Three-dimensionally molded article and method for manufacturing three-dimensionally molded article

Abstract

The invention provides a three-dimensionally molded article and a method for manufacturing the three-dimensionally molded article, and the appearance of the three-dimensionally molded article can be improved by using stack marks. The three-dimensional forming object comprises a three-dimensional forming object body and a sheet, the sheet is tightly formed on the side face of the three-dimensional forming object body in the stacking direction of the three-dimensional forming object body, and a plurality of forming layers of the three-dimensional forming object body comprise the first forming layer and the second forming layer. The second molding layer protrudes more on the side surface than the first molding layer to form a protrusion on the side surface. The surface of the sheet is undulating along the outer shape of the protrusion. The manufacturing method of a three-dimensional molded article includes: a first step of forming a three-dimensional molded article body in which a second molded layer protrudes more than a first molded layer on a side surface of the three-dimensional molded article body to form a protruding portion on the side surface; and a second step in which a sheet is tightly formed on the side surface in the stacking direction of the three-dimensional molded body, and the surface of the sheet is undulated along the outer shape of the protrusion.

Description

Technical Field

[0001] The invention relates to a three-dimensional formed object and a method for manufacturing the three-dimensional formed object. Background Art

[0002] In recent years, for three-dimensional molding technology that uses resin materials to manufacture three-dimensional molded objects with three-dimensional shapes, such as three-dimensional printing and other methods of gradually depositing molten resin, stacking marks may be produced in the stacking direction (i.e., the height direction of the three-dimensional molded object) due to the misalignment of the molding layer, resulting in poor appearance. Such three-dimensional molded objects are difficult to be used as exterior parts with high appearance requirements like parts manufactured by injection molding or injection molding. Therefore, in the prior art, in order to make the stacking marks on the surface of the obtained three-dimensional molded object less obvious, there is a method of forming a smooth surface on the three-dimensional molded object using acetone vapor and other methods. However, such a method increases the processing steps of acetone vapor. Therefore, it is expected to develop a technical solution that can make use of the stacking marks on the three-dimensional molded object to improve the appearance.

[0003] [Prior art literature]

[0004] [Patent Document]

[0005] [Patent Document 1] Japanese Patent Publication No. 2016-055603 Summary of the invention

[0006] The present invention provides a three-dimensional formed object and a method for manufacturing the three-dimensional formed object, which can utilize stacking marks to improve the appearance.

[0007] The three-dimensional molded article provided by the present invention includes: a three-dimensional molded object body, formed by stacking multiple molding layers; and a sheet material, which is tightly formed on the side surface of the three-dimensional molded object body along the stacking direction of the three-dimensional molded object body, wherein the multiple molding layers include at least one first molding layer, and at least one second molding layer, the second molding layer is more protruding on the side surface than the first molding layer, so as to form at least one protrusion on the side surface extending in a direction orthogonal to the stacking direction, and the surface of the sheet material tightly formed on the side surface undulates along the shape of the protrusion.

[0008] In an embodiment of the present invention, the plurality of molding layers include a plurality of second molding layers, the plurality of second molding layers are stacked on the first molding layer, and the plurality of second molding layers are spaced apart from each other in the stacking direction.

[0009] In one embodiment of the present invention, a decorative pattern is formed on the surface of the sheet, the decorative pattern has a plurality of characteristic lines parallel to each other, and the sheet is closely formed on the side surface in such a manner that the characteristic lines intersect the protrusions.

[0010] The method for making a three-dimensional molded object provided by the present invention includes: a first step, forming a three-dimensional molded object body by stacking multiple molding layers, wherein the multiple molding layers include at least one first molding layer and at least one second molding layer, and the second molding layer protrudes more than the first molding layer on the side of the three-dimensional molded object body, so as to form at least one protrusion on the side extending in a direction orthogonal to the stacking direction of the three-dimensional molded object body; and a second step, tightly forming a sheet on the side along the stacking direction, and making the surface of the sheet tightly formed on the side undulate along the shape of the protrusion.

[0011] In one embodiment of the present invention, the plurality of molding layers include a plurality of second molding layers, and in the first step, the plurality of second molding layers are stacked on the first molding layer, and the plurality of second molding layers are separated from each other in the stacking direction.

[0012] In one embodiment of the present invention, a decorative pattern is formed on the surface of the sheet, the decorative pattern having a plurality of characteristic lines parallel to each other, and in the second step, the sheet is tightly formed on the side surface in such a manner that the characteristic lines intersect the protrusions.

[0013] Based on the above, in the three-dimensional molded article and the method for making the three-dimensional molded article of the present invention, the multiple molded layers of the three-dimensional molded object body include a first molded layer and a second molded layer, the second molded layer protrudes more than the first molded layer on the side of the three-dimensional molded object body to form a protrusion (i.e., stacking mark) on the side, and the sheet is tightly formed on the side and undulates along the shape of the protrusion. In this way, the protrusion (i.e., stacking mark) provided on the side of the three-dimensional molded object body is reflected to the outside by the sheet in close contact with the side after appropriate arrangement, so that a decorative texture can be formed on the side of the three-dimensional molded object body. Accordingly, the three-dimensional molded object and the method for making the three-dimensional molded object of the present invention can make use of the stacking mark to improve the appearance.

[0014] In order to make the above features and advantages of the present invention more clearly understood, embodiments are given below with reference to the accompanying drawings for detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a side view of a three-dimensional formed article according to an embodiment of the present invention;

[0016] Figure 2yes Figure 1 A schematic cross-sectional view of the three-dimensional formed article at line II';

[0017] Figure 3 yes Figure 1 A schematic front view of a sheet material used for the three-dimensionally formed object shown;

[0018] Figure 4 yes Figure 3 a schematic side view of the sheet shown;

[0019] Figure 5 yes Figure 1 A schematic flow chart of a method for producing a three-dimensional formed object is shown.

[0020] Description of reference numerals:

[0021] 100: Three-dimensional shaped objects;

[0022] 110: three-dimensional molding body;

[0023] 112: forming layer;

[0024] 112a: first molding layer;

[0025] 112b: second molding layer;

[0026] 114: protrusion;

[0027] 120: Sheet;

[0028] D1: stacking direction;

[0029] D2: salient direction;

[0030] D3: extension direction;

[0031] L: characteristic line;

[0032] P: decorative pattern;

[0033] S01: first step;

[0034] S02: second step;

[0035] S1: lateral;

[0036] S2: Surface. DETAILED DESCRIPTION

[0037] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Figure 1 is a side view of a three-dimensional formed article according to an embodiment of the present invention, Figure 2 yes Figure 1The schematic cross-sectional view of the three-dimensional shaped object at line II' is shown. Figure 3 yes Figure 1 A schematic front view of a sheet material used for a three-dimensionally formed object is shown, Figure 4 yes Figure 3 A schematic side view of the sheet shown, Figure 5 yes Figure 1 The following is a schematic diagram of the process of making a three-dimensional formed object. Figures 1 to 5 The specific structure and manufacturing method of the three-dimensional formed article 100 of this embodiment are described, but these are only some examples of the present invention and the present invention is not limited thereto.

[0038] In this embodiment, if Figures 1 to 4 As shown, the three-dimensional molded object 100 includes a three-dimensional molded object body 110 and a sheet 120. The three-dimensional molded object body 110 is formed by stacking a plurality of molded layers 112. Accordingly, the sheet 120 is tightly formed on the side S1 of the three-dimensional molded object body 110 along the stacking direction D1 of the three-dimensional molded object body 110. The plurality of molded layers 112 include at least one first molded layer 112a and at least one second molded layer 112b. The second molded layer 112b protrudes more than the first molded layer 112a on the side S1 to form at least one protrusion 114 extending in a direction orthogonal to the stacking direction D1 (i.e., the protruding direction D2) on the side S1. Furthermore, the surface S2 of the sheet 120 tightly formed on the side S1 undulates along the outer shape of the protrusion 114.

[0039] Specifically, in this embodiment, if Figure 1 and Figure 2 As shown, the three-dimensional formed object 100 refers to an object having a three-dimensional shape produced through a forming process. The three-dimensional formed object body 110 is formed by stacking a plurality of forming layers 112 by a technique such as three-dimensional printing (not limited thereto). Therefore, the three-dimensional formed object body 110 is constituted as a component that is roughly sheet-shaped (not limited thereto). The edges of the first forming layer 112a and the second forming layer 112b of the three-dimensional formed object body 110 are misaligned during the stacking process, so that a protrusion 114 is formed by the protruding second forming layer 112b at least on the side S1 of the three-dimensional formed object body 110. In other words, the protrusion 114 is equivalent to the stacking mark formed on the side S1 of the three-dimensional formed object body 110 in the process of forming the three-dimensional formed object body 110 by stacking a plurality of forming layers 112. However, the present invention does not limit the specific structure of the three-dimensional formed object body 110, which can be adjusted according to needs.

[0040] Furthermore, in this embodiment, if Figure 3 and Figure 4As shown, the sheet 120 is a thin film structure extending along the stacking direction D1. Figure 1 and Figure 2 As shown, the sheet 120 is tightly formed on the side S1 of the three-dimensional formed body 110. For example, the sheet 120 can be attached to the side S1 of the three-dimensional formed body 110 by a vacuum forming process (but not limited thereto). Figure 3 and Figure 4 The thin film-like sheet 120 shown covers the protrusion 114 along the entire outer surface of the protrusion 114, so that the surface S2 of the sheet 120 is undulating along the outer shape of the protrusion 114, and presents a concave-convex structure (such as Figure 2 As shown). In this way, the sheet 120 tightly formed on the side S1 of the three-dimensional formed body 110 can reflect the protrusion 114 (i.e., the stacking mark) formed on the side S1 toward the outside to form a decorative texture (such as Figure 1 However, the present invention does not limit the specific structure of the sheet 120, which can be adjusted according to needs.

[0041] Please refer to Figure 5 In this embodiment, the manufacturing method of the three-dimensional molded object 100 includes the following process. First, in the first step S01, a three-dimensional molded object body 110 is formed by stacking a plurality of molded layers 112, wherein the plurality of molded layers 112 include at least one first molded layer 112a and at least one second molded layer 112b, and the second molded layer 112b protrudes more than the first molded layer 112a on the side surface S1 of the three-dimensional molded object body 110, so as to form at least one protrusion 114 on the side surface S1 extending in a direction orthogonal to the stacking direction D1 of the three-dimensional molded object body 110 (i.e., the protruding direction D2). In the second step S02, a sheet 120 is tightly formed on the side surface S1 along the stacking direction D1, and the surface S2 of the sheet 120 tightly formed on the side surface S1 is made to undulate along the shape of the protrusion 114. The specific structure and manufacturing method of each component of the three-dimensional molded object 100 can refer to the above description, and will not be repeated here.

[0042] As can be seen, in the three-dimensional molded object 100 and the method for manufacturing the three-dimensional molded object 100 of the present embodiment, the plurality of molded layers 112 of the three-dimensional molded object body 110 are appropriately arranged (i.e., arranged) according to the desired decorative texture, so that the side S1 of the three-dimensional molded object body 110 is formed with a protrusion 114 (i.e., a stacking mark) corresponding to the desired decorative texture, and then after the three-dimensional molded object body 110 is decorated with the sheet 120, the sheet 120 is closely combined so that the outer shape of the protrusion 114 is reflected outward. In this way, the protrusion 114 (i.e., the stacking mark) provided on the side S1 of the three-dimensional molded object body 110 is reflected outward by the sheet 120 in close contact with the side S1 after appropriate arrangement, so that the decorative texture can be formed on the side S1 of the three-dimensional molded object body 110. Accordingly, the three-dimensional molded object 100 and the method for manufacturing the three-dimensional molded object 100 can utilize the stacking mark to improve the appearance.

[0043] Furthermore, in this embodiment, if Figure 1 and Figure 2 As shown, the plurality of molding layers 112 include at least one first molding layer 112a and a plurality of second molding layers 112b. The plurality of second molding layers 112b are stacked on the first molding layer 112a, and the plurality of second molding layers 112b are separated from each other in the stacking direction D1. Figure 5 In the first step S01 shown (i.e., in the process of stacking a plurality of molding layers 112), a plurality of second molding layers 112b are stacked on the first molding layer 112a, and the plurality of second molding layers 112b are separated from each other in the stacking direction D1. For example, the first molding layer 112a and the second molding layer 112b are formed by spraying molding material in the same molding path, but the speed is reduced at a position corresponding to the protrusion of the second molding layer 112b to form the protrusion 114 protruding outward. Alternatively, the molding path for spraying molding material to form the second molding layer 112b is set to protrude outward by about half of the spraying width to form the protrusion 114 protruding outward. The present invention does not limit the specific means for forming the protrusion 114 protruding outward, which can be adjusted according to needs.

[0044] Furthermore, in this embodiment, if Figure 1 and Figure 2As shown, as an example, the three-dimensional molded object body 110 is shown to include three groups (six layers in total) of first molded layers 112a, each of which is two layers, and four second molded layers 112b stacked on the first molded layers 112a. Among them, the multiple second molded layers 112b are separated from each other in the stacking direction D1, for example, a group (two layers) of first molded layers 112a is provided between every two adjacent second molded layers 112b. As a result, a plurality of protrusions 114 formed by the second molded layers 112b on the side S1 of the three-dimensional molded object body 110 are also formed, and the multiple protrusions 114 are separated from each other on the side S1, and then arranged along the stacking direction D1 according to a preset interval. In other words, the shape, size, arrangement order, etc. of the protrusions 114 (i.e., stacking marks) are designed in advance to obtain the desired decorative texture. However, the present invention does not limit the number, size, arrangement method, etc. of the first molded layers 112a and the second molded layers 112b, which can be adjusted according to requirements (e.g., the desired decorative texture). As long as at least one first molding layer 112 a and at least one second molding layer 112 b are provided to form at least one protrusion 114 , the spirit of the present invention is met.

[0045] In addition, in this embodiment, although Figure 1 The protrusion 114 formed on the side S1 of the three-dimensional molded object body 110 is shown as a strip-shaped structure extending in a direction orthogonal to the stacking direction D1 and the protruding direction D2 (i.e., the extension direction D3), that is, the side of the single-layer second molding layer 112b is uniformly wide and flush, but the protrusion can also be formed into other shapes (e.g., columnar). For example, in other embodiments not shown, in the process of forming a single-layer second molding layer by spraying molding material, spray paths of different lengths are set to form a concave-convex structure (non-fluid) on the side of the single-layer second molding layer to form a columnar protrusion on the side. Furthermore, although Figure 1 The protrusion 114 is shown to be formed on one of the side surfaces S1 of the three-dimensional molded object body 110, but the protrusions may also be formed on multiple surfaces of the three-dimensional molded object body with a more complex shape. Preferably, the protrusion 114 is formed on the surface (not limited to a single surface) of the three-dimensional molded object body 110 for attaching the sheet 120. The present invention does not limit the number, size, shape, arrangement, and setting position of the protrusion 114, which can be adjusted according to needs (for example, the desired decorative texture).

[0046] In addition, in this embodiment, Figure 3 and Figure 4 As shown, the surface S2 of the sheet 120 is formed with a decorative pattern P. The decorative pattern P has a plurality of characteristic lines L parallel to each other, and the sheet 120 is closely formed on the side S1 in such a manner that the characteristic lines L intersect with the protrusion 114. As an example, in Figure 5In the second step S02 shown (i.e., in the process of forming the sheet 120), the sheet 120 is tightly formed on the side S1 in such a way that the characteristic line L intersects with the protrusion 114. For example, the sheet 120 is pre-placed on the side S1 of the three-dimensional formed object body 110 according to the position of its characteristic line L, and is attached to the side S1 of the three-dimensional formed object body 110 through the aforementioned vacuum forming process (but not limited thereto) to present the desired decorative texture toward the outside. However, in other embodiments not shown, the sheet 120 may also be formed with a decorative color without a decorative pattern P to present a colorful decorative texture toward the outside, or may be provided with a decorative pattern P and a decorative color at the same time. In addition, a plurality of characteristic lines parallel to each other may also be arranged to be parallel to the protrusion 114. The present invention does not limit the specific structure and whether the decorative pattern P is arranged, and it can be adjusted according to needs.

[0047] It can be seen that in this embodiment, if Figure 1 and Figure 2 As shown, the sheet 120 tightly formed on the side S1 is located outside the three-dimensional formed object 100 to form a decorative layer, and displays its decorative pattern P toward the outside. At this time, the decorative pattern P of the sheet 120 is superimposed on the protrusion 114 of the three-dimensional formed object body 110, and the desired decorative texture (such as Figure 1 In particular, the characteristic line L of the decorative pattern P provided on the surface S2 of the sheet 120 intersects with the protrusion 114, so that the characteristic line L of the decorative pattern P also changes the visual effect with the fluctuation of the shape of the protrusion 114 (please refer to the characteristic line L in Figure 1 and Figure 3 ). Thus, in combination with the decorative pattern P provided on the surface S2 of the sheet 120, the three-dimensional formed object 100 can have a more beautiful decorative texture. It can be imagined that when the design content of the concave-convex structure formed by the protrusion 114 formed on the side S1 of the three-dimensional formed object body 110 (for example, strips, columns, etc.) and the design content of the decorative pattern P provided on the surface S2 of the sheet 120 (for example, diagonal lines, grid lines) are selected differently, the decorative texture presented by the superimposed setting is also different. Therefore, the diversity of the appearance effect of the three-dimensional formed object 100 can be increased. However, the present invention is not limited to this, and it can be adjusted according to needs.

[0048] In summary, in the three-dimensional molded article and the method for making the three-dimensional molded article of the present invention, the multiple molded layers of the three-dimensional molded object body include a first molded layer and a second molded layer, the second molded layer is more protruding than the first molded layer on the side of the three-dimensional molded object body to form a protrusion (i.e., stacking mark) on the side, and the sheet is tightly formed on the side and undulates along the shape of the protrusion. In this way, the protrusion (i.e., stacking mark) provided on the side of the three-dimensional molded object body is reflected to the outside by the sheet in close contact with the side after appropriate arrangement, so that a decorative texture can be formed on the side of the three-dimensional molded object body. Preferably, the multiple second molded layers are stacked on the first molded layer and separated from each other in the stacking direction, and the multiple sheets are tightly formed on the side in a manner that the characteristic lines of the decorative pattern on the surface intersect with the protrusion, so that the three-dimensional molded object can have a more beautiful decorative texture. Accordingly, the three-dimensional molded object and the method for making the three-dimensional molded object of the present invention can make use of the stacking mark to improve the appearance.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A three-dimensional formed object, characterized in that: include: A three-dimensional molded object body is formed by stacking a plurality of molded layers; as well as The sheet is closely formed on the side of the three-dimensional formed object body along the stacking direction of the three-dimensional formed object body, wherein The plurality of molding layers include at least one first molding layer and at least one second molding layer. The second molding layer protrudes more on the side surface than the first molding layer to form at least one protrusion on the side surface extending in a direction orthogonal to the stacking direction, and The surface of the sheet closely formed on the side surface undulates along the outer shape of the protrusion.

2. The three-dimensional shaped article according to claim 1, characterized in that: The plurality of molding layers include a plurality of the second molding layers, A plurality of the second molded layers are stacked on the first molded layer, and the plurality of the second molded layers are spaced apart from each other in the stacking direction.

3. The three-dimensional shaped article according to claim 1 or 2, characterized in that: The surface of the sheet is formed with a decorative pattern, The decorative pattern has a plurality of characteristic lines parallel to each other, and The sheet is closely formed on the side surface in such a manner that the character line intersects the protrusion.

4. A method for making a three-dimensional formed object, characterized in that: include: The first step is to form a three-dimensional molded object body by stacking a plurality of molded layers, wherein the plurality of molded layers include at least one first molded layer and at least one second molded layer, and the second molded layer protrudes more than the first molded layer on a side surface of the three-dimensional molded object body, so as to form at least one protrusion on the side surface extending in a direction orthogonal to a stacking direction of the three-dimensional molded object body; as well as In a second step, a sheet is densely formed on the side surface along the stacking direction, and a surface of the sheet densely formed on the side surface is caused to undulate along the outer shape of the protrusion.

5. The method for making a three-dimensional formed object according to claim 4, characterized in that: The plurality of molding layers include a plurality of the second molding layers, In the first step, a plurality of the second mold layers are stacked on the first mold layer, and the plurality of the second mold layers are spaced apart from each other in the stacking direction.

6. The method for producing a three-dimensionally formed object according to claim 4 or 5, characterized in that: The surface of the sheet is formed with a decorative pattern, The decorative pattern has a plurality of characteristic lines parallel to each other, and In the second step, the sheet is tightly formed on the side surface in such a manner that the character line intersects the protrusion.

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