Material discharge device, injection molding device, and three-dimensional molding device

Abstract

To provide a material discharge device, an injection molding device, and a three-dimensional molding device, capable of supplying an appropriate amount of material.SOLUTION: A material discharge device includes: a material supply unit 10 for supplying a material; a plasticizing part 60 that plasticizes the material supplied from the material supply unit 10 by rotation of a flat screw 110 having a groove-forming surface on which grooves are formed, to generate a plasticized material; a path 500 for supplying the material from the material supply unit 10 to the plasticizing part 60; a nozzle 80 having a nozzle hole for discharging the plasticized material; and a control part 50 that controls driving of the material supply unit 10. The material supply unit 10 has a rotation mechanism 180 that intermittently supplies the material to the plasticizing part 60, and the control part 50 operates the rotation mechanism 180 in conjunction with rotation of the flat screw 110, thereby controlling so that the material does not accumulate in the path 500.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a material discharge device, an injection molding device, and a three-dimensional shaping device.

Background Art

[0002] Patent Document 1 discloses the structure of an injection molding device including a material supply mechanism, a plasticizing mechanism that plasticizes the material received from the material supply mechanism through a supply port to generate a molten material, and a supply path that serves as a path connecting the material supply mechanism and the supply port.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the conventional configuration, there is a problem that the portion connecting the material supply mechanism to the supply path becomes narrow, so the material clogs in the supply path.

Means for Solving the Problems

[0005] The material discharge device includes a material supply unit that supplies a material, a plasticizing unit that plasticizes the material supplied from the material supply unit by rotation of a flat screw having a groove-formed surface to generate a plasticized material, a path that supplies the material from the material supply unit to the plasticizing unit, a nozzle having a nozzle hole that discharges the plasticized material, and a control unit that controls the drive of the material supply unit. The material supply unit has a supply mechanism that intermittently supplies the material to the plasticizing unit, and the control unit operates the supply mechanism in conjunction with the rotation of the flat screw and controls so that the material does not accumulate in the path.

[0006] The injection molding apparatus includes the material discharge apparatus described above.

[0007] The three-dimensional shaping apparatus includes the material discharge apparatus described above.

Brief Description of the Drawings

[0008]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Embodiments for Carrying Out the Invention

[0009] In the following figures, three mutually orthogonal axes will be described as the X-axis, the Y-axis, and the Z-axis. Also, the direction along the X-axis is the "X direction", the direction along the Y-axis is the "Y direction", and the direction along the Z-axis is the "Z direction". The direction of the arrow is the + direction, and the direction opposite to the + direction is the - direction. Note that the Z-axis is a virtual axis along the vertical direction, with the +Z direction being upward and the -Z direction being downward. The -Z direction is the direction in which gravity acts. Also, a plan view from the Z-axis direction is simply referred to as a "plan view".

[0010] Referring to FIGS. 1 and 2, the configuration of an injection molding apparatus 100, which is an example of a material ejection apparatus 100A, will be described.

[0011] As shown in FIG. 1, the injection molding apparatus 100 includes a housing 200 and a material supply unit 10 attached to the housing. Specifically, as shown in FIG. 2, the injection molding apparatus 100 includes a material supply unit 10, an injection unit 20, a mold unit 30, a mold clamping unit 40, a control unit 50, and a plasticizing unit 60.

[0012] The material supply unit 10 supplies a material P (see FIG. 9), which is a raw material, to the plasticizing unit 60. The shape of the material P supplied from the material supply unit 10 is, for example, pellet-shaped or powder-shaped. The shape of the material P supplied from the material supply unit 10 may be a fragmented shape pulverized by a pulverizer.

[0013] The plasticizing unit 60 plasticizes the material P supplied from the material supply unit 10 to make it a plasticized material. The injection unit 20 injects the plasticized material toward the mold unit 30.

[0014] Note that plasticization is a concept that includes melting and is to change from a solid state to a state having fluidity. Specifically, in the case of the material P in which glass transition occurs, plasticization is to raise the temperature of the material P above the glass transition point. In the case of the material P in which glass transition does not occur, plasticization is to raise the temperature of the material P above the melting point.

[0015] In the mold unit 30, a cavity 34 (see FIG. 3) corresponding to the shape of the molded product is formed. The plasticized material injected from the injection unit 20 flows into the cavity 34. Then, the plasticized material is cooled and solidified to produce a molded product.

[0016] The mold clamping unit 40 opens and closes the mold unit 30. After the plasticized material is cooled and solidified, the mold clamping unit 40 opens the mold unit 30. Thereby, the molded product is discharged to the outside.

[0017] The control unit 50 is constituted by, for example, a computer having a processor, a main memory device, and an input / output interface for inputting / outputting signals to / from the outside. The control unit 50 exhibits various functions, for example, by the processor executing a program read into the main memory device. Specifically, the control unit 50 controls the material supply unit 10, the injection unit 20, and the mold clamping unit 40. Note that the control unit 50 may be constituted by a combination of a plurality of circuits instead of a computer.

[0018] Next, with reference to FIG. 3, the specific configuration of the injection molding apparatus 100 will be described.

[0019] As shown in FIG. 3, the injection unit 20 has, for example, a plasticizing unit 60, an injection mechanism 70, and a nozzle 80.

[0020] The plasticizing unit 60 is configured to plasticize the material P supplied from the material supply unit 10, generate a paste-like plasticized material having fluidity, and guide it to the injection mechanism 70. The plasticizing unit 60 and the material supply unit 10 constitute a plasticizing device 102. The plasticizing device 102 includes the plasticizing unit 60 and the material supply unit 10. The plasticizing unit 60 includes, for example, a screw case 62, a drive motor 64, a flat screw 110, a barrel 120, and a heater 130.

[0021] The screw case 62 is a housing that houses the flat screw 110. The flat screw 110 is housed in a space surrounded by the screw case 62 and the barrel 120.

[0022] The drive motor 64 is connected to the screw case 62. The drive motor 64 rotates the flat screw 110. The drive motor 64 is, for example, a servo motor. The shaft 66 of the drive motor 64 is connected to the flat screw 110. The drive motor 64 is controlled by the control unit 50.

[0023] The flat screw 110 has a substantially cylindrical shape in which the size in the direction of the rotation axis R is smaller than the size in the direction orthogonal to the direction of the rotation axis R. In the illustrated example, the rotation axis R is parallel to the Y axis. The flat screw 110 rotates about the rotation axis R by the torque generated by the drive motor 64.

[0024] The flat screw 110 has a motor side surface 111 on the drive motor 64 side, a groove forming surface 112 on the side opposite to the motor side surface 111, and a connection surface 113 connected to the groove forming surface 112.

[0025] Next, with reference to FIG. 4, the specific configuration of the flat screw 110 will be described. For convenience, in FIG. 4, the state shown is the state in which the vertical positional relationship is reversed from the state shown in FIG. 3.

[0026] As shown in FIG. 4, a first groove 114 as a groove is formed in the groove forming surface 112 of the flat screw 110. The shape of the first groove 114 is spiral. The first groove 114 has, for example, a central portion 115, a connection portion 116, and a material introduction portion 117.

[0027] The central portion 115 faces a communication hole 126 formed in the barrel 120. The central portion 115 communicates with the communication hole 126.

[0028] The connection portion 116 connects the central portion 115 and the material introduction portion 117. The connection portion 116 is formed in a spiral shape from the central portion 115 toward the outer periphery of the groove forming surface 112. The material introduction portion 117 is formed on the outer periphery of the groove forming surface 112. That is, the material introduction portion 117 is formed on the connection surface 113 of the flat screw 110.

[0029] The material P supplied from the material supply unit 10 is introduced from the material introduction part 117 into the first groove 114, passes through the connection part 116 and the central part 115, and is conveyed to the communication hole 126 formed in the barrel 120. In the present embodiment, two first grooves 114 are formed. Note that the number of the first grooves 114 is not particularly limited. Although not shown, three or more first grooves 114 may be formed, or only one first groove 114 may be formed.

[0030] As shown in FIG. 3, the barrel 120 is provided facing the flat screw 110. The barrel 120 has a facing surface 122 facing the groove forming surface 112 of the flat screw 110. The facing surface 122 faces the groove forming surface 112 in the Y-axis direction. A communication hole 126 is formed at the center of the facing surface 122.

[0031] Next, the configuration of the barrel 120 will be described with reference to FIG. 5.

[0032] As shown in FIG. 5, a second groove 124 and a communication hole 126 are formed in the facing surface 122 of the barrel 120. A plurality of second grooves 124 are formed.

[0033] In the present embodiment, six second grooves 124 are formed. Note that the number of the second grooves 124 is not particularly limited. The plurality of second grooves 124 are formed around the communication hole 126 when viewed from the Y-axis direction.

[0034] One end of the second groove 124 is connected to the communication hole 126, and extends spirally from the communication hole 126 toward the outer periphery of the facing surface 122. The second groove 124 has a function of guiding the plasticized material to the communication hole 126. The plasticized material flows into the communication hole 126. The communication hole 126 discharges the inflowed plasticized material to the outside of the barrel 120.

[0035] Incidentally, the shape of the second groove 124 is not particularly limited and may be, for example, linear. Also, one end of the second groove 124 does not have to be connected to the communication hole 126. Furthermore, the second groove 124 does not have to be formed on the opposing surface 122. However, considering efficiently guiding the plasticizing material to the communication hole 126, it is preferable that the second groove 124 is formed on the opposing surface 122.

[0036] As shown in FIG. 3, the heater 130 is provided in the barrel 120. The heater 130 heats the material P supplied between the flat screw 110 and the barrel 120. The heater 130 heats the material P supplied to the first groove 114. The heater 130 is controlled by the control unit 50.

[0037] The plasticizing unit 60 heats and plasticizes the material P while conveying it toward the communication hole 126 by the flat screw 110, the barrel 120, and the heater 130 to generate a plasticized material, and causes the generated plasticized material to flow out from the communication hole 126 to the injection mechanism 70.

[0038] The injection mechanism 70 has, for example, a cylinder 72, a plunger 74, and a plunger driving unit 76. The cylinder 72 is a substantially cylindrical member connected to the communication hole 126. The plunger 74 moves inside the cylinder 72. The plunger 74 is driven by a plunger driving unit 76 constituted by a motor, gears, etc. The plunger driving unit 76 is controlled by the control unit 50. Incidentally, the cylinder 72 may be connected to a flow path downstream of the communication hole 126.

[0039] The injection mechanism 70 performs a metering operation and an injection operation by sliding the plunger 74 within the cylinder 72. The metering operation refers to an operation of guiding the plasticized material located at the communication hole 126 into the cylinder 72 by moving the plunger 74 in the -X axis direction away from the communication hole 126 and performing metering within the cylinder 72. The injection operation refers to an operation of injecting the plasticized material within the cylinder 72 into the mold part 30 via the nozzle 80 by moving the plunger 74 in the +X axis direction approaching the communication hole 126.

[0040] The nozzle 80 is formed with a nozzle hole 82 communicating with the communication hole 126. The nozzle 80 injects the plasticized material supplied from the plasticizing part 60 toward the molding die 32 of the mold part 30. Specifically, by performing the above-described metering operation and injection operation, the plasticized material metered within the cylinder 72 is sent from the injection mechanism 70 to the nozzle hole 82 via the communication hole 126. Then, the plasticized material is injected from the nozzle hole 82 into the mold part 30.

[0041] The mold part 30 has a molding die 32. The plasticized material sent to the nozzle hole 82 is injected from the nozzle hole 82 into the cavity 34 of the molding die 32. Specifically, the molding die 32 has a movable die 36 and a fixed die 38 facing each other, and has a cavity 34 between the movable die 36 and the fixed die 38. The cavity 34 is a space corresponding to the shape of the molded product. The materials of the movable die 36 and the fixed die 38 are metals. Note that the materials of the movable die 36 and the fixed die 38 may be ceramics or resins.

[0042] The mold clamping part 40 has, for example, a mold driving part 42 and a ball screw part 44. The mold driving part 42 is constituted by, for example, a motor, gears, etc. The mold driving part 42 is connected to the movable die 36 via the ball screw part 44. The mold driving part 42 is controlled by the control part 50. The ball screw part 44 transmits the power generated by the driving of the mold driving part 42 to the movable die 36. The mold clamping part 40 opens and closes the mold part 30 by moving the movable die 36 by the mold driving part 42 and the ball screw part 44.

[0043] Next, with reference to FIGS. 6 to 9, the configuration of the material supply unit 10 will be described.

[0044] As shown in FIG. 6, the material supply unit 10 includes, for example, a housing 140, a rotation mechanism 180 as a supply mechanism, and a sliding contact member 190. The material supply unit 10 supplies the material P to the supply port 400 of the plasticizing unit 60. The plasticizing unit 60 plasticizes the material P to generate a plasticized material. For convenience, in FIGS. 7 to 9, the plasticizing unit 60 is shown in a simplified manner.

[0045] As shown in FIGS. 7 to 9, the housing 140 houses the material P. The material of the housing 140 is, for example, metal. The housing 140 has, for example, a first structure 150, a second structure 160, and a third structure 170.

[0046] The first structure 150 has a first opening 150a and a second opening 150b. The material P is put into the material supply unit 10 from the first opening 150a by the user and guided to the second opening 150b. When viewed in the Z-axis direction, the second opening 150b overlaps the first opening 150a.

[0047] As shown in FIG. 7, the first structure 150 has, for example, an inclined wall 152, a first wall 154, a second wall 156, and a third wall 158.

[0048] The inclined wall 152, the first wall 154, the second wall 156, and the third wall 158 constitute, for example, a hopper. The walls 152, 154, 156, 158 define a material storage space 2, which is a storage space for the material P, above the rotating member 182 of the rotation mechanism 180.

[0049] The inclined wall 152 is inclined so as to reduce the volume of the material storage space 2 for the material P downward. The inclined wall 152 receives the material P from the first opening 150a and slides and conveys the material P toward the second opening 150b. In the illustrated example, the width of the material storage space 2 becomes narrower as it goes in the -Z-axis direction.

[0050] The second opening 150b of the material accommodating space 2 is a constricted portion where the volume of the material accommodating space is reduced by the inclined wall 152. The second opening 150b is a constricted portion where the width of the material accommodating space 2 is the narrowest. In the example shown in FIG. 9, the width of the material accommodating space 2 is the distance between the inclined wall 152 and the first wall 154. The opening area of the second opening 150b is the smallest in the material accommodating space 2.

[0051] The second structure 160 is connected to the first structure 150. The second structure 160 is provided below the first structure 150. The second structure 160 is provided between the first structure 150 and the third structure 170. In the example shown in FIG. 8, the second structure 160 is supported by the first support member 162.

[0052] As shown in FIG. 9, the second structure 160 has a third opening 160a and a fourth opening 160b. The material P supplied from the second opening 150b of the first structure 150 is introduced into the second structure 160 through the third opening 160a and is guided to the fourth opening 160b through the rotating member 182. In the illustrated example, the second opening 150b and the third opening 160a are in the same position in the Z-axis direction. When viewed from the Z-axis direction, the fourth opening 160b does not overlap the third opening 160a.

[0053] The second structure 160 has, for example, a receiving portion 164 that receives the material P from the third opening 160a and a portion 166 to be slidably contacted by the rotating member 182.

[0054] The receiving portion 164 overlaps the third opening 160a when viewed from the Z-axis direction. The receiving portion 164 is in contact with the material P. The receiving portion 164 has a shape inclined with respect to the horizontal direction so as to guide the material P to the rotating member 182.

[0055] The portion 166 to be slidably contacted is provided below the receiving portion 164. The portion 166 to be slidably contacted is connected to the receiving portion 164. The portion 166 to be slidably contacted has a shape along the outer periphery 182a of the rotating member 182. The portion 166 to be slidably contacted does not contact the material P, for example.

[0056] The third structure 170 is connected to the second structure 160. The third structure 170 is provided below the second structure 160. The third structure 170 is provided between the second structure 160 and the plasticizing unit 60.

[0057] The third structure 170 has a fifth opening 170a and a sixth opening 170b. The material P supplied from the fourth opening 160b of the second structure 160 is introduced into the third structure 170 from the fifth opening 170a and guided to the sixth opening 170b. Then, the sixth opening 170b feeds the material P into the plasticizing unit 60. The sixth opening 170b is an inlet 300 (see FIG. 6) for feeding the material P into the plasticizing unit 60. In the illustrated example, the fourth opening 160b and the fifth opening 170a are in the same position in the Z-axis direction. When viewed from the Z-axis direction, the sixth opening 170b overlaps the fifth opening 170a. Also, the portion connecting from the inlet 300 to the nozzle 80 is referred to as a path 500.

[0058] The third structure 170 has, for example, a fourth wall 172 and a fifth wall 174. The walls 172 and 174 form the inner wall of the housing 140. The walls 172 and 174 define a material flow path 4 that is a flow path for the material P. The material flow path 4 has the fifth opening 170a and the sixth opening 170b and extends from the fifth opening 170a to the sixth opening 170b.

[0059] The fourth wall 172 is inclined with respect to the horizontal direction such that the width of the material flow path 4 becomes narrower as it goes in the -Z-axis direction. In the example shown in FIG. 9, the width of the material flow path 4 is the distance between the fourth wall 172 and the fifth wall 174. The opening area of the sixth opening 170b is smaller than the opening area of the fifth opening 170a. The fourth wall 172 may or may not contact the material P.

[0060] At least a part of the inner wall of the housing 140 is, for example, subjected to a micro dimple (MD) treatment. The entire inner wall of the housing 140 may be subjected to the MD treatment. For example, the walls 152, 154, 156, 158, 172, 174, the receiving portion 164, and the portion to be slidably contacted 166 may be subjected to the MD treatment.

[0061] The opening area of the sixth opening 170b is smaller than the opening areas of the openings 150a, 150b, 160a, 160b, 170a. Therefore, in order to prevent clogging of the material P in the sixth opening 170b, it is particularly preferable that the inner wall of the third structure 170 defining the sixth opening 170b is subjected to the MD treatment. Note that, instead of the MD treatment, a fluorine coating treatment may be performed. Further, in addition to the MD treatment, a fluorine coating treatment may be performed.

[0062] The rotation mechanism 180 has, for example, a rotating member 182, a shaft member 184, and a motor 186 (see FIG. 7).

[0063] The rotating member 182 is provided inside the housing 140. In the illustrated example, the rotating member 182 is provided inside the second structure 160. The rotating member 182 is located above the sixth opening 170b. The rotating member 182 at least partially overlaps with the inclined wall 152 when viewed in the Z-axis direction. The rotating member 182 may entirely overlap with the inclined wall 152 when viewed in the Z-axis direction. The inclined wall 152 functions as a cover for receiving the material P with respect to the rotating member 182.

[0064] The rotating member 182 rotates about the rotation axis Q by the motor 186. The rotation axis Q intersects the Z-axis direction. The rotation axis Q is, for example, orthogonal to the Z-axis direction. In the illustrated example, the rotation axis Q is parallel to the X-axis. The rotating member 182 and the rotation axis Q are located between the center C1 of the second opening 150b and the center C2 of the sixth opening 170b when viewed in the Z-axis direction.

[0065] When viewed from the direction in which the center C1 of the second opening 150b is on the left and the center C2 of the sixth opening 170b is on the right with respect to the virtual plane S, the rotating member 182 rotates clockwise as indicated by the arrow A shown in FIG. 9. The rotating member 182 rotates clockwise when viewed from the direction in which the center C1 of the second opening 150b is on the left and the center C2 of the sixth opening 170b is on the right among the directions along the rotation axis Q. In the illustrated example, the rotating member 182 rotates clockwise. The virtual plane S is a plane parallel to the vertical direction including the rotation axis Q. In the illustrated example, the virtual plane S is parallel to the plane including the X-axis and the Z-axis.

[0066] The rotating member 182 has recesses 183 on its outer periphery 182a. A plurality of recesses 183 are provided. In the illustrated example, twelve recesses 183 are provided. The plurality of recesses 183 are provided at equal intervals, for example, on the outer periphery 182a of the rotating member 182. Due to the plurality of recesses 183, the rotating member 182 has a gear shape. Material P is supplied to the recesses 183. The rotating member 182 lifts the material P supplied to the recesses 183 once above the rotation axis Q and supplies it to the sixth opening 170b through the openings 160b and 170a. The rotating member 182 is a supply mechanism that intermittently supplies the material P to the sixth opening 170b.

[0067] The shaft member 184 is connected to the rotating member 182. When viewed in the X-axis direction, the center of the shaft member 184 and the rotation axis Q overlap. The shaft member 184 is surrounded by the rotating member 182. When the shaft member 184 rotates about the rotation axis Q, the rotating member 182 rotates. The shaft member 184 is, for example, a rod-shaped member extending in the X-axis direction.

[0068] The motor 186 (see FIG. 7) is provided outside the housing 140. In the illustrated example, the motor 186 is disposed on the plate-shaped member 187. The plate-shaped member 187 is supported by the second support member 188. The motor 186 is connected to the shaft member 184. The motor 186 rotates the rotating member 182 via the shaft member 184. The motor 186 is a servo motor. The motor 186 is controlled by the control unit 50.

[0069] As shown in FIG. 9, the folding contact member 190 is provided inside the housing 140. The folding contact member 190 is provided, for example, inside the second structure 160. In the illustrated example, the folding contact member 190 is fixed to the fixing member 192. The fixing member 192 is provided on the lower surface of the upper plate member 168 of the second structure 160. The folding contact member 190 may be screwed to the fixing member 192. In the illustrated example, the folding contact member 190 extends obliquely downward from the fixing member 192.

[0070] The folding contact member 190 is in sliding contact with the outer periphery 182a of the rotating member 182. The folding contact member 190 biases the outer periphery 182a toward the rotation axis Q (biased in the F direction). The folding contact member 190 contacts the material P supplied to the recess 183. The folding contact member 190 presses the material P supplied to the recess 183. The folding contact member 190 is, for example, a leaf spring. The material of the folding contact member 190 is, for example, stainless steel.

[0071] The material P supplied from the material supply unit 10 is mainly various materials such as a thermoplastic material, a metal material, and a ceramic material. Here, the "main material" means the central material that forms the shape of the molded product molded by the injection molding apparatus 100, and means a material that occupies a content rate of 50% by mass or more in the molded product. The above-described materials include those in which the main materials are melted alone and those in which some components contained together with the main materials are melted into a paste form.

[0072] Examples of the thermoplastic material include thermoplastic resins. Examples of the thermoplastic resin include acrylonitrile-butadiene-styrene (ABS) resin, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), and polyvinyl chloride (PVC).

[0073] The thermoplastic resin may be a general-purpose engineering plastic. Examples of general-purpose engineering plastics include polyacetal (POM), polyamide (PA), polylactic acid (PLA), polyphenylene sulfide (PPS), polycarbonate (PC), and modified polyphenylene ether (m-PPE).

[0074] The thermoplastic resin may be a super engineering plastic. Examples of super engineering plastics include polysulfone (PSU), polyethersulfone (PES), polyphenylene sulfide (PPS), polyarylate (PAR), polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), and polyetheretherketone (PEEK).

[0075] The material having thermoplasticity may be an elastomer. Examples of elastomers include polystyrene-based (TPS), olefin / alkene-based (TPO), polyvinyl chloride-based (TPVC), polyurethane-based (TPU), polyester-based (TPEE), and polyamide-based (TPAE). Elastomers have a small Young's modulus and a large fracture strain and are easy to enter gaps. Even if such an elastomer is material P, the material supply unit 10 can suppress the load of material P from concentrating on the rotating member 182 by the inclined wall 152, so that supply failures can be suppressed.

[0076] Additives such as pigments, metals, ceramics, waxes, flame retardants, antioxidants, and heat stabilizers may be mixed into the material having thermoplasticity. The material having thermoplasticity is plasticized in the plasticizing unit 60 and converted into a molten state by the rotation of the flat screw 110 and the heating of the heater 130. The plasticized material thus produced is deposited from the nozzle 80 and then cured by a temperature drop. It is desirable that the material having thermoplasticity be heated above the glass transition point and discharged from the nozzle 80 in a completely molten state.

[0077] In the plasticizing unit 60, instead of the material having the above-described thermoplasticity, for example, a metal material may be used as the main material. In this case, it is desirable that a component that melts during the production of the plasticizing material be mixed with the powdered metal material and then introduced into the plasticizing unit 60.

[0078] Examples of the metal material include single metals such as magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni), or alloys containing one or more of these metals, and also maraging steel, stainless steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt alloy, cobalt chromium alloy.

[0079] In the plasticizing unit 60, instead of the above metal material, a ceramic material may be used as the main material. Examples of the ceramic material include oxide ceramics such as silicon dioxide, titanium dioxide, aluminum oxide, zirconium oxide, and non-oxide ceramics such as aluminum nitride.

[0080] The powdered metal material or ceramic material supplied from the material supply unit 10 may be a mixed material in which powders of a single metal, alloy powders, or ceramic material powders of a plurality of types are mixed. The powdered metal material or ceramic material may be coated with, for example, the above-described thermoplastic resin or other thermoplastic resins. In this case, in the plasticizing unit 60, the thermoplastic resin coating the powdered material may melt and exhibit fluidity.

[0081] For the powder materials of metallic materials and ceramic materials supplied from the material supply unit 10, for example, a solvent can also be added. Examples of the solvent include water; (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetate esters such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, and isobutyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, and acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide-based solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and 2,6-lutidine; tetraalkylammonium acetate (for example, tetrabutylammonium acetate, etc.); ionic liquids such as butyl carbitol acetate, etc.

[0082] In addition, for the powder materials of metallic materials and ceramic materials supplied from the material supply unit 10, for example, a binder may be added. Examples of the binder include acrylic resins, epoxy resins, silicone resins, cellulose-based resins or other synthetic resins, PLA, PA, PPS, PEEK or other thermoplastic resins.

[0083] Hereinafter, with reference to FIG. 10, a material supply method of the injection molding apparatus 100 will be described.

[0084] As shown in FIG. 10, in step S11, weighing of the plasticized material is started. Specifically, as described above, the plunger 74 is moved to guide the plasticized material in the communication hole 126 into the cylinder 72, and weighing is started in the cylinder 72.

[0085] In step S12, the supply of material P is started. Specifically, in step S11, based on receiving a metering start signal for starting the metering of the plasticized material, the control unit 50 controls the rotation of the motor 186. Also, the control unit 50 operates the rotation mechanism 180 in conjunction with the rotation of the flat screw 110. Thereby, the rotating member 182 of the material supply unit 10 rotates, and supplies material P to the plasticizing unit 60.

[0086] In step S13, the metering of the plasticized material is completed. Specifically, the metering operation in the cylinder 72 is completed.

[0087] In step S14, the supply of material P is stopped. Specifically, in step S13, based on receiving a metering end signal for ending the metering of the plasticized material, the control unit 50 controls the rotation of the motor 186. Thereby, the rotation of the rotating member 182 of the material supply unit 10 is stopped, and the supply of material P to the plasticizing unit 60 is ended.

[0088] In this way, by controlling the rotation mechanism 180, it becomes possible to supply only the amount of material P necessary for plasticizing in the plasticizing unit 60, and it is possible to suppress excessive supply of material P to the path 500. Therefore, it is possible to suppress clogging of material P in the path 500.

[0089] Note that it is desirable for the control unit 50 to determine and control the ratio between the number of rotations per unit time of the flat screw 110 and the number of rotations per unit time of the rotating shaft Q according to the type of material P. Also, the control unit 50 controls the rotation mechanism 180 so that the difference between the supply amount per unit time of the material P supplied from the material supply unit 10 and the plasticizing amount per unit time in the flat screw 110 is within ±5%, in other words, within 2 g. This is a value considering the variation in the operation of the rotation mechanism 180. Note that a first sensor for detecting the supply amount of material P may be provided on the side of the material supply unit 10, a second sensor for detecting the amount of the plasticized material may be provided on the side of the plasticizing unit 60, and the rotation mechanism 180 may be controlled based on the detection amounts of the first sensor and the second sensor.

[0090] Next, while referring to FIG. 11, the configuration of the three-dimensional shaping apparatus 1000 including the material discharge device 1000A will be described.

[0091] The three-dimensional shaping apparatus 1000 includes, for example, a material supply unit 10, a control unit 50, a plasticizing unit 60, a nozzle 80, a stage 210, and a position changing unit 220. The three-dimensional shaping apparatus 1000 is a three-dimensional shaping apparatus using the FDM (Fused Deposition Modeling) (registered trademark) method. For convenience, in FIG. 11, the material supply unit 10 is illustrated in a simplified manner.

[0092] The material supply unit 10 supplies the material to the plasticizing unit 60 via the supply path 202. The plasticizing unit 60 plasticizes the material to generate a plasticized material.

[0093] The nozzle 80 discharges the plasticized material supplied from the plasticizing unit 60 toward the stage 210. Specifically, the three-dimensional shaping apparatus 1000 drives the position changing unit 220 while discharging the plasticized material from the nozzle 80 to the stage 210, thereby changing the relative position between the nozzle 80 and the stage 210. As a result, the three-dimensional shaping apparatus 1000 shapes a three-dimensional shaped object having a desired shape on the stage 210.

[0094] The stage 210 is provided below the nozzle 80. In the illustrated example, the shape of the stage 210 is a rectangular parallelepiped. The stage 210 supports the plasticized material discharged from the nozzle 80. The stage 210 has a deposition surface 212 on which the plasticized material is deposited.

[0095] The material of the stage 210 is, for example, a metal such as aluminum. The stage 210 may be composed of a metal plate and an adhesion sheet provided on the metal plate. In this case, the deposition surface 212 is composed of the adhesion sheet. The adhesion sheet can improve the adhesion between the stage 210 and the plasticized material discharged from the nozzle 80.

[0096] The stage 210 may be composed of a metal plate with grooves formed therein (not shown) and a base layer provided to fill the grooves. In this case, the deposition surface 212 is constituted by the base layer. The material of the base layer is, for example, the same as that of the plasticized material. The base layer can improve the adhesion between the stage 210 and the plasticized material discharged from the nozzle 80.

[0097] The position changing unit 220 supports the stage 210. The position changing unit 220 changes the relative position between the nozzle 80 and the stage 210. In the illustrated example, the position changing unit 220 changes the relative position between the nozzle 80 and the stage 210 in the X-axis direction and the Y-axis direction by moving the stage 210 in the X-axis direction and the Y-axis direction. Further, the position changing unit 220 changes the relative position between the nozzle 80 and the stage 210 in the Z-axis direction by moving the nozzle 80 in the Z-axis direction.

[0098] The position changing unit 220 has, for example, a first electric actuator 222, a second electric actuator 224, and a third electric actuator 226. The first electric actuator 222 moves the stage 210 in the X-axis direction. The second electric actuator 224 moves the stage 210 in the Y-axis direction. The third electric actuator 226 moves the nozzle 80 in the Z-axis direction. The third electric actuator 226 supports, for example, the screw case 62 of the plasticizing unit 60.

[0099] Note that the configuration of the position changing unit 220 is not particularly limited as long as it can change the relative position between the nozzle 80 and the stage 210. The position changing unit 220 may have a configuration in which, for example, the stage 210 is moved in the Z-axis direction and the nozzle 80 is moved in the X-axis direction and the Y-axis direction, or a configuration in which the stage 210 or the nozzle 80 is moved in the X-axis direction, the Y-axis direction, and the Z-axis direction.

[0100] As described above, the material discharge device 100A of the present embodiment includes a material supply unit 10 that supplies a material, a plasticizing unit 60 that plasticizes the material P supplied from the material supply unit 10 by the rotation of a flat screw 110 having a groove forming surface 112 with grooves to generate a plasticized material, a path 500 that supplies the material P from the material supply unit 10 to the plasticizing unit 60, a nozzle 80 having a nozzle hole 82 that discharges the plasticized material, and a control unit 50 that controls the drive of the material supply unit 10. The material supply unit 10 has a rotation mechanism 180 that intermittently supplies the material P to the plasticizing unit 60. The control unit 50 operates the rotation mechanism 180 in conjunction with the rotation of the flat screw 110 and controls so that the material P does not accumulate in the path 500.

[0101] According to this configuration, since the control unit 50 controls the rotation mechanism 180 so that the material P does not stay in the path 500, it is possible to supply only the amount of the material P necessary for plasticizing in the plasticizing unit 60, and it is possible to suppress excessive supply of the material P to the path 500. Therefore, it is possible to suppress the material P from clogging in the path 500, and the material discharge device 100A can be operated appropriately.

[0102] Further, in the material discharge device 100A of the present embodiment, the plasticizing unit 60 has a supply port 400 for receiving the material P. The material supply unit 10 has an inlet 300 communicating with the path 500 and a housing 140 for housing the material P. The housing 140 defines a material storage space 2 that is a storage space for the material P above the rotation mechanism 180, and has an inclined wall 152 that is inclined so as to reduce the volume of the material storage space 2 downward. The rotation mechanism 180 preferably has at least a part overlapping with the inclined wall 152 when viewed from the vertical direction, is provided in the housing 140, has a recess 183 on the outer periphery 182a, and rotates about a rotation axis Q intersecting the vertical direction by a motor 186.

[0103] According to this configuration, since the outer periphery 182a of the rotating member 182 has the concave portion 183, when the rotating member 182 rotates, the material P enters the concave portion 183, and the material P corresponding to the amount accommodated in the concave portion 183 can be supplied to the supply port 400 disposed at the tip of the rotating member 182. In other words, the material P can be intermittently supplied little by little.

[0104] Further, in the material discharge device 100A of the present embodiment, it is preferable that the control unit 50 determines the ratio of the number of rotations per unit time of the flat screw 110 to the number of rotations per unit time of the rotating shaft Q according to the type of the material P. According to this configuration, since the ratio of the number of rotations of the flat screw 110 to the number of rotations of the rotating shaft Q is determined according to the type of the material P, it is possible to reduce the error between the supply amount and the plasticization amount of the material P. Therefore, it is possible to prevent the path 500 from being clogged due to an excessive amount of the material P being supplied.

[0105] Further, in the material discharge device 100A of the present embodiment, it is preferable that the control unit 50 controls the rotation mechanism 180 so that the difference between the supply amount per unit time of the material P supplied from the material supply unit 10 and the plasticization amount per unit time in the flat screw 110 is within ±5%. According to this configuration, since the error between the supply amount and the plasticization amount of the material P is controlled within ±5%, it is possible to prevent the path 500 from being clogged due to an excessive amount of the material P being supplied.

[0106] Further, in the material discharge device 100A of the present embodiment, a first sensor is disposed on the side of the material supply unit 10, a second sensor is disposed on the side of the plasticizing unit 60, and it is preferable that the control unit 50 controls the operation of the rotation mechanism 180 based on the detection amount of the first sensor and the detection amount of the second sensor. According to this configuration, based on the detection amount of the first sensor on the supply side of the material P and the detection amount of the second sensor on the plasticizing unit 60 side, the operation of the rotation mechanism 180, that is, the supply amount of the material P is controlled, so that the error between the supply amount and the plasticization amount of the material P can be reduced. Therefore, it is possible to prevent the path 500 from being clogged due to an excessive amount of the material P being supplied.

[0107] Further, the injection molding apparatus 100 of the present embodiment includes the material discharge apparatus 100A described above. According to this configuration, an injection molding apparatus 100 capable of supplying an appropriate amount of the material P can be provided.

[0108] Further, the three-dimensional shaping apparatus 1000 of the present embodiment includes the material discharge apparatus 1000A described above. According to this configuration, a three-dimensional shaping apparatus 1000 capable of supplying an appropriate amount of the material P can be provided.

[0109] Hereinafter, a modification of the above-described embodiment will be described.

[0110] As described above, it is not limited to supplying or stopping the material P from the material supply unit 10 based on the metering start signal or the metering end signal of the plasticized material, and it may be performed as follows.

[0111] For example, the rotation mechanism 180 may be operated in conjunction with the movement of the plunger 74 moving in the cylinder 72. Specifically, a detection unit for detecting the torque of the plunger 74 may be provided, and when a torque equal to or greater than a predetermined value is detected, the operation of the rotation mechanism 180 may be stopped.

[0112] Thus, in the material discharge apparatus 100A of the present embodiment, it preferably has a cylinder 72 connected to the material flow path 4 through which the plasticized material flows and a plunger 74 moving in the cylinder 72, and the control unit 50 operates the rotation mechanism 180 in conjunction with the movement of the plunger 74. According to this configuration, the rotation member 182 of the rotation mechanism 180 is rotated when the rotation mechanism 180 is operated in conjunction with the movement of the plunger 74, in other words, when the metering operation is executed, so that the error between the supply amount and the plasticization amount of the material P can be reduced.

[0113] Further, in the material discharge device 100A of the present embodiment, it is preferable that the control unit 50 has a detection unit that detects the torque of the plunger 74 and stops the rotation mechanism 180 when the detected torque is equal to or greater than a predetermined value. According to this configuration, when the torque is detected, that is, when the amount of the plasticized material used in the cylinder 72 is ensured by measurement as the plunger 74 slides in the cylinder 72, the rotation of the rotating member 182 of the rotation mechanism 180 is stopped, so that the supply of the material P more than necessary can be suppressed.

Explanation of Signs

[0114] 2... Material accommodation space, 4... Material flow path, 10... Material supply unit, 20... Injection part, 30... Mold part, 32... Molding die, 34... Cavity, 36... Movable mold, 38... Fixed mold, 40... Mold clamping part, 42... Mold drive part, 44... Ball screw part, 50... Control part, 60... Plasticizing part, 62... Screw case, 64... Drive motor, 66... Shaft, 70... Injection mechanism, 72... Cylinder, 74... Plunger, 76... Plunger drive part, 80... Nozzle, 82... Nozzle hole, 100... Injection molding device, 100A... Material discharge device, 102... Plasticizing device, 110... Flat screw, 111... Motor side surface, 112... Groove forming surface, 113... Connection surface, 114... First groove, 115... Central part, 116... Connection part, 117... Material introduction part, 120... Barrel, 122... Opposing surface, 124... Second groove, 126... Communication hole, 130... Heater, 140... Housing, 150... First structure, 150a... First opening, 150b... Second opening, 152... Inclined wall, 154... First wall, 156... Second wall, 158... Third wall, 160... Second structure, 160a... Third opening, 160b... Fourth opening, 162... First support member, 164... Receiving part, 166... Part to be folded and contacted, 168... Upper plate member, 170... Third structure, 170a... Fifth opening, 170b... Sixth opening, 172... Fourth wall, 174... Fifth wall, 180... Rotating mechanism as supply mechanism, 182... Rotating member, 182a... Outer circumference, 183... Recess, 184... Shaft member, 186... Motor, 187... Plate-like member, 188... Second support member, 190... Folding and contacting member, 192... Fixed member, 200... Housing, 202... Supply path, 210... Stage, 212... Deposition surface, 220... Position changing part, 222... First electric actuator, 224... Second electric actuator, 226... Third electric actuator, 300... Inlet, 400... Supply port, 500... Path, 1000... Three-dimensional shaping device, 1000A... Material discharge device.

Claims

1. A material supply unit for supplying a material, A plasticizing unit that plasticizes the material supplied from the material supply unit by rotation of a flat screw having a groove-forming surface with a groove formed thereon to generate a plasticized material, A path for supplying the material from the material supply unit to the plasticizing unit, A nozzle having a nozzle hole for discharging the plasticized material, A control unit for controlling the drive of the material supply unit, comprising: The material supply unit has a supply mechanism for intermittently supplying the material to the plasticizing unit, The control unit operates the supply mechanism in conjunction with the rotation of the flat screw and controls so that the material does not accumulate in the path, a material discharge device.

2. The material discharge device according to claim 1, The plasticizing unit has a supply port for receiving the material, The material supply unit has an inlet communicating with the path and a housing for accommodating the material, The housing defines a storage space for the material above the supply mechanism and has an inclined wall inclined so as to reduce the volume of the storage space downward, The supply mechanism is provided in the housing, at least partially overlaps the inclined wall when viewed in the vertical direction, has a recess on the outer periphery, and rotates about a rotation axis intersecting the vertical direction by a motor, a material discharge device.

3. The material discharge device according to claim 2, The control unit determines a ratio between the number of rotations per unit time of the flat screw and the number of rotations per unit time of the rotation axis according to the type of the material, a material discharge device.

4. The material discharge device according to claim 1, The control unit controls the supply mechanism such that the difference between the supply amount per unit time of the material supplied from the material supply unit and the plasticization amount per unit time in the flat screw is within ±5%, a material discharge device.

5. The material discharge device according to claim 1, wherein a first sensor is disposed in the material supply unit and a second sensor is disposed in the plasticization unit, and the control unit controls the operation of the supply mechanism based on the detection amount of the first sensor and the detection amount of the second sensor, a material discharge device.

6. The material discharge device according to claim 1, a cylinder connected to a flow path through which the plasticized material flows, a plunger that moves inside the cylinder, and having, wherein the control unit operates the supply mechanism in conjunction with the movement of the plunger, a material discharge device.

7. The material discharge device according to claim 6, having a detection unit that detects the torque of the plunger, and the control unit stops the supply mechanism when the torque equal to or greater than a predetermined value is detected, a material discharge device.

8. An injection molding device comprising the material discharge device according to any one of claims 1 to 7.

9. The material discharge device according to any one of claims 1 to 7, and a stage that receives the plasticized material discharged from the nozzle of the material discharge device, a three-dimensional shaping device comprising.

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