JPH09216290A - Shaping of three-dimensional matter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize the rapid formation of a cross-sectional shape by a simple constitution to shape an inexpensive three-dimensional matter precossable at a high speed, in a method for shaping the three-dimensional matter by laminating cross-sectional shapes, by forming a cross-sectional shape to a sheet like film to be folded back by particles and fusing and bonding them before removing an unnecessary part. SOLUTION: A preliminarily folded back strip like continuous film 11 is pulled out to be fed and a shaping material composed of a resin material is bonded to the film by an electrophotographic system to continuously form an auxiliary shape 22 along with the cross-sectional shape 21 of three- dimensional matter and the film 11 is bent so that the cross-sectional shape 21 and the auxiliary shape 22 are superposed one upon another to be laminated. The laminated film 11 and the cross-sectional shape are fused and bonded and a part other than the bonded cross-sectional shape 21 is removed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a three-dimensional object, and more particularly to a method for forming a three-dimensional object by laminating cross-sectional shapes.

[0002]

2. Description of the Related Art Conventionally, CAD (Computer Aided Des
3D object designed by ign system) (prototype etc.)
There is known a method of directly using CAD data for modeling. As a molding method of this kind of three-dimensional object, for example, an optical molding method is known. This stereolithography method (hereinafter, referred to as a first conventional example) is such that a liquid resin material (photocurable resin) that is cured by irradiation with ultraviolet rays or the like is contained in a container, and the cross section of CAD data is placed on the liquid surface. One cross-sectional shape is produced by scanning light based on the shape data, and thereafter, a resin material is made to flow into the upper surface thereof, and a similar operation is repeated to form a three-dimensional object.

Further, in Japanese Patent Laid-Open No. 7-68647,
A method of forming a three-dimensional object by laminating a solidified material that can be partially vaporized and removed by irradiating laser light and filling the removed portion with a photocurable resin and curing it, and repeating this (hereinafter, The second conventional example) has been proposed. Further, in JP-A-6-190929 and JP-A-6-278214, three-dimensional objects are formed by joining sheets one by one with an adhesive, cutting each sheet into a cross-sectional shape at each joining, and repeating this. Has been proposed (hereinafter referred to as a third conventional example).

[0004]

However, in the first conventional example, since the resin material is cured by scanning with light, it takes 10 to 20 hours even when a small product of 10 cm square is produced. In addition to the cost, the device is expensive (40 million yen or more for a device using ultraviolet rays). Further, this problem is the same as in the second conventional example because the laser beam is scanned in order to remove the solidified material.

In addition, in the third conventional example, it is necessary to apply and adhere the adhesive and cut the sheet for each layer according to the cross-sectional shape, and the cross-sectional shape changes, so that a complicated shape is produced. However, there is a problem that it takes time, although it seems that it is not as great as the above-mentioned conventional example.
Further, when laser light is used to enable cutting of a complicated shape, there is a problem that the cost becomes high.

Therefore, according to the present invention, particles are formed into a cross-sectional shape on a sheet-like film to be folded and then these are weld-bonded to each other, and then unnecessary portions are removed to obtain a quick cross-sectional shape with a simple structure. An object of the present invention is to provide a method for forming a three-dimensional object that is inexpensive and can be processed at high speed by realizing the formation. In addition, by holding the film even in unnecessary parts to be separated, it is possible to realize more accurate modeling of three-dimensional objects and to facilitate the separation of unnecessary parts from the molded three-dimensional object to improve workability. The purpose is to plan.

[0007]

In order to achieve the above-mentioned object, the invention according to claim 1 conveys a continuous film in the form of a band and deposits molding particles made of a resin material on the film to form a cross-sectional shape of a three-dimensional object. And a second step of bending a film having a cross-sectional shape so that the cross-sectional shapes overlap each other and laminating the film and modeling particles.
And a third step of welding and joining the laminated film and the modeling particles, and a fourth step of removing a portion other than the joined cross-sectional shape.

According to the first aspect of the present invention, the strip-shaped film is conveyed in the continuous direction, and after the cross-sectional shape of the three-dimensional object is continuously formed on the film by the modeling particles,
The films and the modeling particles are laminated by bending the films so that the cross-sectional shapes are overlapped. And after this,
The excess portion is removed by welding and joining the film and the modeling particles. Therefore, the cross-sectional shape can be formed by simply adhering the particles to the film, for example, by transferring the particles, and then the cross-sectional shape can be laminated by simply bending the film at regular intervals. Further, when the modeling particles are fine particles, they can be melted at the time of welding to bond the films.

According to a second aspect of the present invention, in addition to the structure of the first aspect of the invention, in the first step, after the electrostatic latent image having a sectional shape is formed on the photoconductor, the electrostatic latent image is formed. The molding particles are attached to the film and transferred to a film to form a cross-sectional shape of the molding particles on the film. According to the second aspect of the invention, the cross-sectional shape formed on the film is formed by a so-called electrophotographic method. This electrophotographic system is capable of accurately transferring particles with a simple structure due to the advancement of technology in recent years.
The cure depth, which is a problem in the conventional example, is also irrelevant. Therefore, the cross-sectional shape can be formed by continuously transferring particles with high accuracy and at high speed by a simple configuration of an electrophotographic system.

[0010] The third aspect of the present invention is the first or second aspect.
In addition to the constitution of the invention described in, in the first step, the auxiliary particles made of the resin material are attached to a certain position apart from the sectional shape of the three-dimensional object, and in the fourth step, the auxiliary particles are It is also characterized by removing. This claim 3
In the invention described above, the auxiliary particles are adhered to a certain position separated from the cross-sectional shape on the film, for example, a position at a predetermined distance from the fold, and the auxiliary particles are also auxiliary laminated together with the film and the modeling particles. Therefore, the distance between the films near the outer edge of the cross-sectional shape is held by the auxiliary particles and the deformation of the film is prevented. The auxiliary particles may be made of a material different from that of the modeling particles, but by using the same material, they can be attached (transferred) to the film at the same time as the modeling particles.

According to a fourth aspect of the invention, in addition to the configuration of the invention according to any one of the first to third aspects, in the first step,
The present invention is characterized in that support particles made of a material that is not welded under the welding conditions for modeling particles are attached to the film so as to be adjacent to the cross-sectional shape of the three-dimensional object, and the support particles are also removed in the fourth step. According to a fifth aspect of the invention, in addition to the configuration of the fourth aspect of the invention, as the support particles, particles made of a resin material having a higher melting point than the modeling particles are used.

According to the inventions of claims 4 and 5, the supporting particles are attached adjacent to the modeling particles forming the cross-sectional shape on the film, and the supporting particles are laminated together with the film and the modeling particles. The support particles do not weld to the film and the modeling particles. Therefore, the distance between the films in the vicinity of the outer edge of the cross-sectional shape is held by the supporting particles, and the deformation of the film is more reliably prevented. The support particles may be a material that can be attached to the film or a material that can be transferred by an electrophotographic method, but it is preferable that the particles be attached to the film under the same conditions as those for the modeling particles. It is preferable to use a resin material having a melting point higher than that of the modeling particles as in the invention described in 1.

According to a sixth aspect of the invention, in addition to the constitution of the invention according to any one of the first to fourth aspects, as the film,
It is characterized in that it is wound in a roll and can be continuously supplied. In the invention according to claim 6, a belt-shaped film is drawn out from a roll-shaped film and conveyed,
Continuously supply to the attachment (transfer) position of the modeling particles. Therefore, the position of the fold of the film can be changed arbitrarily.

According to a seventh aspect of the invention, in addition to the constitution of the invention according to any one of the first to fourth aspects, as the film,
The feature is that it is folded at a constant interval and can be continuously supplied. According to the seventh aspect of the present invention, a belt-shaped film is drawn out from a preliminarily folded fold and is conveyed, and is continuously supplied to the attachment (transfer) position of the modeling particles. Therefore, it is not necessary to make a crease in the film in order to overlap the cross-sectional shapes in the second step, and the load for pulling it out for transporting is smaller than that for rolling in a roll shape.

According to an eighth aspect of the invention, in addition to the constitution of the invention according to any of the first to fourth aspects, after the first step, one or both of pressure and heat are applied to the modeling particles and the film. In addition, it is characterized in that the modeling particles are attached onto a film. In the invention according to claim 8, not only heating for fusion bonding after lamination of the cross-sectional shape, but also after forming the cross-sectional shape, that is, before laminating the cross-sectional shape, for example, by sandwiching the molding particles and Apply pressure or heat to the film. Therefore, the molding particles are pressure-bonded to the film before lamination of the cross-sectional shape,
Welded and thermocompression bonded.

According to a ninth aspect of the invention, in addition to the constitution of the invention according to any of the first to fourth aspects, in the third step, the laminated film and the modeling particles are heated to have an outer diameter dimension. It is characterized by applying a constant pressure and thermocompression-bonding the modeling particles onto the film. In the invention according to claim 9, at the time of heating for fusion-bonding after stacking the cross-sectional shapes, pressure for making the outer diameter dimension constant, for example, stacking larger than the design shape, and then reducing to the design shape is performed. Apply pressure. Therefore, the cross-sectional shape can be formed with high accuracy during transfer, and the height can also be adjusted with high accuracy after lamination.

According to a tenth aspect of the invention, in addition to the constitution of the invention according to any one of the first to fourth aspects, a resin material showing thermoplasticity or thermosetting property near the melting temperature of the modeling particles is used as the film. It is characterized by using the configured one. According to the tenth aspect of the present invention, since a film that exhibits thermoplastic or thermosetting properties near the temperature applied during welding of the modeling particles is used, the film having thermoplasticity shrinks due to the thermoplasticity, and thermosetting is performed. A film having properties is hardened and brittle due to its thermosetting property. Therefore, since the film is thin, the part of the modeled object welded to the modeling particles and the other part are naturally separated from each other, or a small external force is applied to separate them.

According to an eleventh aspect of the invention, in addition to the structure of the tenth aspect of the invention, in the fourth step, a fluid or powder is sprayed to separate an extra portion other than the cross-sectional shape from the modeled object. Is characterized by. According to the eleventh aspect of the present invention, after the lamination, heating is performed to weld and bond the film and the modeling particles, and then the fluid or powder is sprayed. Therefore, since the excess portion other than the shaped article is easily separated from the shaped article due to the thermoplasticity or thermosetting property of the film, it can be separated only by spraying the particles or powder. At this time, when a gas such as air is used as the fluid, the shaped object is not wetted or contaminated, and can be obtained at a low cost by a compressor or the like. In addition, when a liquid such as water is used as the fluid, there is no pollution, the cost is low, and the separation ability can be higher than that of the gas. Moreover, when powder is used, the separation ability can be further increased.

According to a twelfth aspect of the invention, in addition to the constitution of the invention according to any one of the first to fourth aspects, a film made of a water-soluble material is used as the film.
The step (2) is characterized by immersing in water or spraying water to separate extra portions other than the cross-sectional shape from the modeled object. According to the twelfth aspect of the invention, since the water-soluble film is used, the film can be immersed in water to make it brittle, and when spraying water, an external force can be applied while making it brittle. Therefore, an unnecessary portion can be separated from the modeled object with a small external force.

The invention according to claim 13 is the invention according to claims 10 to 1.
In addition to the configuration of the invention described in any one of 2 above, in the fourth step, vibration is applied to separate an extra portion other than the cross-sectional shape from the modeled object. In the invention according to the thirteenth aspect, vibration is applied to the molded article on which the film and the modeling particles are welded. Therefore, it is possible to separate the parts other than the modeled object, which has become brittle due to thermoplasticity, thermosetting property, and water solubility, without touching.

Here, the above-mentioned modeling particles may be selected according to the size and accuracy of the three-dimensional object to be modeled. For accurate modeling, the particle size is about 0.05 to 0.5 mm.
This is preferable because the cross-sectional shapes can be overlapped without applying a load near the folds of the film. Also, the same applies to the film, but considering the transport accuracy and the load near the fold,
It is preferable that the thickness is about 0.03 to 0.3 mm.

In order to fold the film, it is preferable to make a perforation at that position so that the film can be bent without load and can be bent without alignment. The film and the modeling particles may be heated by a heater, but may be heated rapidly and uniformly by using high frequency.

The fluid may be a gas such as air or a liquid such as water, and the powder may be sand or the like. Needless to say, the water-soluble substance is not limited to water. further,
Separation of the excess part from the model is not limited to the above method,
It is needless to say that an external force (external pressure) may be simply applied, for example, it may be removed with a brush or the like, and since the film itself is thin, it may be removed with a cutter or the like.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings. 1 to 5 are views showing an example of a modeling apparatus for carrying out a first embodiment of a method for modeling a three-dimensional object according to the present invention, and FIG. 1 is an apparatus for carrying out the first to second steps thereof. 2 shows an apparatus section for carrying out the third step, FIG. 3 shows an apparatus section for carrying out the fourth step, FIG. 4 shows a state after lamination, and FIG. 5 shows a state after modeling. Shows.

First, an apparatus configuration for carrying out this embodiment will be described. In FIG. 1, 11 is a film folded at regular intervals, and the film 11 is formed of a predetermined resin material in a sheet shape (strip shape) with a thickness of about 0.03 to 0.3 mm. It is folded in advance at intervals and set so that it can be continuously pulled out and conveyed from above. The film 11 can be folded and stacked again at the interval after being conveyed, and is folded inside the frame 23 by, for example, abutting against the frame 23 placed at a laminating position described later to limit the movement. be able to.
It should be noted that the film 11 may be preliminarily provided with perforations at a folding position so that the film 11 can be folded without load. In addition, a dedicated device may be installed in the vicinity of the stacking position in order to fold the film 11 again. 12, 13
Is a pair of rollers separated from each other in the transport direction (continuous direction) of the film 11, and the roller pair 12 is driven to rotate by the transport of the film 11 while being pressed against each other, while the roller pair 13 is driven to rotate while being pressed against each other. Then, the other is driven to rotate, thereby applying a pinching pressure to the films 11 held between each other and pulling out the film 11 to convey it to the downstream stacking position.

Reference numeral 14 is a photosensitive drum that rotates in synchronization with the transport of the film 11. On the photosensitive drum 14, for example,
An optical system (not shown) optically scans an electrostatic latent image to form an electrostatic latent image based on data for each sectional shape of the three-dimensional object designed by CAD. Along with the image, an auxiliary image having a predetermined area is formed at a position apart from the outer edge of the image and at a constant distance from the fold line. Reference numeral 15 denotes a developing device, which develops the electrostatic latent image formed on the surface of the photosensitive drum 14 with a predetermined resin material and has a particle size of 0.00
A modeling material (modeling particles, auxiliary particles) 20 of about 5 to 0.5 mm is attached and developed to form a cross-sectional shape 21 and an auxiliary shape 22 of a three-dimensional object. Reference numeral 16 denotes a transfer device, and the transfer device 16 has a sectional shape 21 and an auxiliary shape 22 formed on the photoconductor drum 14.
Is attached to the film 11 conveyed between the roller pairs 12 and 13 and transferred. In the figure, 17 is a cleaning device for removing the modeling material 20 remaining on the surface of the photoconductor drum 14, 18 is a static eliminator for neutralizing the surface of the photoconductor drum 14, and 19 is a photoconductor drum 14
This is a charger for uniformly charging the surface, and since the photosensitive drum 14 to the charger 19 have the same structure as that of a known electrophotographic apparatus, a further description will be omitted.

Here, the resin material forming the film 11 and the modeling material 20 is, for example, polyethylene (137 °),
Polypropylene (176 °), polyvinylidene chloride (1
98 °), polyvinyl chloride (212 °), polycarbonate (220 °), polystyrene (240 °), nylon (265 °), etc., but since the film 11 and the molding material 20 are melt-bonded, they are the same. It is preferable to use the material. The temperature in the parentheses indicates the melting point of the resin material.

The thickness of the film 11 is preferably about 0.03 to 0.3 mm in consideration of the transportation accuracy and the load in the vicinity of the fold line, but it is not limited to this, and the three-dimensional object to be molded is not limited to this. It may be selected according to the size, and thinner or thicker one may be used. In addition, the particle size of the modeling material 20 is also the same.
It is preferable that the thickness is about 0.005 to 0.5 mm so that the film 11 can be accurately overlapped in the vicinity of the fold line without giving a load, but it is selected according to the size of the three-dimensional object to be molded and the molding accuracy, and a smaller diameter Needless to say, one having a large diameter or one having a large diameter may be used. Further, the film 11 may be selected from those having thermoplasticity, thermosetting property, or water solubility in consideration of handling described later.

2 and 3, reference numeral 23 denotes a frame installed at the laminating position of the film 11, and the frame 23 is composed of a lower surface block 24, a side surface block 25 and an upper surface block 26, and is located at the laminating position. Film 11 being transported
Can be housed inside, and its movement can be restricted by the side block 25, and can be re-folded at a crease provided in advance to be laminated inside. The frame 23 can be heated by a heater or high frequency from the outside, and can heat the film 11 and the like housed inside. Also, the frame
The lower block 24 of 23 is made so that it can be installed, for example, on a mechanism that vibrates in the horizontal direction, and the side block 25 is formed at a height lower than that of the film 11 after lamination and is removable from the lower block 24. When the top block 26 is manufactured and placed on the side block 26, a load is applied to the film 11 and the like inside. Further, 27 is a nozzle that blows compressed air (fluid), and the nozzle 27 is, for example, a film inside.
After removing the upper block 26 and the lower block 24 from the frame 23 in which 11 and the cross-sectional shape 21 and the auxiliary shape 22 are laminated, compressed air is blown to the film 11 or the like. In the present embodiment, the frame 23 allows all of the lamination of the film 11, the vibration, and the blowing of the air. However, it is also possible to separately perform the operations with the devices provided at different positions. Needless to say. Further, instead of the compressed air from the nozzle 27, water (fluid) is blown out or sand (powder) is used.
May be blown out.

Next, the method of forming a three-dimensional object according to the present embodiment will be described for each step along with the operation. First, before starting the modeling work of the three-dimensional object, the film 11 is paired with the roller pair 12,
It is sandwiched between 13 and, for example, when the CAD data is received, the modeling work of the three-dimensional object is started. <First Step: FIG. 1> Then, the roller pair 13 and the photoconductor drum 14 are rotationally driven to pull out the film 11 and convey the film 11 downstream, and on the photoconductor drum 14 that rotates in synchronization with the conveyance. The cross-sectional shape 21 and the auxiliary shape 22 are developed and formed by the molding material 20, and are transferred and attached onto the film 11 to be conveyed. Then, the cross-sectional shape 21 and the auxiliary shape 22 are formed every time the film 11 is conveyed by a constant amount, that is, so as to correspond to the crease intervals.

At this time, since the film 11 is simply folded at regular intervals, it can be pulled out without load and continuously supplied to the transfer positions of the sectional shape 21 and the auxiliary shape 22 by the photosensitive drum 14, and after that. There is no need to insert folds or perforations for stacking. And
The cross-sectional shape 21 and the auxiliary shape 22 are attached and formed on the film 11 by forming the electrostatic latent image formed on the photoconductor drum 14 into the modeling material 20.
Since it is performed by an electrophotographic method that develops and transfers by
The cross-sectional shape 21 and the auxiliary shape 22 can be formed on the film 11 with high accuracy and at high speed with a simple configuration without problems such as the curing depth. In addition, the cross-sectional shape 21 and the auxiliary shape 22 are turned upside down every other time when the film 11 is folded, so that the mirror surface processing used in the electrophotographic method is performed in the transport direction of the film 11 and the front-back direction is reversed. The cross-sectional shape 21 and the auxiliary shape 22 are formed. It should be noted that every other cross-sectional shape 21 may be formed so as not to perform this mirror surface treatment.

Next, when the cross-sectional shape 21 reaches the position where the roller pair 13 is arranged as the film 11 is conveyed, the roller pair 13 together with the passing film 11 cross-sectional shape 21 and auxiliary shape 22.
Is narrowed, and the shaping material 20 is pressure-bonded (attached) to the film 11 by the pressure. Therefore, the modeling material 20 forming the cross-sectional shape 21 and the auxiliary shape 22 is pressure-bonded to the film 11. The roller pair 13 may be crimped by embedding a heater inside the roller pair 13 so that the film 11 and the molding material 20 are thermocompressed (temporarily welded). It is also possible to heat and temporarily weld without applying pressure.

<Second Step: FIGS. 1 and 2> Then,
The film 11 is transported further downstream, is accommodated in the frame 23 placed at the stacking position, and its tip is a side block 25.
The film 11 and the cross-sectional shape 21 and the auxiliary shape 22 are frame 23
Stack inside. At this time, as shown in FIG.
21 is laminated via the film 11 to form a three-dimensional object 28 temporarily. Further, since the auxiliary shape 22 is also laminated via the film 11 and the formation positions thereof coincide with each other in the vertical direction, the film 11 has a gap outside the cross-sectional shape 21 of the auxiliary material 22 (cross-sectional shape 21). ) Is maintained at the thickness of. Therefore, the deformation of the film 11 on the outer edge side of the cross-sectional shape 21 is prevented.

<Third Step: FIG. 2> Next, the upper block 26 of the frame 23 is placed on the film 11 or the like to apply a load, and then the frame 23 is heated from the outside to cross-section with the film 11. The shape 21 and the auxiliary shape 22 are heated to such an extent that at least their surfaces are melted. Therefore, the film 11 is welded and bonded to the cross-sectional shape 21 and the auxiliary shape 22 while applying pressure, and the three-dimensional object 28 is formed inside the film 11 while the height is limited to the height of the side block 25. At this time,
When a film 11 having thermoplasticity is used as the film 11, only the film 11 is naturally separated from the part where the cross-sectional shape 21 is formed by shrinking due to its characteristics. Also,
When a film having a thermosetting property is used as the film 11, it is hardened due to its characteristics and only the film 11 becomes brittle. Further, when the modeling material 20 having a particle size such that it melts at the time of heating is used, the films 11 can be melted and welded to each other. In addition, when the frame 23 is heated by high frequency, the heat treatment can be performed quickly and uniformly.

<Fourth step: FIG. 3> Next, after cooling (preferably gradually cooling) the frame 23, the side block 25 is removed and the state shown in FIG. Vibrate block 24. Since only the film 11 is brittle when it has thermoplasticity or thermosetting property, the wind force (external force) by compressed air and the inertial force (external force) due to the weight of the auxiliary shape 22 and the like.
The three-dimensional object 28 shown in FIG.
Can be obtained. Therefore, three-dimensional object 28 (modeled object)
Therefore, the film 11 and the auxiliary shape 22 in the unnecessary portion can be separated without any special treatment, and the work with a brush or the like can be omitted. Further, since air is blown at this time, the three-dimensional object 28 is not soiled or wet, and the compressed air itself can be obtained at low cost by a compressor or the like. Further, when it is desired to increase the efficiency of separating the excess portion, liquid such as water or powder such as sand may be used. Furthermore, when a water-soluble film is used as the film 11, it can be dissolved by water sprayed due to its characteristics. When a water-soluble film is used, it is also effective to immerse it in water and apply vibration.

As described above, in the present embodiment, the cross-sectional shape 21 and the auxiliary shape 22 are continuously formed by the shaping material 20 on the film 11 to be conveyed, and the cross-sectional shape is formed by folding the film 11 at regular intervals. 21 and the auxiliary shape 22 are sandwiched, and thereafter, the entire film is heated and the film 11 and the sectional shape 21 and the auxiliary shape 22 are welded and joined to each other to remove an excessive portion, so that the sectional shape 21 can be easily formed. ,And,
The three-dimensional object 28 can be formed by rapidly forming and stacking. Further, since the film 11 that has been folded in advance is used, the work for bending the film 11 can be omitted, and since there is no carrying load, the film 11 can be carried by a small drive source.

In the first step, the cross sectional shape 21
And the auxiliary shape 22 is formed by transferring the modeling material 20 onto the film 11 by the electrophotographic method using the photoconductor drum 14.
It can be formed with high precision and at high speed. Also,
Since the auxiliary shape 22 is formed at a position separated from the cross-sectional shape 21 by a certain distance, it is possible to prevent the film 11 near the outer edge of the cross-sectional shape 21 from being deformed after being laminated. Furthermore, since the cross-sectional shape 21 and the auxiliary shape 22 are pressed against the film 11 by the roller pair 13 after the transfer, it is possible to prevent the modeling material 20 from peeling off during transportation.

In the third step, a load is applied by the upper surface block 26 at the time of heating after stacking and the side surface block 25 is applied.
Since the height is limited to the height, the height can be adjusted with high accuracy. Further, in the fourth step, by using the film 11 having thermoplasticity or thermosetting property, the film 11 other than forming the three-dimensional object 28 is made fragile at the time of welding with the cross-sectional shape 21 and the auxiliary shape 22. Unnecessary parts can be easily separated, and they can be separated without any action by spraying compressed air, water, sand or the like and applying vibration. Further, by using the water-soluble film 11, it is possible to easily separate unnecessary portions while making them brittle by immersing in water or spraying water.

As a first other aspect of the present embodiment, as shown in FIG. 6, the three-dimensional object 28 may be molded without forming the auxiliary shape 22 on the film 11. In this other aspect, the film near the outer edge of the cross-sectional shape 21
This can be adopted when modeling the three-dimensional object 28 with a precision that does not affect the deformation of 11, and the auxiliary shape 22 can be omitted, so that the consumption amount of the modeling material 20 can be reduced.

As a second other mode, as shown in FIG. 7, the film 21 is taken out from the frame 23 after being laminated, or the load of the upper surface block 26 is not applied.
The film 11 may be heated and welded to the cross-sectional shape 21 and the auxiliary shape 22. This other embodiment is a solid
It is suitable for modeling a case or for manufacturing a plurality of three-dimensional objects 28 in a short time, and it is not necessary to arrange a plurality of sets of frames 23 and the like.

Next, FIG. 8 is a diagram showing an example of a modeling apparatus for carrying out the second embodiment of the method for modeling a three-dimensional object according to the present invention, which is an apparatus for carrying out the first to second steps. Parts are shown. Since the present embodiment is substantially the same as the above-described embodiment, the same reference numerals are given to the same configurations in the device unit that performs the same, and only the characteristic portions will be described. First, a device configuration for implementing this embodiment will be described.

In the figure, 31 is a film, and the film 31 is produced in the same manner as in the above-mentioned embodiment and wound into a roll, so that the film 31 can be continuously drawn out by a pair of rollers 12, 13. It is held by a holder (not shown). Reference numeral 32 is a crease imparting device (hereinafter, referred to as a crease device), and the crease device 32 puts perforations extending in the width direction in the film 31 conveyed to the downstream side of the roller pair 13 at a constant interval and bends at that interval. In such a manner that the films 31 can be overlapped, the film 31 is folded and laminated in the frame 23 at perforated intervals. It should be noted that this perforation is inserted at regular intervals by, for example, detecting the amount of conveyance of the film 31 by the roller pairs 12 and 13, or forming and detecting a mark at a constant position with respect to the cross-sectional shape 21 by the molding material 20 or the like. You can do it like this. The film
The jig 31 may be bent at an acute angle using a jig or the like to be folded, but it is preferable to make perforations as in the present embodiment in order to fold it at an arbitrary position without load. Further, since the perforations are inserted during the transportation of the film 31, the interval can be changed according to the size of the three-dimensional object 28 to be modeled.

Next, the characteristic part of the method for modeling a three-dimensional object in the first step according to the present embodiment will be described together with its operation. In this embodiment, a method of forming only the cross-sectional shape 21 on the film 31 will be described. First, while pulling out the film 31 and transporting it downstream, the film 31 to be transported
The cross-sectional shape 21 is continuously transferred (attached) to the cross-sectional shape 21
After the whole is located on the downstream side of the roller pair 13, the fold device 32 moves the blade in the direction of the roller pair 13 to insert perforations in the film 31 at constant intervals in the transport direction, and the cross-sectional shape of the perforation is set to the roller pair. Do it every time you pass 13.

Thereafter, as in the above-described embodiment, the three-dimensional object 28 is modeled by processing. Thus, in this embodiment,
In addition to the function and effect of the first embodiment described above, the film 31 wound in a roll shape is pulled out and conveyed, so that the position of perforation is changed according to the size of the cross-sectional shape 21, and the position of the fold is arbitrarily changed. Can be made. Therefore, the film 31 can be effectively used, and the running cost can be reduced.

Next, FIG. 9 is a diagram showing an example of a molding apparatus for carrying out the third embodiment of the method for molding a three-dimensional object according to the present invention, and an apparatus for carrying out the first step to the second step. Parts are shown. Since the present embodiment is substantially the same as the above-described embodiment, the same reference numerals are given to the same configurations in the device unit that performs the same, and only the characteristic portions will be described. First, a device configuration for implementing this embodiment will be described.

In the figure, reference numeral 44 designates a photosensitive drum which is arranged on the downstream side of the photosensitive drum 14 so as to be spaced apart therefrom. The photosensitive drum 44 has an optical element (not shown) based on CAD data for each sectional shape. The system optically scans to form an electrostatic latent image on the photosensitive drum 14 in an area other than the electrostatic latent image for developing the sectional shape 21 (area adjacent to the sectional shape 21 when transferred to the film 11). This photoconductor drum 44
The electrostatic latent image formed on the support member (support particles) 40 made of a resin material having the same particle diameter as the modeling material 20 but having a high melting point is developed by the developing device 45 to form the support shape 42. . Similar to the cross-sectional shape 21, the support shape 42 is designed such that the transfer device 16 attaches it to the film 11 to transfer it, and the cleaning device 17, the static eliminator 18, and the charger 19 operate in the same manner. That is, in this embodiment, the modeling material 20 and the support material 40 are formed into the film 11 by the two-type electrophotographic method.
The cross-sectional shape 21 and the support shape 42 are transferred to the film 11
Form on top. The electrostatic latent image formed on the photosensitive drum 44 is formed so as to be adjacent to the cross-sectional shape 21, but it is formed in consideration of the transport accuracy of the film 11 and the like. Also, in the figure,
46 is a roller pair disposed between the photoconductor drums 14 and 44, and the roller pair 46 relays the conveyance of the film 11 between the roller pairs 12 and 13.

Here, it is preferable that the resin material forming the support material 40 has a melting point as high as possible with respect to the molding material 20, and nylon (265 °) or the like can be used. It is sufficient if the material 20 is not welded to the film 11 at the time of welding and joining, and it is not necessary to use a resin material as long as the electrostatic latent image can be developed. Next, the characteristic part of the method for modeling a three-dimensional object according to the present embodiment will be described together with the operation.

First, the film 11 is sandwiched between the roller pairs 12, 13, and 46 before starting the modeling operation of the three-dimensional object, and the modeling operation of the three-dimensional object is started by receiving the CAD data, for example. <First Step> Then, while pulling out the film 11 and transporting it downstream, the cross-sectional shape 21 is continuously transferred (attached) to the transported film 11 by the photosensitive drum 14.
Then, similarly, the support shape 42 is transferred by the photosensitive drum 44 so as to be adjacent to the cross-sectional shape 21 to cover almost the entire surface of the film 11. It should be noted that a space may be provided around the fold line so as not to hinder the bending of the film 11.

Then, when the cross-sectional shape 21 and the support shape 42 reach the position where the roller pair 13 is arranged as the film 11 is conveyed, the roller pair 13 compresses the cross-sectional shape 21 and the support shape 42 together with the film 11 passing therethrough, The pressure causes the molding material 20 and the support material 40 to be pressed (attached) to the film 11.
Let it. At this time, the modeling material 20 and the support material 40 forming the cross-sectional shape 21 and the support shape 42 are pressed to the film 11 and prevented from peeling off from the film 11 during transportation, but the internal heater of the roller pair 13 is prevented. Even when the molding material 20 is thermocompression-bonded (temporarily welded) to the film 11 by the above, since the support material 40 has a high melting point, the film 11 and the molding material 20
It will never be welded to.

<Second Step: FIGS. 1 and 2> Then,
The film 11 is transported further downstream, and is laminated together with the cross-sectional shape 21 and the support shape 42 in the frame 23 as in the above embodiment. At this time, the film 11 is held in the thickness interval by the cross-sectional shape 21 and the support shape 42, the cross-sectional shape 21 is laminated in the support shape 42, and the three-dimensional object 28 is temporarily molded. Therefore, the deformation of the film 11 on the outer edge side of the cross-sectional shape 21 is more reliably prevented.

<Third to Fourth Steps> Next, as in the above-described embodiment, the frame 23 is externally heated to weld and join the film 11 and the cross-sectional shape 21. At this time, the three-dimensional object 28 is molded inside, but the melting point of the support material 40 is high and it does not weld to the film 11 and the cross-sectional shape 21. Then, after cooling (preferably gradually cooling) the frame 23, compressed air or the like is blown from the nozzle 27 or immersed in water, and the lower surface block 24 is vibrated to support the three-dimensional object 28 together with the film 11 other than the modeling. The material 40 is separated to obtain the three-dimensional object 28.

As described above, in this embodiment, in addition to the effects of the first embodiment, the cross-sectional shape between the films 11 is increased.
Since the support shape 42 made of the support material 40 is sandwiched adjacent to the film 21, the deformation of the film 11 can be prevented more reliably, and a more accurate three-dimensional object 28 can be easily formed. Next, FIG. 10 is a diagram showing an example of a modeling apparatus for carrying out a fourth embodiment of a method for modeling a three-dimensional object according to the present invention,
The apparatus part which implements the 1st process to the 2nd process is shown. Since the present embodiment is substantially the same as the above-described embodiment, the same reference numerals are given to the same configurations in the device unit that performs the same, and only the characteristic portions will be described.

First, a device configuration for carrying out this embodiment will be described. In the figure, reference numeral 54 denotes a photoconductor drum which is arranged on the downstream side of the photoconductor drum 14 at a distance from the photoconductor drum.
54 is located on the back side of the film 11 and forms the cross-sectional shape 21 and the auxiliary shape 22 based on the CAD data on the film 11 similarly to the photoconductor drum 14. These photosensitive drums 14, 54
Cross-sectional shape 21 and auxiliary shape 22 on both sides of the film 11.
However, since the film 11 faces each other when folded, the cross-sectional shape 21 and the auxiliary shape 22 are formed by two sets of continuous CAD data for each of the photosensitive drums 14 and 54. That is, in this embodiment, the cross-sectional shape 21 and the auxiliary shape 22 are formed on the film 11 by the two-type electrophotographic method.

Next, the characteristic parts of the method for modeling a three-dimensional object in the first and second steps according to the present embodiment will be described together with the operation. First, before starting the work of modeling three-dimensional objects,
The film 11 is sandwiched between the roller pairs 12, 13, and 46, and, for example, the CAD data is received to start the modeling operation of the three-dimensional object.

Then, the film 11 is pulled out and conveyed downstream, and the cross-sectional shape 21 and the auxiliary shape 22 are continuously transferred (attached) onto the conveyed film 11 by the photosensitive drums 14, 54. Next, after the roller pair 13 press-bonds (attaches) the cross-sectional shape 21 and the auxiliary shape 22 formed on both sides with the transport of the film 11 to the film 11, the film 11 is transported further downstream and the cross-sectional shape 21 And the auxiliary shape 22 is laminated in the frame 23. At this time, two layers of cross-sectional shapes 21 are laminated between the folded films 11, and the three-dimensional object 28 is provisionally molded together with the film 11. Therefore, C
AD data can be processed at double speed.

Thereafter, in the same manner as in the above-described embodiment, the three-dimensional object 28 is modeled by processing. Thus, in this embodiment,
In addition to the function and effect of the first embodiment described above, when the cross-sectional shape 21 and the auxiliary shape 22 are formed on both surfaces of the film 11 and sandwiched between the films 11 when they are folded, the three-dimensional object 28 can be molded at higher speed. You can

[0057]

According to the first aspect of the invention, the particles for molding are attached to the band-shaped film to be bent, the cross-sectional shape is continuously formed and laminated, and then the film and the particles for molding are fusion-bonded to each other. Since such a portion is removed, the cross-sectional shape can be easily formed, and the cross-sectional shape can be laminated simply by bending the film at a constant interval to easily form (manufacture) a three-dimensional object. Further, when the modeling particles are fine particles, they can be melted at the time of welding to bond the films. Therefore, it is possible to form a three-dimensional object at low cost by stacking cross-sectional shapes at high speed with a simple configuration.

According to the second aspect of the present invention, the cross-sectional shape is formed by a so-called electrophotographic method. According to this electrophotographic method, the cross-sectional shape can be easily formed (transferred) with particles accurately. Therefore, it is possible to model a three-dimensional object with a simple structure at high speed and with high accuracy at low cost. According to the third aspect of the present invention, the auxiliary particles are sandwiched between the films in addition to the shaped particles, so that the film near the outer edge of the cross section can be prevented from being deformed. Therefore, a more accurate three-dimensional object can be easily modeled.

According to the fourth and fifth aspects of the invention, since the supporting particles are sandwiched between the shaping particles forming the cross-sectional shape between the films, it is possible to prevent the film near the outer edge of the cross-sectional shape from being deformed. It can be surely prevented. Therefore, a more accurate three-dimensional object can be easily modeled. According to the invention described in claim 6, since the film is drawn out from the rolled form and conveyed, it is possible to arbitrarily change the position of the fold, for example, to adjust the cross-sectional shape size for each modeling. You can Therefore, the film can be effectively used, and the running cost can be reduced.

According to the seventh aspect of the present invention, the film is pulled out from the pre-folded one with the creases at regular intervals and conveyed. Therefore, the work of making the creases in the film can be omitted, and the film is rolled. Compared with the above, the transport load is small and the capacity of the drive source can be reduced. Therefore, it can be implemented by an inexpensive device.

According to the eighth aspect of the invention, one or both of pressure and heat are applied to the modeling particles and the film before laminating the cross-sectional shapes, so that the modeling particles are pressure-bonded, welded, or laminated before laminating the cross-sectional shapes. It can be bonded to the film with high strength by thermocompression bonding. Therefore, it is possible to prevent the modeling particles from peeling off during transportation before stacking,
The molding accuracy can be improved.

According to the ninth aspect of the present invention, after the cross-sectional shapes are stacked, the pressure for reducing the outer diameter dimension is applied together with the heating, so that the cross-sectional shapes can be formed with high accuracy at the time of transfer, and the height can also be adjusted with high accuracy. Can be adjusted to. Therefore,
A three-dimensional object can be molded with high precision. According to the tenth aspect of the invention, since a film having thermoplasticity or thermosetting property is used, when the modeling particles are welded, the film other than the portion which is welded to the modeling particles and constitutes the modeled article is thermoplastic. The film itself is thin and can be used to naturally separate unnecessary parts from the modeled object, or to reduce the external force applied to separate it. it can. Therefore, unnecessary parts can be easily separated from the formed three-dimensional object, and workability can be improved.

According to the eleventh aspect of the present invention, since the fluid and the powder are sprayed after the film and the modeling particles are welded and joined to form a three-dimensional object, it is easy to separate due to the thermoplasticity or thermosetting property of the film. It is possible to easily separate unnecessary parts other than the existing shaped objects. Therefore, workability can be improved. The fluid or powder used at this time may be appropriately selected.

According to the twelfth aspect of the invention, a water-soluble film is used, and it is possible to add an external force while making it brittle by immersing it in water, or making it brittle by spraying water with a small external force. It is possible to easily separate unnecessary parts from the modeled object. Therefore, workability can be improved. According to the invention as set forth in claim 13, vibration is applied to the molded article having the film and the particles for modeling welded thereto, and therefore, the portion other than the molded article which has become brittle due to thermoplasticity, thermosetting property, and water solubility does not need to be modified. Can be separated. Therefore, workability can be further improved.

[Brief description of drawings]

FIG. 1 is a diagram showing an example of a modeling apparatus for carrying out a first embodiment of a method for modeling a three-dimensional object according to the present invention, and is a schematic configuration diagram of a device section for carrying out a first step to a second step thereof. Is.

FIG. 2 is a schematic configuration diagram of an apparatus unit that performs the third step.

FIG. 3 is a schematic configuration diagram of an apparatus section for performing the fourth step.

FIG. 4 is a perspective view showing a state after the lamination.

5A and 5B are views showing the completed shaped product, in which FIG. 5A is a perspective view thereof, and FIG. 5B is a plan view from one direction thereof.

FIG. 6 is a schematic configuration diagram of an apparatus unit that performs a first step to a second step of the first other aspect.

FIG. 7 is an explanatory diagram illustrating a third step of the second other aspect.

FIG. 8 is a diagram showing an example of a modeling apparatus for carrying out a second embodiment of a three-dimensional object modeling method according to the present invention, and is a schematic configuration diagram of a device section for carrying out the first step to the second step thereof. Is.

FIG. 9 is a diagram showing an example of a modeling apparatus for carrying out a third embodiment of a method for modeling a three-dimensional object according to the present invention, and is a schematic configuration diagram of a device section for carrying out the first step to the second step thereof. Is.

FIG. 10 is a diagram showing an example of a modeling apparatus for carrying out a fourth embodiment of a three-dimensional object modeling method according to the present invention, and is a schematic configuration diagram of a device section for carrying out the first step to the second step thereof. Is.

[Explanation of symbols]

 11, 31 Film 12, 13, 46 Roller pair 14, 44, 54 Photoreceptor drum 20, 40 Modeling material (modeling particles, auxiliary particles) 21 Cross-sectional shape 22 Auxiliary shape 23 Frame 24 Bottom block 25 Side block 26 Top block 27 Nozzle 28 Three-dimensional object (molded object) 32 Creasing device 40 Support material (support particles) 42 Support shape

Claims (13)

[Claims] 1. A first step of transporting a continuous film in a strip shape and adhering modeling particles made of a resin material on the film to continuously form a cross-sectional shape of a three-dimensional object, and forming the cross-sectional shape. A second step of bending the film so that the cross-sectional shapes overlap, a second step of laminating the film and the modeling particles, a third step of welding and bonding the laminated film and the modeling particles, and other than the bonded cross-sectional shapes A fourth step of removing a part, and a method of modeling a three-dimensional object, comprising: 2. In the first step, after forming an electrostatic latent image having a cross-sectional shape on a photoconductor, forming particles are attached to the electrostatic latent image and transferred to a film, and the electrostatic latent image is transferred onto the film. A cross-sectional shape comprising particles for modeling is formed.
A method for modeling the three-dimensional object described. 3. In the first step, auxiliary particles made of the resin material are attached to a fixed position apart from the sectional shape of the three-dimensional object, and in the fourth step, the auxiliary particles are also removed. The method for forming a three-dimensional object according to claim 1 or 2, which is characterized. 4. In the first step, supporting particles made of a material that does not weld under the welding conditions of the modeling particles are attached to the film adjacent to the cross-sectional shape of the three-dimensional object, and in the fourth step, The method for modeling a three-dimensional object according to claim 1, wherein the particles for support are also removed. 5. The method for modeling a three-dimensional object according to claim 4, wherein particles made of a resin material having a melting point higher than that of the modeling particles are used as the support particles. 6. A film which is wound in a roll shape and can be continuously supplied is used as the film.
4. The method for forming a three-dimensional object according to any one of 4. 7. The method for modeling a three-dimensional object according to claim 1, wherein the film is a film that is folded at regular intervals and can be continuously supplied. 8. After the first step, one or both of pressure and heat are applied to the modeling particles and the film to deposit the modeling particles on the film. A method for forming a three-dimensional object according to any one of the items. 9. In the third step, the laminated film and the modeling particles are heated and pressure is applied so as to make the outer diameter constant, and the modeling particles are thermocompression-bonded onto the film. The method for modeling a three-dimensional object according to claim 1. 10. A film made of a resin material exhibiting thermoplasticity or thermosetting property in the vicinity of the melting temperature of the modeling particles is used as the film.
A method of forming a three-dimensional object according to any one of 1. 11. The method for modeling a three-dimensional object according to claim 10, wherein in the fourth step, a fluid or powder is sprayed to separate an extra portion other than the cross-sectional shape from the molded object. 12. A film made of a water-soluble material is used as the film, and in the fourth step, the surplus part other than the cross-sectional shape is separated from the modeled object by immersing in water or spraying water. The method for modeling a three-dimensional object according to any one of claims 1 to 4, characterized in that. 13. The method for modeling a three-dimensional object according to claim 10, wherein in the fourth step, vibration is applied to separate an extra portion other than the cross-sectional shape from the molded object. .