JP7200962B2 - Modeling apparatus, manufacturing method of modeled object, and conveying apparatus - Google Patents

Description

The present invention relates to a modeling apparatus, a method of manufacturing a modeled object, and a conveying apparatus.

A medium (thermally expandable sheet) having a thermally expandable layer containing a thermally expandable material that expands due to heat and having an image formed from a light-absorbing material (thermally expandable sheet) is irradiated with light to form a three-dimensional image (modeled object). A forming technique is known (for example, Patent Document 1).

JP 2013-178353 A

Patent Document 1 discloses an apparatus for forming a stereoscopic image, which includes developing means for forming a developer image by a developer containing a light-absorbing material on a medium provided with a thermally expandable layer containing a thermally expandable material; and an irradiating means for irradiating the medium on which the developer image is formed with light having a wavelength that is absorbed by the developer.

In the image forming apparatus of Patent Document 1, a medium on which a developer image is formed is irradiated with light while being placed on a conveying belt. In the image forming apparatus of Patent Document 1, the medium on which the developer image is formed is merely placed on the conveying belt. It is difficult to stably form a stereoscopic image because it differs depending on the medium on which it is formed.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a modeling apparatus, a method for manufacturing a model, and a conveying apparatus capable of stably manufacturing a model.

In order to achieve the above object, the modeling apparatus according to the first aspect of the present invention includes:
a conveying unit that conveys a molded sheet that expands when irradiated with a predetermined electromagnetic wave along the conveying path while being tensioned to warp along the conveying path curved in a convex shape;
an irradiating unit that irradiates the predetermined electromagnetic wave to the molded sheet being conveyed while maintaining the tensioned state by the conveying unit ,
The molded sheet is
a base material;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; Prepare.

A method for manufacturing a modeled object according to a second aspect of the present invention includes:
a conveying step of conveying a molded sheet that expands when irradiated with a predetermined electromagnetic wave along a convexly curved conveying path;
a step of applying tension to the molded sheet being conveyed so that it warps along the conveying path;
an irradiation step of irradiating the formed sheet conveyed in the conveying step with the predetermined electromagnetic wave while maintaining the state in which the tension is applied in the applying step ;
The molded sheet is
a substrate;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; Prepare.

A conveying device according to a third aspect of the present invention includes:
an irradiation unit that irradiates a predetermined electromagnetic wave;
While maintaining a state in which the molded sheet that expands when irradiated with the predetermined electromagnetic wave is warped along the convexly curved conveying path in the area irradiated with the predetermined electromagnetic wave, a transport unit that transports along the transport path ,
The molded sheet is
a substrate;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; Prepare.

According to the present invention, since a tension is applied to the molded sheet to warp it along the convexly curved conveying path, it is possible to stably manufacture a modeled object.

It is a mimetic diagram showing a section of a forming sheet concerning an embodiment of the present invention. 1 is a perspective view showing a modeled object according to an embodiment of the present invention; FIG. FIG. 3 is a cross-sectional view of the modeled object shown in FIG. 2 taken along line AA. It is a figure which shows the structure of the modeling apparatus which concerns on embodiment of this invention. It is a mimetic diagram showing a molding device concerning an embodiment of the present invention. FIG. 4 is a side view showing a conveying belt, a tension section, and a formed sheet according to the embodiment of the present invention; FIG. 4 is a top view showing a conveying belt, a tension section, and a formed sheet according to the embodiment of the present invention; FIG. 4 is a schematic diagram for explaining tension applied to the molded sheet according to the embodiment of the present invention; It is a schematic diagram which shows the irradiation part which concerns on embodiment of this invention. It is a flow chart which shows a manufacturing method of a model concerning an embodiment of the present invention. FIG. 2 is a schematic diagram showing a base material and a thermal expansion layer of a molded sheet according to an embodiment of the present invention; It is a schematic diagram which shows the cross section of the shaping|molding sheet which concerns on the modification of this invention. It is a schematic diagram which shows the cross section of the molded article which concerns on the modification of this invention. It is a schematic diagram which shows the cross section of the shaping|molding sheet which concerns on the modification of this invention. It is a schematic diagram which shows the cross section of the molded article which concerns on the modification of this invention. It is a schematic diagram which shows the cross section of the shaping|molding sheet which concerns on the modification of this invention. It is a schematic diagram which shows the cross section of the molded article which concerns on the modification of this invention. It is a schematic diagram for demonstrating the tension applied to the tension part which concerns on the modification of this invention, and a molded sheet.

A modeling apparatus according to an embodiment of the present invention will be described below with reference to the drawings.

A modeling apparatus 100 of the present embodiment manufactures a modeled object 50 from a formed sheet 10 . The modeled object 50 is used as a decorative sheet, wallpaper, or the like. In the present specification, a "modeled object" is a sheet having irregularities molded (formed) on a predetermined surface, and the irregularities constitute geometric shapes, characters, patterns, decorations, and the like. Here, "decoration" is something that evokes a sense of beauty through sight and/or touch. "Molding (or molding)" means creating something with a shape, and includes concepts such as decoration that adds decoration and decoration that forms decoration. In addition, the modeled object 50 of the present embodiment is a three-dimensional object having unevenness on a predetermined surface. (2.5D) objects or pseudo-three-dimensional (Pseudo-3D) objects. The technology for manufacturing the modeled object 50 of the present embodiment can also be called 2.5D printing technology or Pseudo-3D printing technology.

(molded sheet)
First, the molded sheet 10 will be described with reference to FIG. The molded sheet 10 expands when irradiated with a predetermined electromagnetic wave (for example, infrared light). A modeled object 50 is formed by expanding the molded sheet 10 . The molded sheet 10 includes a base material 20, a thermal expansion layer 30 laminated on a first main surface 22 of the base material 20, and a second surface of the base material 20 in a pattern corresponding to the unevenness 52 of the modeled object 50 described later. and a heat conversion layer 40 laminated on the main surface 24 . In this embodiment, the thermal expansion layer 30 is laminated on the entire surface of the first main surface 22 .

The substrate 20 of the formed sheet 10 has a first major surface 22 and a second major surface 24 opposite the first major surface 22 . Base material 20 supports thermal expansion layer 30 . The base material 20 is formed in a sheet shape, for example. Materials constituting the base material 20 are, for example, thermoplastic resins such as polyolefin resins (polyethylene (PE), polypropylene (PP), etc.) and polyester resins (polyethylene terephthalate (PET), polybutylene terephthalate (PBT), etc.). is. The type of material forming the base material 20 and the thickness of the base material 20 are selected according to the application of the modeled object 50 .

Thermal expansion layer 30 of molded sheet 10 is laminated onto first major surface 22 of substrate 20 . The thermal expansion layer 30 includes a binder 31 and a thermal expansion material (thermal expansion material before expansion) 32 a dispersed in the binder 31 . The binder 31 is any thermoplastic resin such as vinyl acetate polymer, acrylic polymer, or the like. The thermal expansion material 32a expands to a size corresponding to the amount of heat to be heated (specifically, heating temperature, heating time, etc.) when heated to a predetermined temperature or higher. The thermal expansion material 32a expands by being heated to 80° C. to 120° C. or higher, for example. The thermally expandable material 32a is, for example, a thermally expandable microcapsule.

Thermally expandable microcapsules are microcapsules in which a foaming agent composed of propane, butane, or other low-boiling substances is enclosed in a thermoplastic resin shell. The heat-expandable microcapsule shells are made of thermoplastic resins such as polystyrene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyacrylate, polyacrylonitrile, polybutadiene, and copolymers thereof. When the thermally expandable microcapsules are heated to a predetermined temperature (expansion start temperature) or higher, the shell softens and the foaming agent vaporizes, and the shell expands into a balloon shape due to the pressure of the vaporized foaming agent. Thermally expandable microcapsules expand to about five times the particle size before expansion. The average particle size of the thermally expandable microcapsules before expansion is, for example, 5 μm to 50 μm.

The thermally expandable layer 30 of the molded sheet 10 is expanded by expansion of the thermally expandable material 32a, and irregularities 52 are formed on the surface 35 opposite to the substrate 20. As shown in FIG.

The heat conversion layer 40 of the molded sheet 10 is provided to form the unevenness 52 of the shaped article 50 . The heat conversion layer 40 is laminated on the second main surface 24 of the base material 20 in a pattern corresponding to the irregularities 52 .

The heat conversion layer 40 converts the radiated predetermined electromagnetic waves into heat and emits the converted heat. As a result, the thermal expansion layer 30 (that is, the thermal expansion material 32a before expansion) of the molded sheet 10 is heated to a predetermined temperature. The temperature at which the thermal expansion material 32a before expansion is heated depends on the density of the heat conversion layer 40 containing the heat conversion material described later, and the amount of energy per unit area and unit time of the predetermined electromagnetic waves irradiated to the heat conversion layer 40. can be controlled by Since the heat conversion layer 40 converts a predetermined electromagnetic wave into heat more quickly than the other portions of the molded sheet 10, the area (thermal expansion layer 30) in the vicinity of the heat conversion layer 40 is selectively heated. . In the following, the given electromagnetic waves are also simply referred to as electromagnetic waves.

The heat conversion layer 40 is made of a heat conversion material that converts absorbed electromagnetic waves into heat. Heat conversion materials include carbon black, metal hexaboride compounds, tungsten oxide compounds, and the like. For example, carbon black absorbs visible light, infrared light, etc. and converts it into heat. In addition, metal hexaboride compounds and tungsten oxide compounds absorb near-infrared light and convert it into heat. Among metal hexaboride compounds and tungsten oxide compounds, lanthanum hexaboride (LaB ₆ ) and cesium tungsten oxide have high absorptivity in the near-infrared region and high transmittance in the visible light region. preferable. Note that the heat conversion layer 40 may not have a layer structure with a clear boundary because the heat conversion material forming the heat conversion layer 40 is absorbed by the substrate 20, the thermal expansion layer 30, and the like. For ease of understanding, the heat conversion layer 40 is illustrated herein as a layer with distinct boundaries.

(modeled object)
Next, the modeled object 50 will be described with reference to FIGS. 2 and 3. FIG. A shaped article 50 is formed from the shaped sheet 10 . As shown in FIG. 2, the modeled article 50 is a sheet-like modeled article, and has irregularities 52 on its surface.

As shown in FIG. 3, the modeled object 50 includes a substrate 20, a thermal expansion layer 30 laminated on the first main surface 22 of the substrate 20 and having unevenness 52 on the side opposite to the substrate 20, the substrate A heat conversion layer 40 is laminated in a pattern corresponding to the unevenness 52 on the second main surface 24 of 20 . Since the structure of the base material 20 and the heat conversion layer 40 of the modeled article 50 is the same as that of the base material 20 and the heat conversion layer 40 of the molded sheet 10, the thermal expansion layer 30 of the modeled article 50 will be described here.

The thermal expansion layer 30 of the model 50 includes, as shown in FIG. 3, a binder 31, a thermal expansion material (thermal expansion material before expansion) 32a, and an expanded thermal expansion material 32b. The binder 31 of the thermal expansion layer 30 of the shaped article 50 is the same as the binder 31 of the thermal expansion layer 30 of the molded sheet 10 . Also, the thermal expansion material 32 a of the thermal expansion layer 30 of the modeled article 50 is the same as the thermal expansion material 32 a of the thermal expansion layer 30 of the molded sheet 10 . The expanded thermally expandable material 32b is a thermally expandable material that has been expanded by heating the thermally expandable material 32a to a predetermined temperature or higher. The unevenness 52 of the thermal expansion layer 30 is composed of convex portions 54 containing the expanded thermal expansion material 32b and concave portions 56 containing the thermal expansion material 32a before expansion.

(modeling device)
The modeling apparatus 100 will be described with reference to FIGS. 4 to 9. FIG. The modeling apparatus 100 manufactures a model 50 from the molded sheet 10 by irradiating the molded sheet 10 with a predetermined electromagnetic wave that expands the molded sheet 10 . As shown in FIG. 4 , the modeling apparatus 100 includes a conveying unit 110 that conveys the formed sheet 10 while tension is applied to the formed sheet 10 , and an irradiation unit that irradiates the formed sheet 10 with a predetermined electromagnetic wave that expands the formed sheet 10 . It includes a unit 140 and a control unit 150 that controls each unit. The transport unit 110 includes a transport section 120 that transports the formed sheet 10 and a tension section 130 that applies tension to the formed sheet 10 . As shown in FIG. 5 , the transport section 120 , the tension section 130 , the irradiation section 140 and the control section 150 are provided inside the housing 105 . The housing 105 has a carry-in port 105a through which the molded sheet 10 is carried in, and a carry-out port 105b through which the manufactured molded article 50 is carried out.
In order to facilitate understanding, in this specification, the longitudinal right direction (right direction on the paper surface) of the modeling apparatus 100 in FIG. The direction perpendicular to the direction (the front direction of the paper surface) will be described as the +Y direction. In this specification, the -Z direction is the vertical direction. In addition, the −Z side may be described as downward and the +Z side may be described as upward.

(transport unit)
The transport unit 110 of the modeling apparatus 100 applies tension to the formed sheet 10 carried in from the carry-in port 105a of the housing 105 along the convexly curved transport path R, and moves the formed sheet 10 along the transport path R. transport along. In the present embodiment, the convexly curved conveying path R protrudes and curves in the +Z direction. Further, the conveying unit 110 conveys the formed sheet 10 along the conveying path R from the +X side to the −X direction. The conveying unit 110 includes a conveying section 120 that conveys the formed sheet 10 along the conveying path R, and a tension section 130 that applies tension to the formed sheet 10 along the conveying path R.

(Conveyor)
The transport section 120 of the transport unit 110 transports the molded sheet 10 loaded from the inlet 105a of the housing 105 along the convexly curved transport path R in the -X direction. Further, the transport unit 120 transports the manufactured modeled article 50 and unloads the modeled article 50 from the outlet 105 b of the housing 105 . The transport section 120 includes a guide section 122 , a driven roller 124 a , a drive roller 124 b , a tension roller 124 c and a transport belt 126 . The conveying section 120 further includes a carry-in roller 128a and a carry-out roller 128b.

As shown in FIGS. 5 and 6, the guide portion 122 of the conveying portion 120 supports the forward portion of the conveying belt 126 from the −Z side in a curved state along the convexly curved conveying path R. FIG.

The driven roller 124a of the transport unit 120 is wrapped around the transport belt 126, as shown in FIG. The driven roller 124 a is arranged on the inlet 105 a side (+X side) of the housing 105 . The rotation shaft of the driven roller 124a is arranged in a direction (Y direction) orthogonal to the conveying direction (−X direction) of the formed sheet 10 and the projecting direction (+Z direction) of the conveying path R. is pivotally supported on the side plate of the

A transport belt 126 is wound around the drive roller 124b of the transport unit 120 . The drive roller 124b is arranged on the outlet 105b side (−X side) of the housing 105 . The rotating shaft of the driving roller 124 b is arranged in the Y direction like the rotating shaft of the driven roller 124 a , and the driving roller 124 b is supported by the side plate of the housing 105 . The drive roller 124b rotates counterclockwise when viewed from the +Y direction by the rotation of a motor (not shown), causing the transport belt 126 to run.

The tension roller 124c of the conveying unit 120 presses the returning portion of the conveying belt 126 from the -Z side to apply tension to the conveying belt 126. FIG. The rotation axis of the tension roller 124 c is arranged in the Y direction like the rotation axis of the driven roller 124 a , and the tension roller 124 c is pivotally supported by the side plate of the housing 105 .

The conveying belt 126 of the conveying unit 120 is an endless belt, and conveys the molded sheet 10 and the manufactured object 50 . The conveying belt 126 is wound around the driven roller 124a and the driving roller 124b. The outward path portion of the transport belt 126 is curved in a convex shape along the convexly curved transport path R by being supported by the guide portion 122 . The conveying belt 126 is driven by the rotation of the drive roller 124b. The forward portion of the transport belt 126 runs in the −X direction along the transport path R, and the return portion of the transport belt 126 runs in the +X direction. As shown in FIG. 5, the molded sheet 10 is placed on the conveyor belt 126 from the carry-in port 105a of the housing 105 and conveyed in the -X direction. The molded sheet 10 is placed on the transport belt 126 with the thermal expansion layer 30 facing the transport surface 126 a of the transport belt 126 .

The carry-in roller 128a of the transport section 120 is pivotally supported by the side plate of the housing 105 in the same manner as the driven roller 124a. The carry-in roller 128a and the conveyor belt 126 sandwich the formed sheet 10 inserted from the carry-in opening 105a of the housing 105 and carry the formed sheet 10 into the housing 105, as shown in FIG.

The carry-out roller 128b of the transport section 120 is pivotally supported by the side plate of the housing 105 in the same manner as the drive roller 124b. The carry-out roller 128 b and the conveyor belt 126 sandwich the manufactured model 50 and carry the model 50 out from the carry-out port 105 b of the housing 105 .

(Tension part)
The tension section 130 of the transport unit 110 applies tension to the formed sheet 10 along the convexly curved transport path R. As shown in FIG. The tension section 130 includes a pair of pressing belts 131 and 132, as shown in FIG. Each of the pressing belts 131 and 132 presses each of the widthwise ends of the conveying belt 126 of the formed sheet 10 (the end in the +Y direction and the end in the −Y direction) against the conveying belt 126 to press the formed sheet 10. is applied with a tension F along the transport path R. The tension unit 130 further includes a first pulley 133a and a second pulley 133b around which the pressing belt 131 is wound, a third pulley 134a and a fourth pulley 134b around which the pressing belt 132 is wound, and four bend pulleys 136-139. Prepare.

First, the pressing belt 131, the first pulley 133a, and the second pulley 133b will be described. The pressing belt 131 presses the +Y-direction end of the formed sheet 10 against the conveying belt 126 to apply a tension F along the conveying path R to the +Y-side end of the formed sheet 10 . A pressing belt 131 is wound around the first pulley 133a and the second pulley 133b.

As shown in FIGS. 6 and 7, the first pulley 133a is located on the upstream side (+X side) of the conveying path R from the apex T of the outward path portion of the convexly curved conveying belt 126. It is arranged above the +Y side end of 126a (+Z side). Further, in the present embodiment, as shown in FIG. 6, the lower end B1 of the outer circumference 133c of the first pulley 133a around which the pressing belt 131 is wound is positioned lower than the top T of the outward travel portion of the conveyor belt 126 (-Z side). ). The first pulley 133a rotates around the shaft 106 fixed to the side plate of the housing 105 as a rotation axis. In the following description, the top portion T of the conveying belt 126 is also referred to as the top portion T of the conveying belt 126 .

As shown in FIGS. 6 and 7, the second pulley 133b is located on the downstream side (−X side) of the conveying path R from the top T of the forward portion of the conveying belt 126, and on the +Y side of the conveying surface 126a of the conveying belt 126. is located above the end of the (+Z side). The lower end B2 of the outer periphery 133d of the second pulley 133b around which the pressing belt 131 is wound is located at a position (-Z side) lower than the top T of the conveying belt 126, as shown in FIG. The second pulley 133b rotates around the shaft 107 fixed to the side plate of the housing 105 as a rotation axis.

The pressing belt 131 is an endless belt and is wound around the first pulley 133a and the second pulley 133b. In this embodiment, the first pulley 133a and the second pulley 133b are arranged on the +X side and the -X side, respectively, with the top T of the conveying belt 126 interposed therebetween. Further, the lower end B2 of the outer circumference 133c of the first pulley 133a and the lower end B2 of the outer circumference 133d of the second pulley 133b are located on the −Z side of the top T of the conveyor belt 126. FIG. Therefore, the forward portion of the pressing belt 131 can press the +Y side end of the formed sheet 10 being conveyed by the conveying section 120 (the conveying belt 126 ) to the conveying belt 126 . Since the pressing belt 131 presses the +Y side end of the formed sheet 10 being conveyed along the convexly curved conveying path R, the +Y side end of the formed sheet 10 is pressed as shown in FIG. A tension F along the transport path R can be applied to .

Since the forward portion of the pressing belt 131 presses the formed sheet 10 being conveyed by the conveying belt 126, it travels in the -X direction as the conveying belt 126 travels. In addition, the return portion of the pressing belt 131 travels in the +X direction.

Next, the pressing belt 132, the third pulley 134a and the fourth pulley 134b will be described. The pressing belt 132 presses the −Y direction end of the formed sheet 10 against the conveying belt 126 to apply a tension F along the conveying path R to the −Y side end of the formed sheet 10 . A pressing belt 132 is wound around the third pulley 134a and the fourth pulley 134b.

As shown in FIG. 7, the third pulley 134a is arranged in the same manner as the first pulley 133a except that it is arranged above (+Z side) the -Y side end of the conveying surface 126a of the conveying belt 126. be. The fourth pulley 134b is arranged in the same manner as the second pulley 133b, except that it is arranged above (+Z side) the -Y side end of the conveying surface 126a of the conveying belt 126. As shown in FIG.

The pressing belt 132 is wound around the third pulley 134a and the fourth pulley 134b, and presses the −Y side end of the conveyed molded sheet 10 against the conveying belt 126. Same as configuration. Since the pressing belt 132 presses the −Y side end of the formed sheet 10 being transported against the transport belt 126 , the −Y side end of the formed sheet 10 is placed on the transport path R in the same manner as the pressing belt 131 . It is possible to apply a tension F along the

In this embodiment, the pair of pressing belts 131 and 132 apply the tension F along the transport path R to the +Y side end and the -Y side end of the formed sheet 10, respectively. Warpage, deflection, etc. of the molded sheet 10 can be suppressed.

The two bend pulleys 136 and 137 press the return portion of the pressing belt 131 to change the running direction of the return portion of the pressing belt 131 . As a result, the return portion of the pressing belt 131 passes under the irradiation section 140 (on the −Z side) as shown in FIGS.

As shown in FIGS. 6 and 7, the bend pulley 136 is located between the irradiation section 140 on the upstream side (+X side) of the transport path R from the top T of the transport belt 126 and the first pulley 133a. It is arranged above the end on the +Y side (+Z side). The lower end of the outer circumference of the bend pulley 136 that presses the conveyor belt 126 is located at a position (−Z side) lower than the lower end of the irradiation section 140 . The bend pulley 136 rotates around the shaft 108 fixed to the side plate of the housing 105 as a rotation axis.

In addition, the bend pulley 137 is positioned above the +Y side end of the conveying surface 126a ( +Z side). The lower end of the outer circumference of the bend pulley 137 that presses the conveyor belt 126 is also located at a position (-Z side) lower than the lower end of the irradiation section 140 . The bend pulley 137 rotates around a shaft 109 fixed to the side plate of the housing 105 as a rotation axis.

The two bend pulleys 138 and 139 press the return portion of the pressing belt 132 to change the running direction of the return portion of the pressing belt 132 . As a result, the return portion of the pressing belt 132 passes under the irradiation unit 140 (on the −Z side).

The bend pulley 138 is positioned between the irradiation unit 140 on the upstream side (+X side) of the conveying path R from the top T of the conveying belt 126 and the third pulley 134a, above the end on the -Y side of the conveying surface 126a (+Z side). The rest of the configuration of bend pulley 138 is similar to that of bend pulley 136 . The bend pulley 139 is positioned above the −Y side end of the transport surface 126a ( +Z side). Other configurations of bend pulley 139 are similar to those of bend pulley 137 .

(Irradiation part)
The irradiation unit 140 of the modeling apparatus 100 irradiates the molded sheet 10 (the heat conversion layer 40) with a predetermined electromagnetic wave, causes the heat conversion layer 40 to emit heat, and expands the thermal expansion layer 30 (the thermal expansion material 32a before expansion). Heat to a specified temperature or higher. In this embodiment, the heat conversion layer 40 is laminated on the second main surface 24 of the base material 20 in a pattern corresponding to the unevenness 52 of the molded article 50 , so that the convex portions 54 of the thermal expansion layer 30 of the molded sheet 10 The corresponding portion is heated to a predetermined temperature or higher to form an expanded thermal expansion material 32b. By forming the expanded thermal expansion material 32 b , the thermal expansion layer 30 expands, and the protrusions 54 (that is, the irregularities 52 ) are formed in the thermal expansion layer 30 .

In this embodiment, the irradiation unit 140 is arranged on the convex side of the conveying path R that is curved in a convex shape, and the forming sheet 10 that is being conveyed along the conveying path R while being tensioned. Irradiate electromagnetic waves that expand the Specifically, as shown in FIGS. 5 and 6, the irradiation unit 140 is arranged above the top T of the conveying belt 126 (on the +Z side). Further, the irradiation unit 140 irradiates the conveying surface 126a of the conveying belt 126 with electromagnetic waves. Then, as shown in FIG. 6, the molded sheet 10 is conveyed along the conveying path R by the conveying section 120 while being tensioned along the conveying path R by the tension section 130, and is irradiated with electromagnetic waves. pass through the area S. As a result, the electromagnetic wave from the irradiation unit 140 is applied to the formed sheet 10 that is being conveyed along the conveying path R under tension.

In this embodiment, the warpage, bending, and the like of the molded sheet 10 are suppressed by the tension applied along the transport path R. As shown in FIG. Then, the electromagnetic wave for expanding the molded sheet 10 is applied to the molded sheet 10 whose warping, bending and the like are suppressed. Therefore, the modeling apparatus 100 can stably manufacture the modeled object 50 .

The irradiation unit 140 includes a cover 142, a lamp 144, a reflector 146, and a fan 148, as shown in FIG. Cover 142 houses lamp 144 , reflector 146 and fan 148 . The lamp 144 is composed of, for example, a straight tubular halogen lamp. The lamp 144 emits predetermined electromagnetic waves to the molded sheet 10 (heat conversion layer 40) in the near-infrared region (wavelength 750 nm to 1400 nm), visible light region (wavelength 380 nm to 750 nm), mid-infrared region (wavelength 1400 nm to 4000 nm). ) and other electromagnetic waves. The reflector 146 is a reflector that reflects the electromagnetic waves emitted from the lamp 144 toward the molded sheet 10 . Fan 148 blows air into cover 142 to cool lamp 144 and reflector 146 .

(control part)
The control unit 150 of the modeling apparatus 100 controls the transport unit 120 of the transport unit 110 and the irradiation unit 140 . As shown in FIG. 4, the control unit 150 includes a CPU (Central Processing Unit) 152 that executes various processes, a ROM (Read Only Memory) 154 that stores programs and data, and a RAM that stores data. (Random Access Memory) 156, and an input/output interface 158 for inputting/outputting signals between each unit. The functions of control unit 150 are implemented by CPU 152 executing programs stored in ROM 154 . The input/output interface 158 inputs and outputs signals between the CPU 152 and the conveying unit 120 and the irradiation unit 140 .

(Manufacturing method of shaped article)
A method for manufacturing the modeled article 50 will be described with reference to FIGS. 10 and 11 . In the present embodiment, a modeling apparatus 100 is used to manufacture a modeled object 50 from a sheet-like (for example, A4 paper size) molded sheet 10 .

FIG. 10 is a flow chart showing the manufacturing method of the modeled object 50 . The method of manufacturing the modeled object 50 includes a preparation step (step S10) of preparing the molded sheet 10 that expands when irradiated with electromagnetic waves, and a transporting process of transporting the molded sheet 10 along a convexly curved transport path R. step (step S20), applying tension along the conveying path R to the formed sheet 10 being conveyed (step S30), and expanding the formed sheet 10 to the formed sheet 10 in the tensioned state. and an irradiation step (step S40) of irradiating an electromagnetic wave that causes the

In the preparation step (step S10), the molded sheet 10 is prepared. First, a coating liquid in which the binder 31 and the thermal expansion material 32a are mixed is screen-printed on the first main surface 22 of the base material 20, and the printed coating liquid is dried to form the base material as shown in FIG. A thermal expansion layer 30 is laminated on the first major surface 22 of 20 . Next, ink containing a heat conversion material is printed on the second main surface 24 of the substrate 20 in a dark and light pattern corresponding to the unevenness 52 by a printing device. The printing device is, for example, an inkjet printer. As described above, the molded sheet 10 can be manufactured.

Returning to FIG. 10 , in the conveying step (step S20), the molded sheet 10 is inserted from the inlet 105a of the modeling apparatus 100 and conveyed along the convexly curved conveying path R by the conveying section 120 . From the viewpoint of heating the thermal expansion layer 30 with high efficiency, the distance between the heat conversion layer 40 and the irradiation unit 140 is preferably shorter, and the molded sheet 10 is conveyed with the heat conversion layer 40 facing the irradiation unit 140 side. preferably. That is, the molded sheet 10 is preferably conveyed by the conveying section 120 with the thermal expansion layer 30 facing the conveying surface 126 a of the conveying belt 126 .

In the imparting step (step S30), the formed sheet 10 being conveyed by the conveying section 120 is pressed against the conveying belt 126 of the conveying section 120 by the holding belts 131 and 132 of the tension section 130, and the conveying path R is formed on the formed sheet 10. Apply tension along In the present embodiment, tension is applied to the molded sheet 10 along the convexly curved conveying path R, so that the molded sheet 10 can be prevented from warping, bending, or the like.

In the irradiation step (step S40), the formed sheet 10 is conveyed by the conveying unit 120 and is tensioned along the conveying path R by the pressing belts 131 and 132 of the tension unit 130. The formed sheet 10 is irradiated from the irradiation unit 140. Irradiate electromagnetic waves that expand the As a result, the thermal expansion layer 30 of the molded sheet 10 expands to form the irregularities 52, and the modeled object 50 is manufactured. Since the molded sheet 10 in a state of being tensioned along the transport path R is restrained from warping, bending, etc., the molded article 50 can be stably manufactured.
As described above, the modeled object 50 can be manufactured. The manufactured modeled object 50 is unloaded from the unloading port 105 b of the modeling apparatus 100 by the transport unit 120 .

As described above, in the modeling apparatus 100, the tension unit 130 applies tension to the formed sheet 10 along the convexly curved conveying path R, and the irradiation unit 140 applies tension along the conveying path R. The molded sheet 10 is irradiated with an electromagnetic wave that expands the molded sheet 10 . By applying tension along the conveying path R to the molded sheet 10, it is possible to suppress warpage, deflection, and the like of the molded sheet 10. - 特許庁Therefore, the modeling apparatus 100 can stably manufacture the modeled object 50 .

In the manufacturing method of the modeled object 50 of the present embodiment, the molded sheet 10 in a state of being tensioned along the transport path R is irradiated with an electromagnetic wave for expanding the molded sheet 10 . Since the molded sheet 10 in a state where tension is applied along the transport path R is suppressed from warping, bending, etc., the manufacturing method of the molded object 50 of the present embodiment can stably manufacture the molded object 50. .

(Modification)
Although the embodiments of the present invention have been described above, the present invention can be modified in various ways without departing from the gist of the present invention.

For example, the shaped article 50 may be manufactured in a roll form from the rolled formed sheet 10 .

The material forming the base material 20 is not limited to thermoplastic resin, and may be paper, cloth, or the like. The thermoplastic resin forming the substrate 20 is not limited to polyolefin resin and polyester resin, and may be polyamide resin, polyvinyl chloride (PVC) resin, polyimide resin, or the like.

Although the heat conversion layer 40 of the embodiment is laminated on the second main surface 24 of the substrate 20, the heat conversion layer 40 may be laminated on the thermal expansion layer 30 as shown in FIG. good. Using the modeling apparatus 100, a molded article 50A in which the thermal conversion layer 40 is laminated on the thermal expansion layer 30 shown in FIG. Manufactured from In this case, the molded sheet 10A is preferably conveyed by the conveying section 120 (the conveying unit 110) with the heat conversion layer 40 facing the irradiation section 140 side. That is, the molded sheet 10A is preferably conveyed by the conveying section 120 (conveying unit 110) with the second main surface 24 of the base material 20 facing the conveying surface 126a of the conveying belt 126. As shown in FIG.

Also, the heat conversion layer 40 may be laminated on the release layer 60 provided on the second main surface 24 of the base material 20 . For example, as shown in FIG. 14, the molded sheet 10B includes a release layer 60 provided on the second main surface 24 of the substrate 20, and a heat conversion layer 40 laminated on the release layer 60. . A modeled object 50B shown in FIG. 15 is manufactured using the irradiation device 100 from the formed sheet 10B. The modeled object 50</b>B includes a release layer 60 provided on the second main surface 24 of the base material 20 and a heat conversion layer 40 laminated on the release layer 60 . In this case, the molded sheet 10B is preferably transported by the transport section 120 with the heat conversion layer 40 facing the irradiation section 110 side. That is, the molded sheet 10B is preferably conveyed by the conveying section 120 with the thermal expansion layer 30 facing the conveying surface 126 a of the conveying belt 126 . By peeling off the release layer 60 from the modeled article 50B, the heat conversion layer 40 can be easily removed from the modeled article 50B.

Furthermore, the heat conversion layer 40 may be laminated on the release layer 60 provided on the thermal expansion layer 30 . For example, the molded sheet 10C includes a release layer 60 provided on the thermal expansion layer 30 and a heat conversion layer 40 laminated on the release layer 60, as shown in FIG. A modeled object 50C shown in FIG. 17 is manufactured using the irradiation device 100 from the formed sheet 10C. The modeled object 50</b>C includes a release layer 60 provided on the thermal expansion layer 30 and a heat conversion layer 40 laminated on the release layer 60 . In this case, the molded sheet 10C is preferably transported by the transport section 120 with the heat conversion layer 40 facing the irradiation section 110 side. That is, the molded sheet 10</b>C is preferably transported by the transport section 120 with the second main surface 24 of the base material 20 facing the transport surface 126 a of the transport belt 126 . By peeling off the release layer 60 from the modeled article 50C, the heat conversion layer 40 can be easily removed from the modeled article 50C. As a result, dullness of color caused by the heat conversion layer 40 can be removed.

The molded sheets 10, 10A-10C and the shaped articles 50, 50A-50C made from the molded sheets 10, 10A-10C may have layers of any other material between each layer. For example, an adhesion layer may be formed between the base material 20 and the thermal expansion layer 30 to make the base material 20 and the thermal expansion layer 30 more closely adhere to each other. The adhesion layer is composed of, for example, a surface modifier.

Also, the modeled objects 50, 50A, 50B, and 50C may be printed with color images. For example, the modeled object 50 may be formed by laminating a color ink layer representing a color image on the thermal expansion layer 30, which is composed of four color inks of cyan, magenta, yellow, and black.

The modeling apparatus 100 of the embodiment conveys the molded sheet 10 to the area S irradiated with electromagnetic waves. Therefore, the modeling apparatus 100 of the embodiment has an irradiation unit 140 that irradiates an electromagnetic wave, and the molded sheet 10 that expands by being irradiated with the electromagnetic wave is placed in the area S irradiated with the electromagnetic wave in a convexly curved conveying path. It is also expressed as a transport device provided with a transport unit 110 that transports along the transport path R in a state where the tension F is applied along the R.

In the embodiment, the lower end B1 of the outer circumference 133c of the first pulley 133a and the lower end B2 of the outer circumference 133d of the second pulley 133b are positioned lower than the top T of the conveying belt 126 (-Z side). A lower end B1 of the outer circumference 133c of the pulley 133a and a lower end B2 of the outer circumference 133d of the second pulley 133b may be positioned at the same height as the top T of the conveyor belt 126 (at the same position in the +Z direction). As a result, the presser belt 131 can press the +Y side end of the formed sheet 10 against the conveying belt 126 by the sum of the thickness of the formed sheet 10 and the thickness of the presser belt 131 . Further, the lower end of the outer periphery of the third pulley 134a around which the presser belt 132 is wound and the lower end of the outer periphery of the fourth pulley 134b around which the presser belt 132 is wound may be positioned at the same height as the top T of the conveyor belt 126. good. As a result, the pressing belt 132 can press the −Y side end of the formed sheet 10 against the conveying belt 126 by the sum of the thickness of the formed sheet 10 and the thickness of the pressing belt 132 .

The tension section 130 of the embodiment applies a tension F along the conveying path R to the formed sheet 10 by a pair of pressing belts 131 and 132. However, the tension section 130 has a pair of pressing belts 131 and 132. Not limited. For example, as shown in FIG. 18, a roller 162 that sandwiches the formed sheet 10 together with the transport belt 126 may be provided as the tension unit 130 on the downstream side (−X side) of the transport path R from the irradiation unit 140 . The roller 162 and the conveying belt 126 sandwich the conveyed formed sheet 10 , and the roller 162 applies a load to convey the formed sheet 10 . Thereby, the tension F along the conveying path R can be applied to the formed sheet 10 .

The irradiation unit 140 of the embodiment is arranged above the top T (+Z side) of the conveying belt 126, and the irradiation unit 140 emits an electromagnetic wave to the formed sheet 10 under tension F along the conveying path R. It is sufficient if they are arranged at a position where they can be irradiated.

The control unit 150 of the modeling apparatus 100 includes a CPU 152 and executes each process by the functions of the CPU 152 . In the modeling apparatus according to the present invention, the control unit may include dedicated hardware such as an ASIC (Application Specific Integrated Circuit), an FPGA (Field-Programmable Gate Array), a control circuit, etc., instead of the CPU. In this case, each of the processes may be performed by separate hardware. Also, each of the processes may be collectively executed by a single piece of hardware. Part of the processing may be performed by dedicated hardware, and another part of the processing may be performed by software or firmware.

In addition to being able to provide a modeling apparatus having a configuration for realizing the functions according to the present invention in advance, by applying a program, a computer that controls the modeling apparatus realizes each functional configuration of the modeling apparatus 100 of the embodiment. You can also let That is, a program for realizing each functional configuration by the modeling apparatus 100 of the embodiment can be applied so that a CPU or the like that controls an existing information processing device or the like can execute the program.

Moreover, the application method of such a program is arbitrary. The program can be applied by storing it in a computer-readable storage medium such as a flexible disk, a CD (Compact Disc)-ROM, a DVD (Digital Versatile Disc)-ROM, and a memory card. Furthermore, a program can be superimposed on a carrier wave and applied via a communication medium such as the Internet. For example, the program may be posted and distributed on a bulletin board system (BBS) on a communication network. Then, the above processing may be executed by starting this program and executing it in the same manner as other application programs under the control of an OS (Operating System).

Although the preferred embodiments of the present invention have been described above, the present invention is not limited to such specific embodiments, and the present invention includes the invention described in the claims and their equivalents. be The invention described in the original claims of the present application is appended below.

(Appendix 1)
a conveying unit that conveys a molded sheet that expands when irradiated with a predetermined electromagnetic wave along a convexly curved conveying path while being tensioned along the conveying path;
an irradiating unit that irradiates the predetermined electromagnetic wave to the formed sheet being conveyed under the tension by the conveying unit;
molding device.

(Appendix 2)
The transport unit includes a transport section that transports the formed sheet along the transport path;
a tension unit that applies the tension to the molded sheet along the conveying path,
The modeling apparatus according to appendix 1.

(Appendix 3)
The transport unit includes a transport belt that travels along the transport path on which the formed sheet is placed, and a guide part that supports the transport belt in a curved state along the transport path.
The modeling apparatus according to appendix 2.

(Appendix 4)
The irradiation unit is arranged on the convex side of the transport path,
The modeling apparatus according to any one of Appendices 1 to 3.

(Appendix 5)
The irradiation unit is arranged above the top of the transport path,
The modeling apparatus according to appendix 4.

(Appendix 6)
The molded sheet is
a substrate;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; comprising
6. The modeling apparatus according to any one of Appendices 1 to 5.

(Appendix 7)
The transport unit transports the molded sheet with the heat conversion layer facing the irradiation unit.
The modeling apparatus according to appendix 6.

(Appendix 8)
a conveying step of conveying a molded sheet that expands when irradiated with a predetermined electromagnetic wave along a convexly curved conveying path;
a step of applying tension along the conveying path to the formed sheet being conveyed;
an irradiation step of irradiating the predetermined electromagnetic wave to the molded sheet in the tensioned state;
A method of manufacturing a modeled object.

(Appendix 9)
an irradiation unit that irradiates a predetermined electromagnetic wave;
In a region irradiated with the predetermined electromagnetic wave, a molded sheet that expands by being irradiated with the predetermined electromagnetic wave is placed under tension along the convexly curved conveying path, and is moved along the conveying path. a transport unit that transports
Conveyor.

10, 10A, 10B, 10C... molded sheet, 20... base material, 22... first main surface, 24... second main surface, 30... thermal expansion layer, 31... Binder, 32a... Thermal expansion material (thermal expansion material before expansion), 32b... Thermal expansion material after expansion, 35... Surface of thermal expansion layer opposite to base material, 40... Heat Converting layer 50, 50A, 50B, 50C Modeled object 52 Unevenness 54 Convex portion 56 Concave portion 60 Release layer 100 Modeling apparatus 105 Case 105a Carry-in port 105b Carry-out port 106, 107, 108, 109 Shaft 110 Transport unit 120 Transport section 122 Guide part 124a... Driven roller 124b... Drive roller 124c... Tension roller 126... Conveyor belt 126a... Conveyance surface 128a... Carry-in roller 128b... Carry-out Roller 130 Tension part 131, 132 Holding belt 133a First pulley 133b Second pulley 133c Outer circumference of the first pulley around which the conveying belt is wound, 133d... outer periphery around which the conveying belt of the second pulley is wound, 134a... third pulley, 134b... fourth pulley, 136, 137, 138, 139... bend pulley, 140... irradiation unit , 142... cover, 144... lamp, 146... reflector, 148... fan, 150... control section, 152... CPU, 154... ROM, 156... RAM , 158... input/output interface, 162... rollers, B1, B2... lower end, F... tension, R... conveying path, S... area irradiated with electromagnetic waves, T...・top

Claims (8)

a conveying unit that conveys a molded sheet that expands when irradiated with a predetermined electromagnetic wave along the conveying path while being tensioned to warp along the conveying path curved in a convex shape;
an irradiating unit that irradiates the predetermined electromagnetic wave to the molded sheet being conveyed while maintaining the tensioned state by the conveying unit ,
The molded sheet is
a substrate;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; comprising
molding device. The transport unit includes a transport section that transports the formed sheet along the transport path;
a tension unit that applies the tension to the molded sheet along the conveying path,
The modeling apparatus according to claim 1. The conveying unit includes a conveying belt on which the formed sheet is placed and which travels along the conveying path;
a guide unit that supports the conveying belt in a curved state along the conveying path,
The modeling apparatus according to claim 2. The irradiation unit is arranged on the convex side of the transport path,
The modeling apparatus according to any one of claims 1 to 3. The irradiating unit is arranged at a position that irradiates the predetermined electromagnetic wave upward from the top of the transport path.
The modeling apparatus according to claim 4. The transport unit transports the molded sheet with the heat conversion layer facing the irradiation unit.
The modeling apparatus according to any one of claims 1 to 5. a conveying step of conveying a molded sheet that expands when irradiated with a predetermined electromagnetic wave along a convexly curved conveying path;
a step of applying tension to the molded sheet being conveyed so that it warps along the conveying path;
an irradiation step of irradiating the formed sheet conveyed in the conveying step with the predetermined electromagnetic wave while maintaining the state in which the tension is applied in the applying step;
The molded sheet is
a substrate;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; comprising
A method of manufacturing a modeled object. an irradiation unit that irradiates a predetermined electromagnetic wave;
While maintaining a state in which the molded sheet that expands when irradiated with the predetermined electromagnetic wave is warped along the convexly curved conveying path in the area irradiated with the predetermined electromagnetic wave, a transport unit that transports along the transport path,
The molded sheet is
a substrate;
a thermal expansion layer that is laminated on one main surface of the base material and expands when heated;
a heat conversion layer laminated on the other main surface of the base material or on the thermal expansion layer, absorbing the predetermined electromagnetic wave and converting the predetermined electromagnetic wave into heat to heat the thermal expansion layer; comprising
Conveyor.

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