WO2018032531A1 - 光固化3d打印机及3d打印方法 - Google Patents

光固化3d打印机及3d打印方法 Download PDF

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Publication number
WO2018032531A1
WO2018032531A1 PCT/CN2016/097116 CN2016097116W WO2018032531A1 WO 2018032531 A1 WO2018032531 A1 WO 2018032531A1 CN 2016097116 W CN2016097116 W CN 2016097116W WO 2018032531 A1 WO2018032531 A1 WO 2018032531A1
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WIPO (PCT)
Prior art keywords
photosensitive resin
fluid passage
display unit
liquid crystal
crystal display
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PCT/CN2016/097116
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English (en)
French (fr)
Inventor
许蓓蓓
李厚民
王翊坤
范轶旸
朱凯强
Original Assignee
北京金达雷科技有限公司
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Publication of WO2018032531A1 publication Critical patent/WO2018032531A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor

Definitions

  • the present invention relates to 3D printing technology, and more particularly to LCD (Liquid Crystal Display) projection type light curing molding technology.
  • LCD Liquid Crystal Display
  • the photocuring rapid prototyping technology is more common, which uses a liquid state photosensitive resin (UV) to polymerize under illumination, and the light source is irradiated according to the cross-sectional shape of the solid to be solidified, so that the liquid photosensitive resin is After the layers are solidified, they are cumulatively stacked to form a solidified body.
  • UV liquid state photosensitive resin
  • the photocuring rapid prototyping apparatus mainly includes a selective laser curing device (SLA, also known as a stereoscopic curing device) and a mask photocuring device (DLP).
  • SLA selective laser curing device
  • DLP mask photocuring device
  • the selective laser curing device focuses a laser of a specific intensity at a wavelength of 405 nm onto the surface of the liquid photosensitive resin, and cures it in a line-to-line, line-to-face order to complete a cross-sectional thin layer of an object to be printed. Subsequently, another cross-section thin layer is cured in this way, so that the successively cured cross-sectional thin layers are superimposed on each other to finally complete a three-dimensional object to be printed. Since the SLA-based 3D printing apparatus employs the above-described curing program, it is slow in speed and low in efficiency when printing large three-dimensional objects or printing a plurality of three-dimensional objects. For example, the Form2 photocuring 3D printer invented by Fombabs of the United States uses SLA photocuring molding technology.
  • the mask photocuring device uses a DLP projector to project a two-dimensional pattern of a cross section of the object to be printed on the liquid photosensitive resin, so that the liquid photosensitive resin solidifies a thin layer of a corresponding shape according to the pattern. Thereafter, the cured thin layer is adhered layer by layer to form a cured printed object.
  • the mask photocuring device is capable of printing large three-dimensional objects quickly and has a high resolution.
  • due to the need to use DLP equipment it is expensive and can be purchased and used by non-average consumers.
  • the B9C light-curing 3D printer invented by B9Creator in the United States uses DLP light curing technology.
  • CLIP continuous light curing technology
  • a light source with a higher intensity may be selected to illuminate the liquid photosensitive resin, but as the curing speed of the liquid photosensitive resin is increased, the heat released from the liquid photosensitive resin may accumulate at the bottom of the photosensitive resin pool, and if it cannot be cooled, Will significantly reduce the life of the photosensitive resin pool.
  • the present invention provides a photocurable 3D printer comprising:
  • a photosensitive resin pool having a transparent bottom wall and a peripheral wall fixedly disposed above the bottom wall, the bottom wall and the peripheral wall constituting a first receiving space;
  • a carrying unit disposed on the photosensitive resin pool for carrying a printed object, the carrying unit being vertically movable;
  • An LCD liquid crystal display unit located in the first receiving space and covering the bottom wall;
  • a light source located outside the first receiving space and covering the bottom wall.
  • the distance between the light source of the existing photo-curing 3D printer and the LCD liquid crystal display unit is approximately 150 mm, and the light source of the photo-curing 3D printer provided by the present invention is disposed close to the bottom wall of the photosensitive resin pool, and the distance from the LCD liquid crystal display unit. Within 30mm. Therefore, the light source of the light-cured 3D printer provided by the present invention is increased by 25 times by the light intensity of the LCD liquid crystal display unit.
  • the photocurable 3D printer has few components and a low manufacturing cost.
  • the light source comprises:
  • a substrate fixedly disposed under the bottom wall, and a second receiving space is formed between the substrate and the bottom wall;
  • a plurality of light emitting elements fixedly disposed at a focus of each of the reflective bowls.
  • the curing contrast refers to the ratio of the light intensity emitted by the light source to the transparent area of the LCD liquid crystal display unit and the light intensity value outside the transparent area when the LCD liquid crystal display unit displays the cross section of the printed object.
  • the higher the curing contrast the more reasonable the light source design and the higher the light source utilization.
  • the parallel light source helps to increase the curing contrast value, that is, the higher the parallelism of the light emitted by the light source, the larger the curing contrast value, and vice versa.
  • the curing contrast value does not increase indefinitely, and there is a theoretical maximum value.
  • the curing contrast of existing light-cured LCD 3D printers ranges from 50:1 to 100:1.
  • the light source of the photocured 3D printer provided by the invention has a special structure, and can improve the curing contrast value to about 500:1, which is 5 to 10 times that of the prior art.
  • the plurality of reflective bowls are arranged in an array in a projection range of the LCD liquid crystal display unit on the substrate.
  • the distance from the light emitting element to the LCD liquid crystal display unit is less than 30 mm.
  • the bottom wall has a thickness of less than 10 mm.
  • the substrate is internally provided with a meandering first fluid passage, and both ends of the first fluid passage form a first hole and a second hole communicating with the outside on the substrate. .
  • the light source further includes:
  • first cooling plate disposed outside the second receiving space and covering the substrate, the first cooling plate having an inwardly recessed, meandering first fluid passage toward a side of the substrate, Both ends of the first fluid passage form a first hole and a second hole communicating with the outside on the first cooling plate.
  • the first fluid channel is at least 60% of a range over which the substrate is provided with light emitting elements.
  • the first heat source is the light source component, which releases a large amount of heat during operation
  • the second heat source is the heat released during the curing of the liquid photosensitive resin.
  • the first fluid passage for the light source it is possible to cause the coolant to flow in the substrate, thereby absorbing heat generated by the light-emitting element.
  • the coolant is generally water, and a grease having a high transmittance can also be used.
  • the inside of the bottom wall of the photosensitive resin pool is provided with a meandering second fluid passage, and both ends of the second fluid passage form a communication with the outside on the bottom wall.
  • the third hole and the fourth hole are provided with a meandering second fluid passage, and both ends of the second fluid passage form a communication with the outside on the bottom wall.
  • the photosensitive resin pool comprises:
  • a transparent second cooling plate disposed between the bottom wall and the LCD liquid crystal display unit, the second cooling plate having an inwardly concave, meandering side toward a side of the LCD liquid crystal display unit a two-fluid channel, the two ends of the second fluid channel forming a third hole and a fourth hole communicating with the outside on the second cooling plate.
  • the heat released during the curing of the liquid photosensitive resin is the second heat source, which is finally concentrated on the LCD liquid crystal display unit (including the heat released by the LCD display unit itself).
  • a second cooling plate having a second fluid passage may be disposed at a lower portion of the LCD display unit.
  • the refractive indexes of the cooling plate and the cooling liquid used should be uniform to provide the molding precision of the printed article.
  • the first fluid passage and the second fluid passage have a parallelogram in cross section, and an angle a between the side and the bottom side is 15° to 90°, preferably an angle a. It is 30° to 60°.
  • the first fluid passage and the second fluid passage have a trapezoidal cross section, and an angle b between the side and the bottom side is 90° to 150°, preferably the angle b is 120 ° ⁇ 150 °.
  • the second fluid passage is at least 60% of a range in which the LCD liquid crystal display unit is disposed.
  • the second cooling plate and the cooling liquid have the same refractive index.
  • the photosensitive resin pool comprises:
  • the middle portion has a hollow bottom wall, and opposite sides of the bottom wall are recessed inward to form a third receiving space;
  • the second cooling plate and the LCD liquid crystal display unit are disposed in the third receiving space,
  • One end is pivotally connected to the bottom wall, and the other end is a free end locking element, the locking element has an engaging position and a free position;
  • the bottom wall and the peripheral wall are fixed to each other when the locking element is in the engaged position;
  • the bottom wall and the peripheral wall are separable when the locking element is in the free position.
  • the photocurable 3D printer provided by the present invention employs a photosensitive resin bath having a quick release device, and the bottom wall and the peripheral wall can be separated when the locking member is in a free position, so that the operator can be installed and repaired therein.
  • the LCD liquid crystal display unit is convenient for cleaning the photosensitive resin pool.
  • the bottom wall has a "back" shape that is hollowed out in the middle, and the longitudinal section of the locking element has a "[" shape.
  • the photosensitive resin pool comprises:
  • a sealing member fixed to a lower portion of the peripheral wall and having the same cross-sectional shape as the peripheral wall;
  • the locking element When the locking element is in the engaged position, the supporting user element and the peripheral wall are fixed to each other, and the polymer semipermeable membrane is tensionably coated on the LCD liquid crystal display unit.
  • the depth of the third receiving space is substantially equivalent to the sum of the thicknesses of the LCD liquid crystal display unit and the second cooling plate.
  • the photosensitive resin pool further includes:
  • a soft sealing member disposed between the polymeric semipermeable membrane and the contact surface of the peripheral wall.
  • the photocuring 3D printer further includes:
  • a cooling unit disposed below the light source and capable of delivering cooling liquid to the first fluid passage and the second fluid passage;
  • the cooling unit includes:
  • At least one set of heat sinks At least one set of heat sinks
  • the coolant storage container, the radiator, the pump, and the first fluid passage and the second fluid passage are connected in series through a pipeline.
  • the photocuring 3D printer provided by the invention has a complete cooling unit, which can effectively dissipate the heat released when the light source component and the liquid photosensitive resin are cured, and ensure that the 3D printer works at an optimum temperature. In addition, it is also possible to ensure that the semipermeable membrane of the polymer does not curl and wrinkle due to an increase in temperature, thereby further improving the print quality.
  • the light-curing 3D printer using the above-mentioned cold-removing unit enables the liquid photosensitive resin to be continuously cured (continuous printing without spacing), and the liquid photosensitive resin of each layer is cured only for 1 to 5 s (when the layer thickness is very thin, the curing time can even be reached) 0.5s), its printing speed is 20 times higher than the prior art. Therefore, the photocured 3D printer provided by the present invention is not only low in cost, but also greatly improves printing efficiency, and can effectively improve user satisfaction.
  • the photocuring 3D printer further includes:
  • a second temperature monitoring element disposed on the substrate of the light source
  • the control unit capable of controlling the operation of the pump according to the monitored values of the first temperature monitoring element and the second temperature monitoring element, the control unit being further capable of controlling the opening and closing of the light source and the LCD liquid crystal display unit, and Controlling the movement of the carrying unit.
  • the cooling unit can be started at intervals during the printing process. For example, in a normal case, the cooling unit is in a closed state, and when the temperature value detected by the first temperature monitoring element or the second temperature monitoring element exceeds the set temperature value, the cooling unit is activated.
  • the present application also provides a 3D printing method, including:
  • a light source is closely attached to the bottom wall of the photosensitive resin pool, the light source is irradiated to the LCD liquid crystal display unit, and the light is transmitted through the photosensitive resin pool and the LCD liquid crystal display unit to be irradiated to the photosensitive resin.
  • the liquid photosensitive resin in the pool is cured to a shape corresponding to the cross-sectional pattern of the object to be printed.
  • the 3D printing method further includes:
  • the 3D printing method includes:
  • Another 3D printing method provided by the present invention includes:
  • a light source is closely attached to the bottom wall of the photosensitive resin pool, the light source is irradiated to the LCD liquid crystal display unit, and the light is transmitted through the photosensitive resin pool and the LCD liquid crystal display unit to be irradiated to the photosensitive resin.
  • a liquid photosensitive resin in the pool to cure it into a shape corresponding to a cross-sectional pattern of the object to be printed;
  • the control unit controls the coolant to circulate within the first fluid passage and the second fluid passage based on the monitored values of the first temperature monitoring element and the second temperature monitoring element. .
  • FIG. 1 is a schematic view showing the overall structure of a photocuring 3D printer provided by the present invention
  • FIG. 2 is a schematic structural view of a light source
  • Figure 3 is a schematic view showing the structure of a group of reflective bowls and light-emitting elements
  • Figure 4 is a schematic structural view of an array type light source (without a reflective bowl);
  • Figure 5 is a schematic structural view of a first cooling plate
  • Figure 6 is a schematic view of the structure of the photosensitive resin pool (unlocked).
  • Figure 7 is a schematic view of the structure of the photosensitive resin pool (locked).
  • Figure 8A is an exploded view of the upper half of the photosensitive resin pool
  • Figure 8B is a cross-sectional view of the upper half of the photosensitive resin bath
  • Figure 9A is an exploded view of the lower half of the photosensitive resin pool
  • Figure 9B is a cross-sectional view of the lower half of the photosensitive resin bath
  • Figure 10A is a perspective view of a second cooling plate
  • Figure 10B is a front view of the second cooling plate
  • 10C is a schematic view showing the cooperation of the second cooling plate and the LCD liquid crystal display unit
  • 11A is a schematic cross-sectional view of a second cooling plate
  • 11B is another schematic cross-sectional view of the second cooling plate
  • Figure 12A shows the surface of an object printed by a prior art photocurable 3D printer
  • Figure 12B is a surface of an object printed by the photocured 3D printer provided by the present invention.
  • Figure 13 is a schematic structural view of a cooling unit
  • 15 is a schematic structural view of a carrying unit and a driving unit thereof;
  • FIG. 16 is a 3D printing method according to an embodiment of the present invention.
  • FIG. 17 is a 3D printing method according to another embodiment of the present invention.
  • FIG. 18 is a 3D printing method according to a third embodiment of the present invention.
  • an embodiment of the present invention provides a photocuring 3D printer, which mainly includes a photosensitive resin pool 1, a carrying unit 2, an LCD liquid crystal display unit 3, and a light source 4.
  • the photosensitive resin bath 1 has a transparent bottom wall 11 and a peripheral wall 12 fixedly disposed above the bottom wall, and the bottom wall 11 and the peripheral wall 12 constitute a first accommodating space 13.
  • a carrier unit 2 for carrying a printed object is disposed above the photosensitive resin bath 1, which is capable of moving vertically toward or away from the photosensitive resin bath 1.
  • the LCD liquid crystal display unit 3 is located in the first accommodating space 13 of the photosensitive resin bath 1 and is disposed on the bottom wall 11.
  • the light source 4 is disposed on the outer side of the bottom wall 11 , that is, the light source 4 is located outside the first accommodation space 13 .
  • the LCD liquid crystal display unit 3 displays a cross-sectional pattern of the printed object in a light-transmitting area and a light-shielding area, and the light source 4 is transparent through the bottom wall 11 and the LCD.
  • the liquid photosensitive resin in the photosensitive resin bath 1 is irradiated so that the liquid photosensitive resin is cured on the carrying unit 2 in accordance with the cross-sectional pattern of the printed object.
  • the photocured 3D printer provided by the embodiment further includes a housing 5, a driving unit 6, and a cooling unit 7.
  • the photosensitive resin bath 1 is disposed inside the outer casing 5 and substantially at an intermediate portion.
  • the drive unit 6 is disposed in the outer casing 5 and located on the right side of the photosensitive resin bath 1, and is fixedly provided with the carrying unit 2 at a position near the top thereof.
  • the cooling unit 7 is at the lowest end of the entire printer. The specific structure of the drive unit 6 and the cooling unit 7 will be explained in detail below.
  • the light source 4 of the photocured 3D printer provided by the embodiment includes a substrate 41, a reflective bowl 42, and a light-emitting element 43.
  • the substrate 41 is fixedly disposed below the bottom wall 11 and forms a second receiving space 44 with the bottom wall 11.
  • the reflective bowl 42 is fixedly disposed on the substrate 41 and located in the second receiving space 44.
  • the reflective bowl 42 has a plurality of.
  • the light-emitting elements 43 are fixedly disposed at the focus of each of the reflective bowls 42.
  • a set of reflective bowls and a light-emitting element have a structure.
  • the reflective bowl 42 has a hole at a focus, and the light-emitting element 43 can be disposed in the hole and can be fixedly connected to the substrate 41. . Therefore, most of the light emitted from the light-emitting element 43 can be reflected by the reflective bowl 42 and become parallel to each other.
  • a plurality of reflective bowls 42 are distributed in an array on the substrate 41.
  • the distribution range of the reflective bowl 42 is within the projection range of the LCD liquid crystal display unit 3 on the substrate 41, thereby ensuring that the light illuminating the LCD liquid crystal display unit 3 is uniformly distributed.
  • the arrangement is such that the distance from the light-emitting element 43 to the LCD liquid crystal display unit 3 is less than 30 mm. In order to reduce the influence of the bottom wall 11 on light, the thickness should be controlled within 10 mm.
  • the spatial distribution of light intensity emitted by a single illuminating element 43 can be expressed as: Where I 0 is the light intensity of the luminous surface of the LED lamp on the normal line, Why is the normal direction at any angle? The intensity of the direction.
  • the light emitted by the light-emitting surface produces an illumination intensity on the LCD liquid crystal display unit along with the exit angle Increases and decays rapidly.
  • the distance between the optical path system of the existing photo-curing 3D printer and the LCD liquid crystal display unit 3 is large (that is, the r value is large), and the light-emitting power of the light source needs to be increased to ensure that the light intensity value on the LCD liquid crystal display unit 3 is satisfied.
  • the light-emitting element 43 of the photo-curing 3D printer provided by the embodiment has a distance of less than 30 mm from the LCD liquid crystal display unit 3, and can even be closely attached to the bottom wall 11 of the resin pool.
  • the reflective bowl 42 enhances the uniformity of the light, and the intensity of the light radiation at the center of the LCD liquid crystal display unit 3 and the edge is substantially equal, and there is no occurrence angle with the light.
  • such a light source no longer needs to be provided with a lens, and it is no longer necessary to cover the Fresnel lens on the bottom wall 11 of the resin pool using such a light source.
  • the illuminating element 43 employs an LED lamp that emits light having a wavelength of 395 to 460 nm.
  • the light source 4 further includes a first cooling plate 45 disposed outside the space of the second accommodation 44 and covering the substrate 41.
  • the side of the first cooling plate 45 facing the substrate 41 has an inwardly recessed, meandering first fluid passage 451.
  • the first fluid passage 451 is composed of an "S" shaped recess that meets end to end.
  • the range in which the first fluid passage 451 is spread is related to the position at which the substrate 41 is provided with the light-emitting element 43, which is at least 60% of the range in which the substrate 41 is provided with the light-emitting element 43.
  • the upper portion of the substrate 41 is provided with a plurality of light-emitting elements 43, and the liquid in the first fluid passage 451 to which the lower portion of the substrate 41 is attached can absorb the heat accumulated on the substrate 41.
  • Both ends of the first fluid passage 451 form a first hole 452 and a second hole 453 communicating with the outside on the first cooling plate.
  • the first cooling plate 45 may not be added, that is, the inside of the substrate 41 may be provided with a meandering first fluid passage. 451. Both ends of the first fluid passage 451 form a first hole 452 and a second hole 453 communicating with the outside on the substrate 41.
  • the photosensitive resin bath 1 mainly includes two portions of a bottom wall 11 and a peripheral wall 12.
  • the bottom wall 11 has a generally "back" shape with a hollow portion 111 therein and the opposite sides of the solid portion are recessed inwardly to form a third receiving space 112.
  • the transparent second cooling plate 14 and the above-described LCD liquid crystal display unit 3 are disposed in the third housing space 112.
  • the solid portions of the peripheral wall 12 and the bottom wall 11 are identical in shape so that they can still be placed on the bottom wall.
  • One side of the bottom wall 11 is fixedly provided with a locking element 113 which has a longitudinal cross-section in the shape of a "[" and is pivotally connected to the bottom wall 11.
  • the locking member 113 has an engaging position and a free position, and when the locking member 113 is in the engaged position, the bottom wall 11 and the peripheral wall 12 are fixed to each other. When the locking member 113 is in the free position, the bottom wall 11 and the peripheral wall 12 can be separated from each other. That is, the height of the locking element 113 and the height of the peripheral wall 12 should be substantially the same so that it can just snap onto the edge of the peripheral wall 12 when it is rotated to the locked position.
  • the second cooling plate 14 is disposed between the bottom wall 11 and the LCD liquid crystal display unit 3, and has a second inwardly concave, meandering shape toward a side of the LCD liquid crystal display unit 3.
  • the fluid passage 141 and the two ends of the second fluid passage 141 form a third hole 142 and a fourth hole 143 communicating with the outside on the second cooling plate 14.
  • the second fluid passage 141 is at least 60% of the range in which the LCD liquid crystal display unit 3 is disposed, so that the coolant flowing into the concave passage can sufficiently absorb the heat radiated from the LCD liquid crystal display unit 3.
  • the shape of the second fluid passage 141 may be the same as that of the first fluid passage 451.
  • the second fluid passage 141 has a parallelogram in cross section, and the angle a between the side and the bottom side is 15 to 90, and preferably the angle a is 30 to 60.
  • the second fluid passage 141 has a trapezoidal cross section with an angle b between the side and the bottom of the side being 90 to 150, and preferably an angle b of 120 to 150.
  • the first fluid channel 451 can have the same cross-sectional shape and angle as the second fluid channel.
  • the photosensitive resin bath 1 further includes a sealing member 15, a polymer semipermeable membrane 16, and a supporting member 17, which are fixed together by bolts. Specifically, the bolts are sequentially passed through the peripheral wall 11 of the photosensitive resin bath, the flexible sealing member 15, and the polymer semipermeable membrane 16 to fix them on the support member 17.
  • the cross-sectional shape of the soft sealing member 15 is the same as that of the peripheral wall 12, that is, it is located between the contact faces of the polymer semipermeable membrane 16 and the peripheral wall 12 to prevent leakage of the liquid photosensitive resin.
  • the polymer semipermeable membrane 16 is fixed to the sealing member 15 on one side, and the other surface is fixed to the support member 17.
  • the polymer semipermeable membrane 16 When the locking member 113 is in the engaged position, the polymer semipermeable membrane 16 is stretched over the LCD liquid crystal display unit 3. When the locking member 113 is in the free position, the entirety of the peripheral wall 12, the sealing member 15, the polymeric semipermeable membrane 16 and the supporting member 17 can naturally be separated from the bottom wall 11.
  • the polymer semipermeable membrane 16 is capable of forming a gas molecular layer, such as a layer of oxygen molecules, on its surface to prevent the photosensitive resin cured on the carrier unit 2 from sticking to it.
  • the depth of the third accommodating space 112 substantially corresponds to the sum of the thicknesses of the LCD liquid crystal display unit 3 and the second cooling plate 14. More preferably, the depth of the third receiving space 112 may be slightly smaller than the sum of the thicknesses of the LCD liquid crystal display unit 3 and the second cooling plate 14 so that the LCD liquid crystal display unit 3 can be slightly convex upward from the third receiving space 112, This arrangement contributes to better fitting of the polymer semipermeable membrane 16 to the LCD liquid crystal display unit 3.
  • a lower portion of the support member 17 is provided with a barb 171.
  • a hole that cooperates with the barb 171 may be provided on the bottom wall 11 on the opposite side of the locking element 113 to provide a second positioning point other than the first positioning point of the locking element 113 and the edge of the peripheral wall 12. Further, the bottom wall 11 and the peripheral wall 12 are better fixed by means of two positioning points.
  • a cooling unit 7 is disposed below the light source 4 and is capable of delivering cooling liquid to the first fluid passage 451 and the second fluid passage 141.
  • the cooling unit 7 includes a coolant storage container 71, at least one set of radiators 72, a pump 73, and a line 74.
  • the coolant storage container 71, the radiator 72, the pump 73, and the first fluid passage 451 and the second fluid passage 141 pass Lines 74 are connected in series.
  • the first hole 452 of the first fluid passage 451 may serve as a coolant inflow hole, and the second hole 452 may serve as a coolant outflow hole.
  • the third hole 142 of the second fluid passage 141 may serve as a coolant inflow hole, and the fourth hole 143 may serve as a coolant outflow hole.
  • the second hole 452 and the third hole 142 are connected by a pipe 74 to complete the series connection of the entire cooling system.
  • the coolant storage container 71 stores a coolant such as water.
  • the coolant is pumped by pump 73 through line 74 into the upper first fluid passage 451 and then into the second fluid passage 141 and then to the radiator 72.
  • the heat sink 72 can be composed of a fan and a heat sink.
  • Each component of the photocured 3D printer provided by the embodiment of the present invention is controlled by a control unit (not shown).
  • the control unit can control the operation of the pump 74, the light source 4, and the LCD liquid crystal display.
  • the unit 3 is turned on and off, and controls the vertical movement of the carrying unit 2.
  • a first temperature monitoring component (not shown) is disposed on or around the LCD liquid crystal display unit 3, and a second temperature monitoring component (not shown) on the substrate 41 of the light source 4,
  • the control unit is capable of controlling the operation of the pump 74 according to the monitored values of the first temperature monitoring component and the second temperature monitoring component, that is, the temperature value monitored by at least one of the first temperature monitoring component and the second temperature monitoring component is higher than When the value is set, the control unit controls the pump 74 to pump the coolant to the first fluid passage 451 and the second fluid passage 141 to achieve temperature reduction of the light source 4 and the LCD liquid crystal display unit 3.
  • the LCD liquid crystal display unit 3 of the present embodiment has a lower polarizer 31, a TFT substrate 32, a liquid crystal layer 33, a color filter 34, and an upper polarizer 35 which are disposed layer by layer from bottom to top.
  • the light is converted into polarized light by the lower polarizer 31, and the polarization direction of the upper polarizer 35 is orthogonal to the plane of polarization of the polarized light.
  • the light emitted from the light source 4 passes through the bottom wall 11 of the photosensitive resin bath 1 and is converted into polarized light via the lower polarizer 31.
  • the polarization direction changes when the light passes through the liquid crystal layer 33. Therefore, a certain proportion of the light can pass through the color filter 34 to reach the upper polarizer 35, and then is emitted by the upper polarizer 35, and finally irradiated.
  • the liquid photosensitive resin carried in the photosensitive resin bath 1 is cured on the surface of the carrier unit 2.
  • the light ratio can be adjusted by adjusting the magnitude of the voltage applied to the liquid crystal layer 33.
  • the polarization direction of the polarized light does not change, and since the polarization direction of the upper polarizer 35 is orthogonal to the plane of polarization of the polarized light, the light cannot pass through the upper polarizer 35. That is, when the LCD liquid crystal display unit 3 is not energized, even if the liquid crystal display unit 3 is irradiated with the light source 4, the light is not transmitted to cure the liquid photosensitive resin in the photosensitive resin bath 3.
  • the driving unit 6 in this embodiment includes a column 61, a lead screw 62, a motor 63, and a connecting arm 64.
  • the column 61 has a vertical guide rail.
  • the lead screw 62 is rotatably fixedly disposed in the guide rail, and the motor 63 is fixedly disposed at the bottom end of the lead screw 62 for driving the screw 62 to rotate.
  • Connecting arm 64 and the lead screw 62 are associated with each other, and the relationship may be similar to the matched lead screw and the lead nut so that when the lead screw 62 rotates, the connecting arm 64 can move vertically in the guide rail.
  • One end of the connecting arm 64 is fixedly connected to the carrying unit 2. Therefore, the carrying unit 2 can be moved by the connecting arm 64 to move in a direction toward or away from the photosensitive resin bath 1.
  • the invention also provides a 3D printing method, as shown in FIG. 16, which mainly comprises the steps of:
  • a light source is closely attached to the bottom wall of the photosensitive resin pool, the light source is irradiated to the LCD liquid crystal display unit, and the light is transmitted through the photosensitive resin pool and the LCD liquid crystal display unit to be irradiated to the photosensitive resin.
  • the liquid photosensitive resin in the pool is cured to a shape corresponding to the cross-sectional pattern of the object to be printed.
  • step d is:
  • the coolant circulates the coolant within the first fluid passage and the second fluid passage.
  • the photosensitive resin bath 1 is first cleaned, and after it is dried, an appropriate amount of liquid photosensitive resin is poured. Then, the relevant printing parameter settings are made. For example, the curing thickness of each layer is 100 um, the exposure time of the light source is 2 s, and the cooling pump is always turned on during the printing process.
  • the control unit controls the motor 63 to operate such that the carrying unit 2 moves to a set distance (100 um) from the gap of the LCD liquid crystal display unit 3 in the photosensitive resin bath 1, and then the control unit controls the light source 4 to be turned on. Irradiation is performed according to the set time parameter (2s), and light is transmitted through the bottom wall 11 of the photosensitive resin bath 1 to the liquid crystal display courtyard 3.
  • control unit controls the LCD liquid crystal display unit 3 to display the pattern of the cross section of the printed object with the light shielding area and the light transmission area, and then the liquid photosensitive resin located above the LCD liquid crystal display unit 3 will be cured according to the pattern displayed by the LCD liquid crystal display unit 3. Forming, printing of a cross section of the printed object is completed after the irradiation.
  • the control unit controls the pump 74 to start operating, pumping the coolant to the first fluid passage 451 and the second fluid passage 141, absorbing the heat generated by the operation of the light-emitting element 43 and the LCD liquid crystal display unit 3, and ensuring that the system operates at a normal temperature.
  • control unit controls the rotation of the lead screw 62, and the carrying unit 2 drives the printing object to rise. Since the gas layer exists on the polymer semipermeable membrane 15, the printed object does not stick.
  • the carrying unit 2 is raised to a certain height h+H (where h represents the cured thickness of each layer of resin, ie 100 um. H is determined by the viscosity of the liquid photosensitive resin, so that the liquid photosensitive resin does not stick On printed objects, you can usually take 3000um). Thereafter, the carrying unit 2 is lowered by H, that is, the distance between the bottom surface of the printed object which is solidified on the carrying unit 2 and the LCD liquid crystal display unit 3 is h. By repeating the above action, the liquid photosensitive resin is cured layer by layer on the carrying unit 2 in accordance with the cross-sectional pattern of the printed object until a complete printed object is formed.
  • the required light time for curing the liquid photosensitive resin to different layer thicknesses (20 um to 100 um) is different (when the light intensity is constant). For example, curing to 100 um thick requires 5 s of illumination. At some time, the thickness of each cross section of the printed object is different, for example, 300um, 100um, 50um, 20um, respectively, and the corresponding illumination time should be adjusted accordingly.
  • a 3D printer method using the above-described 3D printer with temperature monitoring elements includes the steps of:
  • a light source is closely attached to the bottom wall of the photosensitive resin pool, the light source is irradiated to the LCD liquid crystal display unit, and the light is transmitted through the photosensitive resin pool and the LCD liquid crystal display unit to be irradiated to the photosensitive resin.
  • a liquid photosensitive resin in the pool to cure it into a shape corresponding to a cross-sectional pattern of the object to be printed;
  • the control unit charges the first fluid channel and the second fluid channel with a coolant according to the monitored values of the first temperature monitoring component and the second temperature monitoring component to control the coolant in the first
  • the fluid passage and the second fluid passage circulate.

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Abstract

一种光固化3D打印机及其方法，该打印机包括具有透明的底壁（11）和固定设置于底壁（11）之上的周壁（12）的光敏树脂池（1），底壁（11）和周壁（12）构成第一容纳空间（13）；设置于光敏树脂池（1）上方的用于承载打印物体的承载单元（2），承载单元（2）能够竖直运动；位于第一容纳空间（13）内且覆设于底壁（11）的LCD液晶显示单元（3）；以及位于第一容纳空间（13）外且覆设于底壁（11）的光源（4）。该3D打印机和3D打印方法将光源（4）照射至LCD液晶显示单元（3）的光强提升了25倍，提高了光源的利用效率。该光固化3D打印机的组成零件少，制造成本低。

Description

光固化3D打印机及3D打印方法 技术领域
本发明涉及3D打印技术，尤其涉及基于LCD(Liquid Crystal Display，液晶显示)投影式光固化成型技术。
背景技术
在3D打印技术中，较为常见的是光固化快速成型技术，其利用液体状态的光敏树脂(UV)在光照下发生聚合反应，以光源按照待固化实体的截面形状进行照射，使液态光敏树脂逐层固化成型后累积叠加，最终形成固化实体。
目前，基于上述原理的光固化快速成型装置主要包括选择性激光固化装置(SLA，又称立体光固化成型装置)和掩膜光固化装置(DLP)。
选择性激光固化装置采用405nm波长的特定强度的激光聚焦至液态光敏树脂表面，使其按照由点到线、由线到面的顺序固化，从而完成一个待打印物体的横截面薄层。随后，再按照这种方式固化另一横截面薄层，使先后固化的横截面薄层相互叠加，最终完成一个待打印的三维物体。这种基于SLA技术的3D打印装置由于采用上述固化程序，因此在打印大型三维物体或打印多个三维物体时，速度缓慢，效率低。例如美国Fomlabs公司发明的Form2光固化3D打印机就采用了SLA光固化成型技术。
掩膜光固化装置采用DLP投影仪在液态光敏树脂上投射待打印物体某一横截面的二维图形，使液态光敏树脂按照该图形固化出相应形状的薄层。之后，固化的薄层一层层地粘附累加，从而形成固化的打印物体。掩膜光固化装置能够快速打印较大三维物体，并具有较高的分辨率。但是，由于需要采用DLP设备，因此其价格昂贵，非一般消费者能够购买使用。例如美国B9Creator公司发明的B9C光固化3D打印机采用的就是DLP光固化技术。
无论是选择性激光固化装置还是掩膜光固化装置，都具有复杂的光路，导致其在打印时具有较长的延时，从而降低了固化效率。
为了提高光固化速度，美国Carbon3D发明了一种基于DLP的连续光固化技术(CLIP)，该技术虽然能提高打印速度，但是该种3D打印机的制造成本高昂，售价达到数万美金。
此外，为了提高固化速度，可以选择强度较高的光源照射液态光敏树脂，但是随着液态光敏树脂的固化速度加快，其放出的热量也会累积在光敏树脂池的池底，如果无法降温，将会显著降低光敏树脂池的使用寿命。
再者，采用强度较高的光源就需要考虑到其散热问题，否则大量的热聚集在3D打印机壳体内显然会存在安全隐患。
因此，亟待提供一种制造成本低、光固化速度快且具有降温系统的光固化3D打印机。
发明内容
鉴于现有技术中存在的缺陷，本发明提供一种光固化3D打印机，包括：
具有透明的底壁和固定设置于所述底壁之上的周壁的光敏树脂池，所述底壁和周壁构成第一容纳空间；
设置于所述光敏树脂池上方的用于承载打印物体的承载单元，所述承载单元能够竖直运动；
位于所述第一容纳空间内且覆设于所述底壁的LCD液晶显示单元；以及
位于所述第一容纳空间外且覆设于所述底壁的光源。
现有的光固化3D打印机的光源距离LCD液晶显示单元的距离大致为150mm，而本发明提供的光固化3D打印机的光源紧贴着光敏树脂池的底壁设置，其距离LCD液晶显示单元的距离在30mm之内。因此，本发明提供的光固化3D打印机的光源照射至LCD液晶显示单元的光强提升了25倍。该光固化3D打印机的组成零件少，制造成本低。
在本发明的一些实施方式中，所述光源包括：
固定地设置于所述底壁下方的基板，所述基板和所述底壁之间形成第二容纳空间；
固定地设置于所述基板上且位于所述第二容纳空间内的多个反光碗；以及
固定地设置于每一个所述反光碗的焦点处的多个发光元件。
固化对比度是指LCD液晶显示单元显示打印物体的横截面时，光源发出的光照射至LCD液晶显示单元中透明区域的光强数值和透明区域外的光强数值的比值。固化对比度越高，表明光源设计越合理，光源利用率越高。平行光源有助于提高固化对比度数值，即光源发射出的光平行度越高，固化对比值也就越大，反之越小。但是由于LCD液晶显示单元自身特性，固化对比值并不会无限增大，其会存在一个理论最大值。现有的光固化LCD 3D打印机的固化对比度在50:1～100:1。本发明提供的光固化3D打印机的光源具有特殊的结构，能将固化对比度值提高到500∶1左右，是现有技术的5～10倍。
在本发明的一些实施方式中，所述多个反光碗呈阵列式地分布于所述LCD液晶显示单元在所述基板上的投影范围内。
在本发明的一些实施方式中，所述发光元件至所述LCD液晶显示单元的距离小于30mm。
在本发明的一些实施方式中，所述底壁的厚度小于10mm。
在本发明的一些实施方式中，所述基板内部设置有蜿蜒曲折的第一流体通道，所述第一流体通道的两端在所述基板上形成与外界连通的第一孔和第二孔。
在本发明的一些实施方式中，所述光源还包括：
位于所述第二容纳空间外且覆设于所述基板上的第一冷却板，所述第一冷却板朝向所述基板的一侧具有向内凹陷的、蜿蜒曲折的第一流体通道，所述第一流体通道的两端在所述第一冷却板上形成与外部连通的第一孔和第二孔。
在本发明的一些实施方式中，所述第一流体通道至少遍布所述基板设置有发光元件的范围的60％。
光固化3D打印机在工作过程中，主要存在有两个热源。第一个热源是光源部件，其工作时会释放大量的热，第二个热源是液态光敏树脂固化过程中释放的热。为了保证3D打印机各部件能够在正常温度下工作，需要及时将热源产生的热量散发出去。通过为光源设置第一流体通道，能够使得冷却液在基板中流动，进而吸收发光元件发出的热。冷却液一般为水，也可以采用透射率较大的油脂。
在本发明的一些实施方式中，所述光敏树脂池的底壁的内部设置有蜿蜒曲折的第二流体通道，所述第二流体通道的两端在所述底壁上形成与外界连通的第三孔和第四孔。
在本发明的一些实施方式中，所述光敏树脂池包括:
设置于所述底壁和所述LCD液晶显示单元之间的透明的第二冷却板，所述第二冷却板朝向所述LCD液晶显示单元的一侧具有向内凹陷的、蜿蜒曲折的第二流体通道，所述第二流体通道的两端在所述第二冷却板上形成与外界连通的第三孔和第四孔。
如上所述，液态光敏树脂固化过程中释放的热为第二热源，该热量最终集中在LCD液晶显示单元上(同时包括LCD显示单元自身释放的热)。为了吸收上述热量，可以在LCD显示单元下部设置具有第二流体通道的第二冷却板。但是需要注意，由于光源的光线要透过第二冷却板和冷却液后照射到LCD液晶显示单元上，因此所采用的冷却板和冷却液的折射率应当一致，以提供打印物品的成型精度。
在本发明的一些实施方式中，所述第一流体通道和所述第二流体通道的截面成平行四边形，其侧边和底边的夹角a为15°～90°，优选地夹角a为30°～60°。
在本发明的一些实施方式中，所述第一流体通道和所述第二流体通道的截面成梯形，其侧边和底边的夹角b为90°～150°，优选地夹角b为120°～150°。
在实际打印过程中，当第一流体通道和第二流通通道的截面的侧边和底边垂直时(夹角为90°)，打印物体上会存在明显的条纹状痕迹，该痕迹是由于冷却液的折射率造成的。申请人发现，当调整第一流体通道和所述第二流体通道的形状以及侧边和底边的角度时，能够有效的减少或者消除打印物体表面的痕迹。在这种情况下，打印物体的尺寸、形状更为精准，也更为美观。
在本发明的一些实施方式中，所述第二流体通道至少遍布设置有LCD液晶显示单元的范围的60％。
在本发明的一些实施方式中，所述第二冷却板和所述冷却液的折射率一致。
在本发明的一些实施方式中，所述光敏树脂池包括:
中部具有镂空的底壁，所述底壁的相对两侧向内凹陷以形成第三容纳空间；
所述第二冷却板和所述LCD液晶显示单元设置于所述第三容纳空间内，
能够设置于所述底壁上的周壁；
一端与所述底壁枢转连接，另一端为自由端的锁止元件，所述锁止元件具有卡合位置和自由位置；
当所述锁止元件处于卡合位置时，所述底壁和所述周壁相互固定；
当所述锁止元件处于自由位置时，所述底壁和所述周壁能够分离。
本发明提供的光固化3D打印机采用了一种具有快拆装置的光敏树脂池，当锁止元件处于自由位置时，所述底壁和所述周壁能够被分离，以便于操作者检修设置于其中的LCD液晶显示单元，同时方便对光敏树脂池进行清理。
在本发明的一些实施方式中，所述底壁呈中部镂空的“回”形，所述锁止元件的纵向剖面呈“[”形。
在本发明的一些实施方式中，所述光敏树脂池包括：
固定设置于所述周壁下部且和所述周壁的截面形状相同的密封元件；
固定设置所述密封元件下部的高分子半透膜，所述高分子半透膜能够在 自身表面形成气体分子层；
固定设置于所述高分子半透膜下部的支撑元件；
当所述锁止元件处于卡合位置时，所述支撑用户元件和所述周壁相互固定，所述高分子半透膜被张紧地覆设在所述LCD液晶显示单元上。
在本发明的一些实施方式中，所述第三容纳空间的深度基本相当于所述LCD液晶显示单元和所述第二冷却板的厚度之和。
在本发明的一些实施方式中，所述光敏树脂池还包括：
设置于所述高分子半透膜和所述周壁的接触面之间的柔软的密封元件。
在本发明的一些实施方式中，所述光固化3D打印机，还包括：
设置于所述光源下方且能够向所述第一流体通道和所述第二流体通道输送冷却液的冷却单元；
所述冷却单元包括：
冷却液存储容器；
至少一组散热器；
泵；
所述冷却液存储容器、所述散热器、所述泵以及所述第一流体通道和所述第二流体通道通过管路串联。
本发明提供的光固化3D打印机具备一套完善的冷却单元，其能够有效地将光源部件和液态光敏树脂固化时释放的热量迅速散发出去，保证3D打印机在最佳温度下工作。此外，还能够保证高分子半透膜不会因温度升高而卷曲、褶皱，进一步地提高打印质量。
采用上述冷去单元的光固化3D打印机，使得液态光敏树脂能够连续固化(连续打印，无需间隔)，每层液态光敏树脂固化仅需要1～5s(当层厚很薄时，固化时间甚至可以达到0.5s)，其打印速度相比于现有技术提升了20倍。因此，本发明所提供的光固化3D打印机不但成本低廉，而且极大地提升了打印效率，能够有效地提升用户满意度。
在本发明的一些实施方式中，所述光固化3D打印机，还包括：
设置于所述LCD液晶显示单元上的第一温度监测元件；
设置于所述光源的基板上的第二温度监测元件；以及
能够根据所述第一温度监控元件和第二温度监测元件的监测数值控制所述泵工作的控制单元，所述控制单元还能够控制所述光源和所述LCD液晶显示单元的开启和关闭，并控制所述承载单元的运动。
另外，为了节约能源，可以在打印过程中间隔的启动冷却单元。例如，在通常情况下冷却单元处于关闭状态，当第一温度监测元件或者第二温度监测元件所检测到的温度值超过设定温度值后，启动冷却单元。
另外，本申请还提供了一种3D打印方法，包括：
a.以光敏树脂池容纳液态光敏树脂；
b.以LCD液晶显示单元显示待打印物体的横截面图案；
c.以光源紧贴所述光敏树脂池底壁，使所述光源照射所述LCD液晶显示单元，所述光线透过所述光敏树脂池和所述LCD液晶显示单元照射容纳于所述光敏树脂池内的液态光敏树脂，以使其固化成与所述待打印物体的横截面图案相应的形状。
在本发明的一些实施方式中，所述的3D打印方法还包括：
d.在所述光源的周围设置第一流体通道，在执行步骤c的同时，使冷却液在所述第一流体通道内循环。
在本发明的一些实施方式中，所述的3D打印方法包括：
d.在所述光源周围设置第一流体通道，在所述LCD液晶显示单元的周围设置第二流体通道，在执行步骤c的同时，使冷却液在所述第一流体通道和所述第二流体通道内循环。
本发明提供的另外一种3D打印方法，包括：
a.以光敏树脂池容纳液态光敏树脂；
b.以LCD液晶显示单元显示待打印物体的横截面图案；
c.以光源紧贴所述光敏树脂池底壁，使所述光源照射所述LCD液晶显示单元，所述光线透过所述光敏树脂池和所述LCD液晶显示单元照射容纳于所述光敏树脂池内的液态光敏树脂，以使其固化成与所述待打印物体的横截面图案相应的形状；
d.在所述光源周围设置第一流体通道和第一温度监测元件，在所述LCD液晶显示单元的周围设置第二流体通道和第二温度监测元件；
e.控制单元根据所述第一温度监测元件和第二温度监测元件的监测数值以控制冷却液在所述第一流体通道和所述第二流体通道内循环。。
附图说明
图1为本发明提供的光固化3D打印机的整体结构示意图；
图2为光源的结构示意图；
图3为一组反光碗和发光元件的结构示意图；
图4为阵列式光源的结构示意图(不含反光碗)；
图5为第一冷却板的结构示意图；
图6为光敏树脂池结构示意图(未锁定)；
图7为光敏树脂池结构示意图(锁定)；
图8A为光敏树脂池上半部分爆炸图；
图8B为光敏树脂池上半部分剖视图；
图9A为光敏树脂池下半部分爆炸图；
图9B为光敏树脂池下半部分剖视图；
图10A为第二冷却板的立体图；
图10B为第二冷却板的主视图；
图10C为第二冷却板和LCD液晶显示单元的配合示意图；
图11A为第二冷却板的一种截面形状示意图；
图11B为第二冷却板的另一种截面形状示意图；
图12A现有技术的光固化3D打印机打印出的物体的表面；
图12B为采用本发明提供的光固化3D打印机打印出的物体的表面；
图13为冷却单元的结构示意图；
图14为LCD液晶显示单元的结构示意图；
图15为承载单元及其驱动单元的结构示意图；
图16为本发明一实施例提供的3D打印方法；
图17为本发明另一实施例提供的3D打印方法；
图18为本发明第三种实施例提供的3D打印方法。
具体实施方式
为了使发明的目的、技术方案和优点更加清楚，下面结合附图和具体实施例对发明作进一步详细的说明。虽然附图中显示了本公开示例性实施例，然而应当理解，可以以各种形式实现本发明而不应被这里阐述的实施例所限制。相反，提供这些实施例是为了能够更透彻的理解本发明，并且能够将本发明的范围完整的传达给本领域的技术人员。
如图1所示，本发明一实施例提供了一种光固化3D打印机，其主要包括光敏树脂池1、承载单元2、LCD液晶显示单元3和光源4。光敏树脂池1具有透明的底壁11和固定设置于底壁之上的周壁12，底壁11和周壁12构成第一容纳空间13。光敏树脂池1的详细构造将在下文予以阐述。用于承载打印物体的承载单元2设置于光敏树脂池1的上方，其能够朝向或远离光敏树脂池1竖直运动。LCD液晶显示单元3位于光敏树脂池1的第一容纳空间13内且覆设于底壁上11。光源4覆设于所述底壁11的外侧，即光源4位于第一容纳空间13之外。工作时，LCD液晶显示单元3以透光区域和遮光区域显示出打印物体的横截面图案，光源4透过透明的底壁11和LCD液晶显 示单元3后照射光敏树脂池1中的液态光敏树脂，以使得液态光敏树脂按照打印物体的横截面图案固化于承载单元2之上。
除此之外，本实施例所提供的光固化3D打印机还包括外壳5、驱动单元6和冷却单元7。光敏树脂池1设置于外壳5内且基本处于中间部位。驱动单元6设置于外壳5内且位于光敏树脂池1的右侧，靠近其顶部的位置固定地设置有承载单元2。冷却单元7则处于整个打印机的最低端。驱动单元6和冷却单元7的具体结构将在下文予以详细阐述。
结合图2～5所示，进一步地，本实施例提供的光固化3D打印机的光源4包括基板41、反光碗42和发光元件43。基板41固定地设置于底壁11下方且和底壁11之间形成第二容纳空间44。反光碗42固定地设置于基板41上且位于第二容纳空间44内。反光碗42具有多个。发光元件43则固定地设置于每一个反光碗42的焦点处。在本实施例中，如图3所示的一组反光碗和发光元件的结构示意图，反光碗42的焦点处具有孔，发光元件43则能够设置于所述孔内且能够和基板41固定连接。因此，发光元件43所发射出的大部分光线能够经反光碗42反射后变得相互平行。如图2和图4所示，多个反光碗42呈阵列式地分布于基板41上。反光碗42的分布范围在LCD液晶显示单元3在基板41上投影范围内，以此保证照射LCD液晶显示单元3的光线是均匀分布的。如此设置能够使得发光元件43至LCD液晶显示单元3的距离小于30mm。为了减小底壁11对光线的影响，其厚度应当控制在10mm内。
单个发光元件43发出的光强度空间分布可表示为：
Figure PCTCN2016097116-appb-000001
其中，I0为LED灯的发光面在法线上的光强度，
Figure PCTCN2016097116-appb-000002
为何法线方向成任意角度
Figure PCTCN2016097116-appb-000003
方向的光强。
若忽略发光元件43自身大小，则得到其与LCD显示单元距离为r时，其发射的光线在LCD液晶显示单元3上的光强分布：
Figure PCTCN2016097116-appb-000004
因此，发光面(发光元件)发出的光线在LCD液晶显示单元上产生的光照强度随着出射角
Figure PCTCN2016097116-appb-000005
的增大而迅速衰减。
现有的光固化3D打印机的光路系统至LCD液晶显示单元3的距离较大(即r值较大)，则需要增大光源的发光功率，才能保证LCD液晶显示单元3上的光强度值满足光敏树脂固化要求。而本实施例提供的光固化3D打印机的发光元件43距离LCD液晶显示单元3的距离小于30mm，甚至可以紧紧贴在树脂池底壁11上。此时，反光碗42提升光线的均匀度，且光线辐射在 LCD液晶显示单元3中心处和边缘的强度基本相当，不会出现随着光线的出射角
Figure PCTCN2016097116-appb-000006
的增大而迅速衰减的现象。另外，该种光源不再需要设置透镜，采用这种光源的树脂池的底壁11上也不再需要覆设菲涅尔透镜。
在本发明的一些实施例中，发光元件43采用LED灯，其发射的光线的波长为395～460nm。
如图5所示，在本实施例中，光源4还包括了位于所述第二容纳44空间外且覆设于基板41的第一冷却板45。第一冷却板45朝向基板41的一侧具有向内凹陷的、蜿蜒曲折的第一流体通道451。第一流体通道451由首尾相接的”S”形凹陷组成。第一流体通道451所遍布的范围和基板41设置发光元件43的位置相关，其至少遍布基板41设置有发光元件43的范围的60％。，即基板41的上部设置有多个发光元件43，基板41下部贴合的第一流体通道451中的液体能够吸收基板41上聚集的热量。第一流体通道451的两端在所述第一冷却板上形成与外部连通的第一孔452和第二孔453。
本领域技术人员应当能够理解，当基板41本身具备设置第一流体通道451的条件时，可以无需增加第一冷却板45，即所述基板41的内部可以设置有蜿蜒曲折的第一流体通道451，所述第一流体通道451的两端在所述基板41上形成与外界连通的第一孔452和第二孔453。
参照图6～图9B，下文详细介绍光敏树脂池1的一种具体结构。
本实施例中，光敏树脂池1主要包括底壁11和周壁12两部分。底壁11大致呈“回”形，其中部具有镂空111且实体部分的相对两侧向内凹陷以形成第三容纳空间112。透明的第二冷却板14和上述LCD液晶显示单元3设置于第三容纳空间内112内。周壁12和底壁11的实体部分形状相同，因此其仍然能够设置于所述底壁上。底壁11的一侧固定地设置有锁止元件113，该锁止元件113的纵向剖面呈“[”形且和底壁11枢转连接。锁止元件113具有卡合位置和自由位置，当锁止元件113处于卡合位置时，底壁11和所述周壁12被相互固定在一起。当锁止元件113处于自由位置时，底壁11和周壁12能够相互分离。即锁止元件113的高度和周壁12的高度应当基本相同，以使其旋转至锁止位置时，刚好能够卡合在周壁12的边缘上。
结合图10A～图10C，第二冷却板14设置于底壁11和LCD液晶显示单元3之间，其朝向所述LCD液晶显示单元3的一侧具有向内凹陷的、蜿蜒曲折的第二流体通道141，第二流体通道141的两端在第二冷却板14上形成与外界连通的第三孔142和第四孔143。第二流体通道141至少遍布设置有LCD液晶显示单元3的范围的60％，以使得流入凹通道内的冷却液能够充分的吸收LCD液晶显示单元3散发的热量。第二流体通道141的形状可以和第一流体通道451相同。
如图11A所示，第二流体通道141的截面成平行四边形，其侧边和底边的夹角a为15°～90°，优选地夹角a为30°～60°。如图11B所示，第二流体通道141的截面成梯形，其侧边和底边的夹角b为90°～150°，优选地夹角b为120°～150°。本领域技术人员应当能够理解，第一流体通道451可以和所述第二流体通道具有相同的截面形状和角度。
参照图12A和图12B。在实际打印过程中，当第一流体通道和第二流通通道的截面的侧边和底边垂直时(夹角为90°)，打印物体上会存在明显的条纹状痕迹，该痕迹是由于冷却液的折射率造成的。当调整第一流体通道451和第二流体通道141的形状以及侧边和底边的角度时，能够有效的减少或者消除打印物体表面的痕迹。在这种情况下，打印物体的尺寸、形状更为精准，也更为美观。
如图8A所示，本实施例中，光敏树脂池1还包括通过螺栓固定在一起的密封元件15、高分子半透膜16以及支撑元件17。具体而言，螺栓依次穿过光敏树脂池的周壁11、柔软的密封元件15、高分子半透膜16将它们固定在支撑元件17上。柔软的密封元件15的截面形状和周壁12的截面形状相同，即其位于高分子半透膜16和周壁12的接触面之间，以防止液态光敏树脂泄露。高分子半透膜16一面和上述密封元件15固定，另一面则和支撑元件17固定。当锁止元件113处于卡合位置时，高分子半透膜16被张紧地覆设LCD液晶显示单元3上。当锁止元件113处于自由位置时，周壁12、密封元件15、高分子半透膜16以及支撑元件17组成的整体自然能够和底壁11脱离。高分子半透膜16能够在其表面能够形成气体分子层，例如氧分子层，以防止固化于承载单元2上的光敏树脂和其发生粘连。
为了设置高分子半透膜16，第三容纳空间112的深度基本相当于LCD液晶显示单元3和第二冷却板14的厚度之和。更为优选地，第三容纳空间112的深度可以略小于LCD液晶显示单元3和第二冷却板14的厚度之和，以使得LCD液晶显示单元3能够由第三容纳空间112向上稍微凸出，这样设置有助于高分子半透膜16更好地被张紧贴合于LCD液晶显示单元3。
支撑元件17的下部设置有一个倒钩171。在位于锁止元件113相对侧的底壁11上可以设置一个和所述倒钩171相配合的孔，以提供除锁止元件113和周壁12边缘的第一定位点之外的第二定位点，进而依靠两个定位点更好的固定底壁11和周壁12。
如图1和图13所示，冷却单元7设置于所述光源4的下方且能够向所述第一流体通道451和所述第二流体通道141输送冷却液。冷却单元7包括冷却液存储容器71、至少一组散热器72、泵73和管路74。所述冷却液存储容器71、散热器72、泵73以及第一流体通道451和第二流体通道141通过 管路74串联在一起。第一流体通道451的第一孔452可以作为冷却液流入孔，第二孔452可以作为冷却液流出孔。第二流体通道141的第三孔142可以作为冷却液流入孔，第四孔143可以作为冷却液流出孔。利用管路74将第二孔452和第三孔142连接，既能够完成整个冷却系统的串联。本领域技术人员应当能够理解，第一孔451、第二孔452、第三孔142和第四孔143的连接方式有很多种，再此不再一一阐述。冷却液存储容器71存储有冷却液，例如水。冷却液被泵73经由管路74泵入至上方的第一流体通道451中，然后流入第二流体通道141，随后流向散热器72。散热器72可以由风扇和散热片组成。
本发明实施例所提供的光固化3D打印机的各部件均受控制单元(图未示)控制，具体而言，控制单元能够控制所述泵74的工作、所述光源4和所述LCD液晶显示单元3的开启和关闭，并控制所述承载单元2的竖直运动。
在本发明的另外一个实施例中，LCD液晶显示单元3上或者周围设置第一温度监测元件(图未示)，所述光源4的基板41上的第二温度监测元件(图未示)，控制单元能够根据第一温度监控元件和第二温度监测元件的监测数值控制所述泵74工作，即第一温度监控元件和第二温度监测元件之中的至少一个所监测到的温度数值高于设定数值，则控制单元控制泵74向第一流体通道451和第二流体通道141泵入冷却液，以实现对光源4和LCD液晶显示单元3的降温。
参照图14，本实施例中的LCD液晶显示单元3具有由下至上逐层设置的下偏光片31、TFT基板32、液晶层33、彩色滤光片34以及上偏光片35。光线经过下偏光片31被转化为偏振光，上偏光片35的偏振化方向与偏振光的偏振面正交。
光源4发射的的光线透过光敏树脂池1的底壁11并经由下偏光片31后转化为偏振光。当液晶层33通电时，光线透过液晶层33时偏振化方向发生转变，因此有一定比例的光线可以透过彩色滤光片34达到上偏光片35，之后由上偏光片35射出，最终照射承载于光敏树脂池1内的液态光敏树脂，使其固化于承载单元2表面。通过调整施加于液晶层33上的电压大小，可以调整出光比例。当液晶层33未通电时，偏振光的偏振化方向不改变，由于上偏光片35的偏振化方向与偏振光的偏振面正交，因此光线无法透过上偏光片35。即，在LCD液晶显示单元3未通电时，即使采用光源4照射LCD液晶显示单元3，光线也不会透过以使光敏树脂池3中的液态光敏树脂固化。
参照图15，本实施例中的驱动单元6包括具立柱61、丝杠62、电机63和连接臂64。立柱61具有竖直的导轨，丝杠62可旋转的固定设置在导轨中，电机63则固定地设置于丝杠62的底端以用于驱动丝杠62旋转。连接臂 64和丝杠62相互关联，其关系可以类似于相匹配的丝杠和丝杠螺母，以使得丝杠62旋转时，连接臂64可以在导轨中竖直运动。连接臂64的一端和承载单元2固定连接。因此，承载单元2可以被连接臂64带动，在朝向或者远离所述光敏树脂池1的方向上运动。
本发明还提供了一种3D打印方法，如图16，其主要包括步骤：
a.以光敏树脂池容纳液态光敏树脂；
b.以LCD液晶显示单元显示待打印物体的横截面图案；
c.以光源紧贴所述光敏树脂池底壁，使所述光源照射所述LCD液晶显示单元，所述光线透过所述光敏树脂池和所述LCD液晶显示单元照射容纳于所述光敏树脂池内的液态光敏树脂，以使其固化成与所述待打印物体的横截面图案相应的形状。
进一步地，如图17所示，本发明一实施例提供的另一种3D打印方法，其中步骤d为：
在所述光源周围设置第一流体通道，在所述LCD液晶显示单元的周围设置第二流体通道，在执行步骤c的同时，向所述第一流体通道和所述第二流体通道内充入冷却液，使冷却液在所述第一流体通道和所述第二流体通道内循环。
具体地，在进行3D打印之间，先将光敏树脂池1清洗干净，待其干燥后倒入适量的液态光敏树脂。然后进行相关打印参数设置，例如每层固化厚度为100um，光源曝光时间为2s，冷却泵在打印过程中一直处于开启状态。设置完相关打印参数后，控制单元控制电机63运转，使得承载单元2运动至和光敏树脂池1中的LCD液晶显示单元3的间隙达到设置距离(100um)，紧接着控制单元控制光源4开启，按照设置的时间参数(2s)进行照射，光线将透过光敏树脂池1的底壁11照射到液晶显示大院3上。与此同时，控制单元控制LCD液晶显示单元3以遮光区域和透光区域显示打印物体横截面的图案，那么位于LCD液晶显示单元3上方的液态光敏树脂将按照LCD液晶显示单元3所显示图案固化成形，照射结束后即完成了打印物体一层横截面的打印。控制单元控制泵74开始工作，向第一流体通道451和第二流体通道141泵送冷却液，将发光元件43和LCD液晶显示单元3工作时产生的热量吸收，保证系统在正常温度下工作。
每一层固化完成后，控制单元控制丝杠62旋转，承载单元2带动打印物体上升，由于高分子半透膜15上存在气体层，因此打印物体不会其发生粘连。
承载单元2向上升起一定高度h+H(其中h代表的是每层树脂固化厚度，即100um。H则由液态光敏树脂的粘度决定，以使得液态光敏树脂不会粘连 在打印物体上，通常可以取3000um)。此后，承载单元2下降H，即保持固化于承载单元2上的打印物体的底面和LCD液晶显示单元3的距离为h。重复上述动作，液态光敏树脂按照打印物体的横截面图案一层一层地固化于承载单元2上，直至形成完整的打印物体。
此外，需要说明的是，液态光敏树脂固化为不同层厚(20um～100um)的所需的光照时间是不相同的(当光照强度一定时)。例如固化为100um厚需要光照5s。在一些时候，打印物体的每一个横截面的层厚不同，例如分别为300um，100um，50um，20um，那么其所对应的光照时间也要做出相应调整。
参照图18，采用上述的带有温度监测元件的3D打印机的3D打印机方法，包括步骤：
a.以光敏树脂池容纳液态光敏树脂；
b.以LCD液晶显示单元显示待打印物体的横截面图案；
c.以光源紧贴所述光敏树脂池底壁，使所述光源照射所述LCD液晶显示单元，所述光线透过所述光敏树脂池和所述LCD液晶显示单元照射容纳于所述光敏树脂池内的液态光敏树脂，以使其固化成与所述待打印物体的横截面图案相应的形状；
d.在所述光源周围设置第一流体通道和第一温度监测元件，在所述LCD液晶显示单元的周围设置第二流体通道和第二温度监测元件；
e.控制单元根据所述第一温度监测元件和第二温度监测元件的监测数值向所述第一流体通道和所述第二流体通道内充入冷却液，以控制冷却液在所述第一流体通道和所述第二流体通道内循环。
以上对本发明的各种实施例进行了详细说明。本领域技术人员将理解，可在不偏离本发明范围(由所附的权利要求书限定)的情况下，对实施方案进行各种修改、改变和变化。对权利要求范围的解释应从整体解释且符合与说明一致的最宽范围，并不限于示例或详细说明中的实施范例。

Claims (25)

  1. 光固化3D打印机，包括：
    具有透明的底壁和固定设置于所述底壁之上的周壁的光敏树脂池，所述底壁和周壁构成第一容纳空间；
    设置于所述光敏树脂池上方的用于承载打印物体的承载单元，所述承载单元能够竖直运动；
    位于所述第一容纳空间内且覆设于所述底壁的LCD液晶显示单元；以及
    位于所述第一容纳空间外且覆设于所述底壁的光源。
  2. 根据权利要求1所述的光固化3D打印机，所述光源包括：
    固定地设置于所述底壁下方的基板，所述基板和所述底壁之间形成第二容纳空间；
    固定地设置于所述基板上且位于所述第二容纳空间内的多个反光碗；以及
    固定地设置于每一个所述反光碗的焦点处的多个发光元件。
  3. 根据权利要求2所述的光固化3D打印机，所述多个反光碗呈阵列式地分布于所述LCD液晶显示单元在所述基板上的投影范围内。
  4. 根据权利要求2或3所述的光固化3D打印机，所述发光元件至所述LCD液晶显示单元的距离小于30mm。
  5. 根据权利要求4所述的光固化3D打印机，所述底壁的厚度小于10mm。
  6. 根据权利要求2或3所述的光固化3D打印机，所述基板内部设置有蜿蜒曲折的第一流体通道，所述第一流体通道的两端在所述基板上形成与外界连通的第一孔和第二孔。
  7. 根据权利要求2或3所述的光固化3D打印机，所述光源还包括：
    位于所述第二容纳空间外且覆设于所述基板上的第一冷却板，所述第一冷却板朝向所述基板的一侧具有向内凹陷的、蜿蜒曲折的第一流体通道，所述第一流体通道的两端在所述第一冷却板上形成与外部连通的第一孔和第二孔。
  8. 根据权利要求6或7所述的光固化3D打印机，所述第一流体通道至少遍布所述基板设置有发光元件的范围的60％。
  9. 根据权利要求7所述的光固化3D打印机，所述光敏树脂池的底壁的内部设置有蜿蜒曲折的第二流体通道，所述第二流体通道的两端在所述底壁上形成与外界连通的第三孔和第四孔。
  10. 根据权利要求7所述的光固化3D打印机，所述光敏树脂池包括:
    设置于所述底壁和所述LCD液晶显示单元之间的透明的第二冷却板，所述第二冷却板朝向所述LCD液晶显示单元的一侧具有向内凹陷的、蜿蜒曲折的第二流体通道，所述第二流体通道的两端在所述第二冷却板上形成与外界连通的第三孔和第四孔。
  11. 根据权利要求9或10所述的光固化3D打印机，所述第一流体通道和所述第二流体通道的截面成平行四边形，其侧边和底边的夹角a为15°～90°，优选地夹角a为30°～60°。
  12. 根据权利要求9或10所述的光固化3D打印机，所述第一流体通道和所述第二流体通道的截面成梯形，其侧边和底边的夹角b为90°～150°，优选地夹角b为120°～150°。
  13. 根据权利要求9或10所述的光固化3D打印机，所述第二流体通道至少遍布设置有LCD液晶显示单元的范围的60％。
  14. 根据权利要求9或10所述的光固化3D打印机，所述第二冷却板和所述冷却液的折射率一致。
  15. 根据权利要求10所述的光固化3D打印机，所述光敏树脂池包括:
    中部具有镂空的底壁，所述底壁的相对两侧向内凹陷以形成第三容纳空间；
    所述第二冷却板和所述LCD液晶显示单元设置于所述第三容纳空间内，
    能够设置于所述底壁上的周壁；
    一端与所述底壁枢转连接，另一端为自由端的锁止元件，所述锁止元件 具有卡合位置和自由位置；
    当所述锁止元件处于卡合位置时，所述底壁和所述周壁相互固定；
    当所述锁止元件处于自由位置时，所述底壁和所述周壁能够分离。
  16. 根据权利要求15所述的光固化3D打印机，所述底壁呈中部镂空的“回”形，所述锁止元件的纵向剖面呈“[”形。
  17. 根据权利要求15所述的光固化3D打印机，所述光敏树脂池包括：
    固定设置于所述周壁下部且和所述周壁的截面形状相同的密封元件；
    固定设置所述密封元件下部的高分子半透膜，所述高分子半透膜能够在自身表面形成气体分子层；
    固定设置于所述高分子半透膜下部的支撑元件；
    当所述锁止元件处于卡合位置时，所述支撑用户元件和所述周壁相互固定，所述高分子半透膜被张紧地覆设在所述LCD液晶显示单元上。
  18. 根据权利要求17所述的光固化3D打印机，所述第三容纳空间的深度基本相当于所述LCD液晶显示单元和所述第二冷却板的厚度之和。
  19. 根据权利要求18所述的光固化3D打印机，所述光敏树脂池还包括：
    设置于所述高分子半透膜和所述周壁的接触面之间的柔软的密封元件。
  20. 根据权利要求15或17所述的光固化3D打印机，还包括：
    设置于所述光源下方且能够向所述第一流体通道和所述第二流体通道输送冷却液的冷却单元；
    所述冷却单元包括：
    冷却液存储容器；
    至少一组散热器；
    泵；
    所述冷却液存储容器、所述散热器、所述泵以及所述第一流体通道和所述第二流体通道通过管路串联。
  21. 根据权利要求20所述的光固化3D打印机，还包括：
    设置于所述LCD液晶显示单元上的第一温度监测元件；
    设置于所述光源的基板上的第二温度监测元件；以及
    能够根据所述第一温度监控元件和第二温度监测元件的监测数值控制所述泵工作的控制单元，所述控制单元还能够控制所述光源和所述LCD液晶显示单元的开启和关闭，并控制所述承载单元的运动。
  22. 一种3D打印方法，包括：
    a.以光敏树脂池容纳液态光敏树脂；
    b.以LCD液晶显示单元显示待打印物体的横截面图案；
    c.以光源紧贴所述光敏树脂池底壁，使所述光源照射所述LCD液晶显示单元，所述光线透过所述光敏树脂池和所述LCD液晶显示单元照射容纳于所述光敏树脂池内的液态光敏树脂，以使其固化成与所述待打印物体的横截面图案相应的形状。
  23. 根据权利要求22所述的3D打印方法，还包括：
    d.在所述光源的周围设置第一流体通道，在执行步骤c的同时，使冷却液在所述第一流体通道内循环。
  24. 根据权利要求23所述的3D打印方法，其中：
    d.在所述光源周围设置第一流体通道，在所述LCD液晶显示单元的周围设置第二流体通道，在执行步骤c的同时，使冷却液在所述第一流体通道和所述第二流体通道内循环。
  25. 一种3D打印方法，包括：
    a.以光敏树脂池容纳液态光敏树脂；
    b.以LCD液晶显示单元显示待打印物体的横截面图案；
    c.以光源紧贴所述光敏树脂池底壁，使所述光源照射所述LCD液晶显示单元，所述光线透过所述光敏树脂池和所述LCD液晶显示单元照射容纳于所述光敏树脂池内的液态光敏树脂，以使其固化成与所述待打印物体的横截面图案相应的形状；
    d.在所述光源周围设置第一流体通道和第一温度监测元件，在所述LCD液晶显示单元的周围设置第二流体通道和第二温度监测元件；
    e.控制单元根据所述第一温度监测元件和第二温度监测元件的监测数值以控制冷却液在所述第一流体通道和所述第二流体通道内循环。
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