-052538 filed on March 28, 2022 and Japanese Patent Application No. 2023-027677 filed on February 24, 2023 are incorporated by reference in this specification.

All documents, patent applications, and technical standards described in this specification are incorporated by reference into this specification to the same extent as if each individual document, patent application, or technical standard was cited by reference specifically and individually.

10:Light shaping device 11,11A:Light shaping device 12:Liquid tank 14: Carrier platform 16: Hanging components 18: Photocurable resin 18A: Formation area 19: Shaping forming surface 20:Light irradiation device 22:Frame 23:Single pixel 24:Light source device 24A:Substrate 24B:Next door 24C:Light-emitting element 24D:Sealing material 24E:Protective layer 26:Optical components 26A:Base 26B: Microlens 30:Light sculpture 31:Light sculpture 31A: First resin hardened layer 31B: Second resin hardened layer 32: Support pin 34: Rotation support part 36: Switching element 38:Aperture 38A:Slit 40A, 40B: Image data for modeling 41A, 41B: Image for modeling 42A, 42B: Image for modeling 50:Light irradiation device 53:Single pixel 54:Light source device 55:Projection surface 56:Optical components 57: Reduction of projection optical parts 57A: First light focusing component 57B: Second light focusing member 57C: Optical axis correction component 58:Sealed box 58A: Bottom 58B: Peripheral wall 58C:Top cover C: Optical axis D: diameter RC: Central Region RO: overlapping area RP: peripheral area W1: maximum width W2: Width W3: Width X1,X2:X electrode components Y1, Y2: Y electrode components

FIG. 1 is a front view of the light shaping device according to the first embodiment, with a portion of the liquid tank and the light irradiation device cut away. FIG. 2 is a cross-sectional view along line 2-2 in FIG. 3 illustrating the light source device and optical elements of the light irradiation device according to the first embodiment. FIG. 3 is a top view illustrating the light source device and optical elements of the light irradiation device according to the first embodiment. 4A is a diagram illustrating the operation of the optical element when the optical element provided in the unit area corresponding to a single pixel is one microlens. 4B is a diagram illustrating the operation of the optical element when the optical element provided in the unit area corresponding to a single pixel is a plurality of microlenses. FIG. 5 is a top view illustrating the switching element of the light irradiation device according to the first embodiment. 6 is a cross-sectional view of a part of the liquid tank and the light irradiation device to explain the method of manufacturing a photo-shaped object using the photo-shaping device according to the first embodiment. 7 is a top view illustrating the light source device and optical elements of the light irradiation device according to the first modification. 8 is a top view illustrating the light source device and optical elements of the light irradiation device according to the second modification. FIG. 9 is a top view illustrating the light source device and optical elements of the light irradiation device according to the third modification. FIG. 10 is a cross-sectional view along line 10-10 in FIG. 9 illustrating the light source device and optical elements of the light irradiation device according to the third modification. FIG. 11 is a top view illustrating the light source device and optical elements of the light irradiation device according to the fourth modification example. FIG. 12 is a top view illustrating the light source device and optical elements of the light irradiation device according to the second embodiment. FIG. 13 is a cross-sectional view along line 13-13 in FIG. 12 illustrating the light source device and optical elements of the light irradiation device according to the second embodiment. FIG. 14 is a front view showing a part of the liquid tank and the light irradiation device cut away to illustrate the light shaping device according to the third embodiment. FIG. 15 is a perspective view illustrating the optical elements of the light irradiation device according to the third embodiment. 16 is a cross-sectional view of a part of the liquid tank and the light irradiation device to explain the method of manufacturing a photo-shaped object using the photo-shaping device according to the third embodiment. 17 illustrates the image data used to photo-shape the first resin hardened layer, the shaping image having an area N times the area of the photo-shaped object in the light source device when M=N, and the optical element in which the area is The exposure image reduced to 1/M is the image used for modeling. 18 illustrates the image data used to photo-shape the second resin hardened layer, the shaping image having an area N times the area of the photo-shaped object in the light source device when M=N, and the area in the optical element being The exposure image reduced to 1/N is the image used for modeling. FIG. 19 is a perspective view illustrating a state in which a first resin cured layer and a second resin cured layer are laminated during photolithography. FIG. 20 is a cross-sectional view of a part of the liquid tank and the light irradiation device to illustrate the light shaping device according to the fifth modification.

10: Light shaping device

12: Liquid tank

14: Carrier

16: Hanging components

18: Photocurable resin

18A: Formation area

19: Shaping forming surface

20:Light irradiation device

22: Frame

24:Light source device

26:Optical components

Claims (14)

A light shaping device comprising: Liquid tank, which accumulates liquid light-hardening resin; The light source device arranges a plurality of single pixels including partition walls and light-emitting elements accommodated in the partition walls into a regular matrix, and the maximum width of the single pixel is less than 200 μm; An optical element is arranged between the light source device and the liquid tank, uses the light emitted from the single pixel to form point-shaped light that is irradiated to the photocurable resin, and transmits a plurality of the point-shaped lights in the liquid tank. The forming area forms the exposed image; and, The stage supports the resin cured layer of the photocurable resin cured by the exposure image, and moves in the up and down direction. The light shaping device according to claim 1, wherein, The optical element has a microlens that collects light emitted from the single pixel; The distance between the microlenses is above the light source wavelength [nm] of the light-emitting element and below the distance between single pixels. The light shaping device according to claim 1 or 2, wherein, The optical element has a microlens that collects light emitted from the single pixel; A plurality of the microlenses are configured for the single pixel. The light shaping device according to claim 2, wherein, The microlens is circular in plan view; The distance between the microlenses is more than twice the wavelength [nm] of the light source of the light-emitting element. The light shaping device according to claim 1, wherein, The optical element is an aperture that has a plurality of slits that narrow the light emitted from the single pixel, and uses the slits to form point-like light that is irradiated to the photocurable resin. The light shaping device according to claim 1 or 2, wherein, The light source device is arranged on the lower side of the liquid tank; The resin hardened layer is supported on the bottom side of the carrier; The stage can rise while supporting the resin hardened layer. The light shaping device according to claim 1 or 2, wherein, Switch elements respectively corresponding to a plurality of the light-emitting elements are provided. A light shaping device comprises: a liquid tank storing liquid photocurable resin; a light source device having a projection surface formed by a plurality of single pixels, and projecting a shaping image of N times (where N>1) the area of the light shaping object to be shaped from the projection surface; a reduced projection optical component disposed between the projection surface of the light source device and the bottom surface of the liquid tank, which reduces the area of the shaping image to 1/M (where M>1) and projects it onto the shaping surface in the liquid tank; and, a stage supporting the resin curing layer of the photocurable resin cured by the shaping image on the shaping surface, and moving in the up-down direction. The light shaping device according to claim 8, wherein, The reduced projection optical parts include: The first light focusing component is arranged on the side of the light source device; and, The optical axis correcting member corrects the optical axis of the light concentrated by the first light condensing member in a direction perpendicular to the shaping surface. The light shaping device according to claim 9, wherein, The reduction projection optical component further includes a second light focusing component with a refractive index greater than that of air between the first light focusing component and the optical axis correction component. A light shaping device as described in any one of claim 8 to claim 10, wherein N is greater than or equal to 3. A light shaping device as described in any one of claims 8 to 10, wherein: the light source device is disposed below the liquid tank; the resin hardening layer is supported on the bottom side of the carrier; the carrier can rise while supporting the resin hardening layer. A method for manufacturing a light-shaped object comprises the following steps: A step of projecting a shaping image of N times (where N>1) the area of the light-shaped object to be shaped from a projection surface formed by a plurality of single pixels of a light source device; and A step of reducing the area of the shaping image to 1/M (where M>1) by using a reduction projection optical component, and projecting the reduced shaping image onto a shaping surface in a liquid tank containing liquid photocurable resin, and curing the photocurable resin. A reduced projection optical component for a light shaping device is an optical element used in the light shaping device, and the light shaping device includes: a liquid tank storing liquid photocurable resin; a light source device having a projection surface formed by a plurality of single pixels, and projecting a shaping image of N times (where N>1) the area of the light shaping object to be shaped from the projection surface; and, a carrier supporting a resin hardening layer of the photocurable resin hardened by the shaping image and moving in the up-down direction; the reduced projection optical component for the light shaping device is arranged between the projection surface of the light source device and the bottom surface of the liquid tank, and it reduces the area of the shaping image to 1/M (where M>1) and projects it onto the shaping surface in the liquid tank.

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