Core / sheath structure, method of manufacturing flocked products, and flocked products

Abstract

To provide molding or flocking products with a comfortable tactile feel.SOLUTION: The core / sheath structure constituting a molding material or a molding object that is a melt-cured product of the molding material, comprises a core having a linear shape and an outer surface and containing a first thermoplastic polymer, and a sheath covering the outer surface and containing a second thermoplastic polymer and at least one selected from a group consisting of fibers and particles dispersed in the second thermoplastic polymer. The flock product has a body having a surface that is a modeling material containing a thermoplastic polymer or a melt-cured product of the modeling material, an adhesive layer disposed on the surface, and a flock impinging on the adhesive layer.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present disclosure relates to a core / sheath structure, a method for manufacturing a flocked product, and a flocked product.

Background Art

[0002] Patent Document 1 discloses a consumable filament. The consumable filament is melted and extruded in an additive manufacturing system. The consumable filament includes a core portion and a sheath portion that wraps the core portion. The core portion includes a matrix of a first base polymer and particles dispersed in the matrix. The sheath portion includes a second base polymer. The particles of the core portion are selected from metal particles, non-metal particles, magnetic particles, and combinations thereof, and may be ferrite particles (paragraph

[0005] ). The particles of the core portion do not penetrate the outer surface of the sheath portion (paragraph

[0074] ).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When a shaped object is manufactured using the consumable filament disclosed in Patent Document 1, the shaped object has a rubber-like touch, a plastic-like touch, etc., and does not have a comfortable touch.

[0005] The present disclosure has been made in view of this problem. One aspect of the present disclosure is to provide, for example, a shaped object or a flocked product having a comfortable touch.

Means for Solving the Problems

[0006] The core / sheath structure according to one aspect of the present disclosure is a core / sheath structure that constitutes a shaped article made of a shaping material or a melt-cured product of the shaping material, has a linear shape, has an outer peripheral surface, and includes a core containing a first thermoplastic polymer, and a sheath that covers the outer peripheral surface and includes a second thermoplastic polymer and at least one selected from the group consisting of fibers and particles dispersed in the second thermoplastic polymer.

[0007] A method for manufacturing a flocked product according to another aspect of the present disclosure includes: a) a step of disposing an adhesive layer on the surface of an object to be treated, which is a shaped article made of a shaping material containing a thermoplastic polymer or a melt-cured product of the shaping material; b) a step of piercing the adhesive layer with flock; and c) a step of curing the adhesive layer after step b).

[0008] A flocked product according to another aspect of the present disclosure includes a main body that is a shaped article made of a shaping material containing a thermoplastic polymer or a melt-cured product of the shaping material and has a surface, an adhesive layer disposed on the surface, and flock pierced into the adhesive layer.

Brief Description of the Drawings

[0009]

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Mode for Carrying Out the Invention

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the drawings, the same or equivalent elements are denoted by the same reference numerals, and redundant descriptions are omitted.

[0011] 1 First Embodiment 1.1 Outline of Modeling Material FIG. 1 is a perspective view schematically showing the modeling material of the first embodiment. FIG. 2 is a cross-sectional view schematically showing the modeling material of the first embodiment. FIG. 3 is a photograph of a cross-section of a prototype of the modeling material of the first embodiment.

[0012] The modeling material 1 of the first embodiment shown in FIGS. 1, 2, and 3 is used to manufacture a modeled object. When a modeled object is manufactured using the modeling material 1, the modeling material 1 is melted, a shape is given to the melted modeling material, and the shaped modeling material is cured. Thereby, a modeled object that is a melt-cured product of the modeling material 1 is manufactured. Therefore, the modeling material 1 is a consumable that is consumed to manufacture a modeled object.

[0013] The modeling material 1 is used, for example, to manufacture a modeled object by a three-dimensional (3D) printer and to manufacture a modeled object by a fused deposition modeling (FDM) method. However, the modeling material 1 may be used to manufacture a modeled object by a modeling device other than a 3D printer, or may be used to manufacture a modeled object by a modeling method other than the FDM method. The FDM method is also called the fused filament fabrication (FFF) method.

[0014] The shaping material 1 has a linear shape and is thermoplastic. When the shaping material 1 is used to manufacture a shaped object, the shaping material 1 is heated while being fed in the length direction. Thereby, the shaping material 1 is melted. Further, the shaping material 1 has flexibility and elasticity. The shaping material 1 having these characteristics is also called a filament. When the shaping material 1 is used by a 3D printer to manufacture a shaped object, the shaping material 1 has a circular cross-sectional shape and a diameter suitable for the 3D printer. The diameter is, for example, 1.75 mm or 2.85 mm. However, the shaping material 1 may have a cross-sectional shape other than a circular cross-sectional shape and may have a diameter other than 1.75 mm or 2.85 mm.

[0015] The main part of the shaping material 1 is thermoplastic. Thereby, the shaping material 1 can be melted to separate the shaping material 1 into a plurality of components. Also, a new shaping material or other types of products can be manufactured from the shaping material 1. For this reason, the shaping material 1 is recyclable.

[0016] The shaping material 1 can be sold in the DIY market to consumers who make their own shaped objects as it is. Also, the shaped objects manufactured using the shaping material 1 can be sold to ordinary consumers in ordinary stores and ordinary markets.

[0017] 1.2 Cross-sectional Structure and Material of the Shaping Material As shown in FIGS. 1, 2, and 3, the shaping material 1 has a two-layer structure and is composed of a core / sheath structure 101 including a core 111 and a sheath 112. The sheath 112 is also called a shell. The core / sheath structure 101 is also called a core / shell structure. The shaping material 1 may have a multi-layer structure of three or more layers. The shaping material 1 having a multi-layer structure of two or more layers is also called a multi-filament. In contrast to the multi-filament, the shaping material having a single-layer structure is called a mono-filament.

[0018] The core 111 has a linear shape. The core 111 has flexibility. The core 111 has a circular cross-sectional shape. The core 111 may have a cross-sectional shape other than the circular cross-sectional shape. The sheath 112 covers the outer peripheral surface 111S of the core 111. Therefore, the sheath 112 is an outer layer disposed on the radially outer side of the core 111, and is the outermost layer disposed on the radially outermost side of the shaping material 1.

[0019] As shown in FIG. 2, the core 111 includes a first thermoplastic polymer 121. The sheath 112 includes a second thermoplastic polymer 122 and at least one selected from the group consisting of fibers and particles (hereinafter referred to as "fiber / particle") 123.

[0020] The second thermoplastic polymer 122 serves as a matrix. The fiber / particle 123 is dispersed in the second thermoplastic polymer 122 serving as a matrix. The fiber / particle 123 forms protrusions on the surface of the produced shaped object, and imparts a comfortable touch feeling to the produced shaped object.

[0021] The first thermoplastic polymer 121 and the second thermoplastic polymer 122 are the main components of the core 111 and the sheath 112, respectively.

[0022] The first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be either the same type of thermoplastic polymer or different types of thermoplastic polymers. Each thermoplastic polymer of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may be one type of thermoplastic polymer or a mixture of two or more types of thermoplastic polymers.

[0023] Each thermoplastic polymer includes at least one selected from the group consisting of, for example, a rigid component and a flexible component, and preferably includes a flexible component.

[0024] The rigid component includes, for example, a thermoplastic resin.

[0025] The thermoplastic resin contains at least one selected from the group consisting of, for example, acrylonitrile-butadiene-styrene (ABS), polylactic acid (PLA), polyethylene terephthalate (PET) and other polyester derivatives, polycarbonate (PC), polyvinyl alcohol (PVA), polyamide (PA), styrene-based polymers, polyvinyl chloride (PVC), and acrylic-based polymers.

[0026] The flexible component contains, for example, a thermoplastic elastomer. By including the thermoplastic elastomer in the core 111 or the sheath 112, the flexibility and elasticity of the core 111 or the sheath 112 are improved respectively, and the flexibility and elasticity of the shaping material 1 are improved. Also, the flexibility and elasticity of the core or the sheath provided in the manufactured shaped object are improved respectively, and the flexibility and elasticity of the manufactured shaped object are improved.

[0027] The thermoplastic elastomer contains at least one selected from the group consisting of, for example, olefin-based thermoplastic elastomers (TPO), styrene-based thermoplastic elastomers (TPS), vinyl chloride-based thermoplastic elastomers (TPVC), amide-based thermoplastic elastomers (TPAE), ester-based thermoplastic elastomers (TPEE), urethane-based thermoplastic elastomers (TPU), and acrylic elastomers, and preferably contains TPU.

[0028] The fiber / particle 123 contains at least one selected from the group consisting of natural and synthetic substances. Examples of natural powders and fibers include ramie, cotton, wool, silk, chitosan, etc. Examples of mineral powders include chalk and calcium carbonate.

[0029] At least one of the core 111 and the sheath 112 may contain a strengthening component. By the core 111 or the sheath 112 containing a strengthening component, the strength of the core 111 or the sheath 112 is improved respectively, and the strength of the shaping material 1 is improved. Also, the strength of the core or the sheath provided in the manufactured shaped object is improved respectively, and the strength of the manufactured shaped object is improved. The strengthening component includes, for example, a filler. The filler includes at least one selected from the group consisting of, for example, fibers, particles, fine particle powders, nanoparticles, nanofibers, and additives similar thereto. The filler includes at least one selected from the group consisting of, for example, natural products and synthetic products.

[0030] At least one of the core 111 and the sheath 112 may contain a liquid additive in addition to a plasticizer. At least one of the core 111 and the sheath 112 may contain an additive for forming pores. By the core 111 or the sheath 112 containing an additive for forming pores, a large number of pores are respectively formed in the core or the sheath provided in the manufactured shaped object, and the flexibility, elasticity, and air permeability of the core or the sheath provided in the manufactured shaped object are improved, and the flexibility, elasticity, and air permeability of the manufactured shaped object are improved. The additive for forming pores includes at least one selected from the group consisting of, for example, a foaming agent and a blowing agent. A filament having a foamed core / sheath structure in which either the core or the sheath foams and the other layer does not foam has higher strength than a filament having a fully foamed structure because the strength of the non-foamed layer is highly consistent.

[0031] The core 111 may contain particles, additives, mixtures, etc. that do not correspond to the above-described components. The particles, additives, mixtures, etc. are dispersed in the first thermoplastic polymer 121 serving as a matrix. The sheath 112 may contain particles, additives, mixtures, etc. that do not correspond to the above-described components. The particles, additives, mixtures, etc. are dispersed in the second thermoplastic polymer 122 serving as a matrix.

[0032] In the first example, the first thermoplastic polymer 121 is a TPU having a hardness of 70 Shore A. Also, the second thermoplastic polymer 122 is a TPU having a hardness of 60 Shore A.

[0033] In the second example, the first thermoplastic polymer 121 is a TPU. Also, the second thermoplastic polymer 122 is PVA. Also, the fiber / particle 123 is a natural fiber.

[0034] In the third example, the first thermoplastic polymer 121 is a TPU. Also, the second thermoplastic polymer 122 is a mixture of TPU and PVA. Also, the sheath 112 contains a foaming agent.

[0035] In the fourth example, the second thermoplastic polymer 122 is a TPU. Also, the fiber / particle 123 is a natural fiber.

[0036] In the fifth example, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are TPUs. Also, the fiber / particle 123 is a ramie fiber.

[0037] The ratio of the outer diameter of the sheath 112 to the diameter of the core 111 reflects the composition or mass fraction of the material constituting the core 111 and the material constituting the sheath 112, and can be controlled within a wide range from 1:1.01 to 1:10.

[0038] 1.3 Manufacturing method of the shaping material The shaping material 1 can be manufactured by co-extruding the material constituting the core 111 and the material constituting the sheath 112 using an appropriate feed block and nozzle. The same applies when the shaping material 1 has layers other than the core 111 and the sheath 112.

[0039] For example, when the shaping material 1 is manufactured, the material constituting the core 111 and the material constituting the sheath 112 are co-extruded in a co-extrusion line. The co-extrusion line includes two extruders, a feed block / multi-manifold die head, and a nozzle. The two extruders respectively form two feeds consisting of the feed made of the material constituting the core 111 and the feed made of the material constituting the sheath 112. The feed block / multi-manifold die head converges the two formed feeds. The nozzle co-extrudes the shaping material 1 using the converged feeds.

[0040] 1.4 Variant FIG. 4 is a cross-sectional view schematically showing the shaping material of a variant of the first embodiment.

[0041] In the shaping material 1 of the first embodiment shown in FIGS. 1, 2, and 3, the core 111 is a solid body. In contrast, in the shaping material 1M of the variant of the first embodiment shown in FIG. 4, the core 111 is a porous body. Therefore, in the shaping material 1M, a large number of pores are formed in the core 111. Thereby, the flexibility, flexibility, elasticity, and air permeability of the core 111 can be improved, and the flexibility, flexibility, elasticity, and air permeability of the shaping material 1M can be improved. Further, the flexibility, flexibility, elasticity, and air permeability of the core provided in the manufactured shaped object can be improved, and the flexibility, flexibility, elasticity, and air permeability of the manufactured shaped object can be improved. The core 111 that is a porous body mimics a multifilament.

[0042] 2 Second Embodiment 2.1 Outline of the Shaped Object FIG. 5 is a plan view schematically showing the shaped object of the second embodiment.

[0043] The shaped object 2 of the second embodiment shown in FIG. 5 is manufactured using the shaping material 1 of the first embodiment. Therefore, the shaped object 2 is a melt-cured product of the shaping material 1.

[0044] The shaped object 2 is a new type of textile (fabric) or fabric (fabric product). The shaped object 2 constitutes, for example, clothing that can be continuously worn on the body. The clothing includes clothes, hats, gloves, socks, footwear, ornaments, etc. The shaped object 2 may constitute an article other than clothing.

[0045] The clothing may be a self-made product made by a consumer, a custom-made product made for a specific consumer, or a ready-made product made for unspecified consumers. However, the production of the shaped object 2 by a 3D printer is suitable for self-made products and custom-made products.

[0046] The shaped object 2 can be sold to ordinary consumers in ordinary stores and ordinary markets.

[0047] The main part of the shaped object 2 has thermoplasticity. Thereby, the shaped object 2 can be melted and separated into a plurality of components. Also, a new shaped object or other types of products can be manufactured from the shaped object 2. For this reason, the shaped object 2 is recyclable after use.

[0048] The characteristics of the shaped object 2 can be adjusted by the materials constituting the shaping material 1 used in the production, the structure of the shaping material 1 used in the production, the process parameters when manufacturing the shaped object 2, etc. The adjustment is performed to improve the flexibility, softness, strength, and breathability of the shaped object 2 in addition to the ease of manufacturing the shaped object 2.

[0049] 2.2 Planar shape of the shaped object As shown in FIG. 5, the shaped object 2 includes a first linear body 201 and a second linear body 202.

[0050] Each first linear body 201 extends in the first direction D1 while meandering. The first linear bodies 201 are arranged in the second direction D2. There is a gap between adjacent first linear bodies 201. Each second linear body 202 extends in the second direction D2 while meandering. The second linear bodies 202 are arranged in the first direction D1. There is a gap between adjacent second linear bodies 202. The second direction D2 is perpendicular to the first direction D1. Thus, in a plan view, the first linear bodies 201 intersect the second linear bodies 202. Also, the shaped object 2 has a lattice-like planar shape. The shaped object 2 may have a structure different from the structure shown in FIG. 5.

[0051] The second linear body 202 is disposed on the first linear body 201. The second linear body 202 is in contact with the first linear body 201.

[0052] 2.3 Cross-sectional Structure and Material of the Linear Body FIG. 6 is a cross-sectional view schematically showing the linear body provided in the shaped object of the second embodiment. In FIG. 6, the shaping material is shown by a dashed line so that the size of the shaping material of the first embodiment and the size of the linear body provided in the shaped object of the second embodiment can be compared.

[0053] The linear body 210 shown in FIG. 6 is each of the above-described first linear bodies 201 and second linear bodies 202.

[0054] The linear body 210 is formed by stretching the shaping material 1 in the length direction. Therefore, as shown in FIG. 6, the linear body 210 is also constituted by a core / sheath structure 221 including a core 231 and a sheath 232. However, the diameter of the linear body 210 is smaller than the diameter of the shaping material 1. Also, the diameter of the core 231 is smaller than the diameter of the core 111. Also, the thickness of the sheath 232 is thinner than the thickness of the sheath 112.

[0055] The core 231 and the sheath 232 provided in the linear body 210 are respectively derived from the core 111 and the sheath 112 provided in the shaping material 1. For this reason, the core 231 has a linear shape. The sheath 232 covers the outer peripheral surface 231S of the core 231. The core 231 includes a first thermoplastic polymer 121. The sheath 232 includes a second thermoplastic polymer 122 and fibers / particles 123. The fibers / particles 123 are dispersed in the second thermoplastic polymer 122. The core 231 and the sheath 232 provided in the linear body 210 may each include components that the core 111 and the sheath 112 provided in the shaping material 1 may include. The core 231 may be a porous body.

[0056] FIG. 7 is an overall electron microscope (SEM) photograph of a cross-section of a linear body provided in a prototype of the shaped article of the second embodiment. FIG. 8 is an SEM photograph of a peripheral portion of a cross-section of a linear body provided in a prototype of the shaped article of the second embodiment.

[0057] In the SEM photograph of FIG. 7, although a clear interface between the core 231 and the sheath 232 cannot be confirmed, almost no fibers / particles 123 can be confirmed in the region that becomes the core 231, and dispersed fibers / particles 123 can be confirmed in the region at the tip of the arrow that becomes the sheath 232. Also, in the SEM photograph of FIG. 8, although a clear interface between the core 231 and the sheath 232 cannot be confirmed, almost no fibers / particles 123 can be confirmed in the region that becomes the core 231, and dispersed fibers / particles 123 can be confirmed inside the circle that becomes the sheath 232. Therefore, from the SEM photographs of FIGS. 7 and 8, it can be understood that the sheath 232 contains the fibers / particles 123 and the fibers / particles 123 are dispersed in the second thermoplastic polymer 122. The reason why a clear interface between the core 231 and the sheath 232 cannot be confirmed is that the second thermoplastic polymer 122, which is the main component of the sheath 232, is similar to the first thermoplastic polymer 121, which is the main component of the core 231, and may be the same as the first thermoplastic polymer 121.

[0058] FIG. 9 is an enlarged cross-sectional view schematically showing the vicinity of the interface between the shaped object of the second embodiment and the human skin that has come into contact with the shaped object.

[0059] As shown in FIG. 9, the linear body 210 includes a linear body main body 241 and a protrusion 242.

[0060] The linear body main body 241 constitutes the main part of the linear body 210. The protrusion 242 protrudes from the outer peripheral surface 241S of the linear body main body 241, and forms irregular unevenness characteristic of the outer peripheral surface of the linear body 210.

[0061] The fiber / particle 123 includes an intersecting fiber / intersecting particle 251 that intersects the outer peripheral surface 241S of the linear body main body 241. One end of the intersecting fiber / intersecting particle 251 is embedded in the second thermoplastic polymer 122 that constitutes the linear body main body 241. Thereby, the intersecting fiber / intersecting particle 251 is fixed to the linear body main body 241, and it is possible to suppress the intersecting fiber / intersecting particle 251 from falling off from the linear body main body 241. The remainder of the intersecting fiber / intersecting particle 251 protrudes from the outer peripheral surface 241S of the linear body main body 241 and is covered with the second thermoplastic polymer 122 that constitutes the protrusion 242. Thereby, it is possible to suppress the intersecting fiber / intersecting particle 251 from being exposed, and it is possible to suppress the human skin 261 from directly contacting the intersecting fiber / intersecting particle 251. The protrusion 242 includes the remainder of the intersecting fiber / intersecting particle 251 and the second thermoplastic polymer 122 that covers the remainder of the intersecting fiber / intersecting particle 251. The second thermoplastic polymer 122 that constitutes the linear body main body 241 and the second thermoplastic polymer 122 that constitutes the protrusion 242 are continuous and integrated.

[0062] The irregular unevenness formed is similar to the unevenness formed when the filling rate of the fiber / particle dispersed in the matrix is high. The unevenness can be described as "mountains and valleys". In the linear body 210, the protrusion 242 becomes a mountain, and between adjacent protrusions 242, that is, the region rich in the second thermoplastic polymer 122 becomes a valley.

[0063] The size of the irregular unevenness formed can be controlled by the shape, size, etc. of the fiber / particle 123. Therefore, the surface roughness of the shaped article 2 can be controlled by the shape, size, etc. of the fiber / particle 123.

[0064] When the human skin 261 touches the shaped article 2, the human skin 261 comes into contact with the protrusion 242, and a gap 262 is formed between the human skin 261 and the outer peripheral surface 241S of the linear body main body 241. An air flow can be generated in the formed gap 262. Therefore, when the human skin 261 touches the shaped article 2, the air flow generated in the gap 262 can quickly dry the human skin 261 and can cool the human skin 261 well. For this reason, the shaped article 2 does not have a rubber-like touch, a plastic-like touch, etc., has a cloth-like touch, and has a comfortable touch.

[0065] Also, when the human skin 261 touches the shaped article 2, the human skin 261 can deflect the protrusion 242 with a weak force. Also, the human skin 261 only weakly contacts the surface of the shaped article 2, and the frictional force generated between the human skin 261 and the shaped article 2 is small. Thereby, the shaped article 2 has a soft touch.

[0066] FIG. 10 and FIG. 11 are SEM photographs of cross-sections of a prototype of the shaped article of the second embodiment.

[0067] In the SEM photographs of FIGS. 10 and 11, it can be confirmed that the protrusion 242 protrudes from the sheath 112 and forms irregular unevenness on the outer peripheral surface of the linear body 210.

[0068] FIGS. 12 and 13 are SEM photographs of cross-sections of a prototype of a shaped article manufactured using a monofilament. FIGS. 14 and 15 are SEM photographs of the upper surface of a prototype of a shaped article manufactured using a monofilament.

[0069] In the SEM photographs of FIGS. 12, 13, 14, and 15, it can be confirmed that the surface of the linear body provided in the prototype of the shaped object manufactured using the monofilament is smooth, clean, and has no significant irregularities. Note that in the SEM photographs of FIGS. 14 and 15, the white spots are dust.

[0070] The shaped object 2 having the above-described characteristics has flexibility, strength, breathability, wicking property, controlled roughness and smoothness, a cloth-like texture, and a comfortable touch. Also, the color of the shaped object 2 can be changed.

[0071] FIG. 16 is an SEM photograph of a prototype of a shaped object manufactured using the shaping material of a modification of the first embodiment. FIG. 17 is a microscopic photograph of a polyester monofilament. FIG. 18 is a microscopic photograph of a polyester multifilament.

[0072] The polyester monofilament shown in FIG. 17 is strong, hard, and rigid. For this reason, the polyester monofilament cannot be used for clothing. Also, when the monofilament is used, irregular irregularities cannot be formed on the surface of the shaped object.

[0073] On the other hand, the polyester multifilament shown in FIG. 18 is soft and not rigid. For this reason, the polyester monofilament can be used for clothing. Also, when the multifilament is used, irregular irregularities can be formed on the surface of the shaped object. However, when a polyester monofilament is used, the shaped object cannot be printed by a 3D printer.

[0074] In the SEM photograph of FIG. 16, it can be confirmed that irregular irregularities are formed on the surface of the shaped object manufactured by a 3D printer using the shaping material 1M in which the core 111 is a porous body.

[0075] 2.4 Manufacturing method of the shaped object FIG. 19 is a side view schematically showing a 3D printer used for manufacturing the shaped object of the second embodiment.

[0076] The 3D printer 271 shown in FIG. 19 prints the shaped object 2 by the FDM method using the shaping material 1. Hereinafter, the shaping material 1 is referred to as the filament 1.

[0077] A filament spool 281 is attached to the 3D printer 271. The 3D printer 271 includes a print head 282, a drive mechanism 283, and a plate 284.

[0078] The filament spool 281 supplies the filament 1.

[0079] The print head 282 melts the supplied filament 1 to generate a melt, and discharges the generated melt 288. The print head 282 is disposed vertically above the upper surface 284S of the plate 284. For this reason, the discharged melt 288 falls and is supplied onto the upper surface 284S of the plate 284. The melt 288 may be directly supplied onto the upper surface 284S of the plate 284, or may be supplied onto the upper surface 284S of the plate 284 by being overlaid on the melt already supplied onto the upper surface 284S of the plate 284 or a cured product of the melt.

[0080] The drive mechanism 283 moves the print head 282 in a direction parallel to the upper surface 284S of the plate 284. Thereby, the position where the melt 288 is supplied moves. The drive mechanism 283 can set the position where the melt 288 is supplied to an arbitrary position within the printing range.

[0081] The plate 284 supports the supplied melt 288. The supported melt 288 hardens to become a melt-cured product. The plate 284 supports the melt-cured product.

[0082] When the 3D printer 271 prints the object 2, while discharging the melt 288 from the print head 282, the drive mechanism 283 is moved above the linear region where the linear body 210 provided in the object 2 is printed. Thereby, a linear melt is formed on the linear region. The formed linear melt hardens to become the linear body 210.

[0083] The print head 282 includes a filament feeder 291, a heater 292, and a nozzle 293.

[0084] The filament 1 supplied to the print head 282 is inserted into the filament feeder 291. The filament feeder 291 feeds the inserted filament 1 in the length direction and inserts it into the heater 292.

[0085] The heater 292 heats the inserted filament 1 to generate the melt 288 and supplies the generated melt 288 to the nozzle 293.

[0086] The nozzle 293 discharges the supplied melt 288.

[0087] When the print head 282 melts the filament 1 to generate the melt 288, the core / sheath structure is maintained. For this reason, the linear body 210 has a core / sheath structure 221. However, since the filament 1 is stretched, the diameter of the linear body 210 becomes smaller than the diameter of the filament 1. Also, the thickness of the sheath 232 becomes thinner than the thickness of the sheath 112. For example, the diameter of the linear body 210 becomes about 1 / 4 of the diameter of the filament 1. Also, the thickness of the sheath 232 becomes about 1 / 4 of the thickness of the sheath 112. In this case, the filament 1 having a diameter of 1.75 mm becomes a linear body 210 having a diameter of about 0.40 mm. Also, the sheath 112 having a thickness of 0.2 mm becomes a sheath 232 having a thickness of about 0.05 mm.

[0088] The size of the fiber / particle 123 included in the sheath 112 provided in the filament 1, for example, the length of the fiber or the diameter of the particle, is selected to be sufficiently smaller than the thickness of the sheath 232 provided in the linear body 210 to be printed. Therefore, when the shaped article 2 is printed, it is unlikely that the fiber / particle 123 will penetrate into the core 231. Therefore, most of the fiber / particle 123 remains in the sheath 232, and a part of the fiber / particle 123 becomes the intersecting fiber / intersecting particle 251 that intersects the outer peripheral surface 111S of the linear body main body 241.

[0089] 3 Third Embodiment 3.1 Outline of Flocked Product FIG. 20 is a plan view schematically showing a flocked product according to the third embodiment. FIG. 21 is an enlarged cross-sectional view schematically showing the vicinity of the interface between the flocked product according to the third embodiment and the human skin contacted by the flocked product.

[0090] The flocked product 3 according to the third embodiment shown in FIGS. 20 and 21 is a product obtained by flocking a shaped article manufactured using a shaping material.

[0091] The flocked product 3 is a new type of textile or fabric. The flocked product 3 constitutes, for example, clothing that can be continuously worn on the body. The clothing includes clothes, hats, gloves, socks, footwear, ornaments, and the like. The flocked product 3 may constitute an article other than clothing.

[0092] The clothing may be any of self-made products made by consumers, ordered products made for specific consumers, and ready-made products made for unspecified consumers. However, the manufacturing of the shaped article by a 3D printer and the manufacturing of the flocked product 3 by flocking are suitable for self-made products and ordered products.

[0093] The main part of the flocked product 3 has thermoplasticity. Thereby, the flocked product 3 can be melted and separated into a plurality of components, and a new flocked product or other types of products can be manufactured from the flocked product 3. For this reason, the flocked product 3 is recyclable after being used. Thus, the sustainability and circularity for the global environment can be improved. The other types of products to be manufactured may be co-extruded filaments. Recycling into co-extruded filaments varies depending on the presence or absence of fibers in the polymer, but can be carried out while minimizing the deterioration of properties.

[0094] 3.2 Structure of Flocked Product As shown in FIGS. 20 and 21, the flocked product 3 includes a main body 301, an adhesive layer 302, and flocks 303.

[0095] The main body 301 is a shaped object manufactured using a shaping material, that is, a shaped object that is a melt-cured product of the shaping material. The shaping material may be a shaping material having a single-layer structure, the shaping material 1 of the first embodiment having a multi-layer structure, or other shaping materials, but includes a thermoplastic polymer. The main body 301 is manufactured by a 3D printer. The main body 301 may be the shaping material itself.

[0096] The adhesive layer 302 is disposed on the surface 301S of the main body 301 and covers the surface 301S of the main body 301. The adhesive layer 302 adheres the flocks 303 to the surface 301S of the main body 301 and fixes the flocks 303 on the surface 301S of the main body 301.

[0097] The flocks 303 pierce into the adhesive layer 302. One end of the flocks 303 is buried in the adhesive layer 302. The remaining part of the flocks 303 is disposed outside the adhesive layer 302. For this reason, the flocks 303 protrude from the adhesive layer 302.

[0098] As shown in FIG. 21, when the human skin 311 comes into contact with the flocked product 3, the human skin 311 contacts the flock 303, and a gap 321 is formed between the human skin 311 and the surface of the structure composed of the main body 301 and the adhesive layer 302. An air flow can be generated in the formed gap 321. Therefore, when the human skin 311 comes into contact with the flocked product 3, the air flow generated in the gap 321 can quickly dry the human skin 311 and can cool the human skin 311 well. For this reason, the flocked product 3 does not have a rubber-like touch, a plastic-like touch, etc., has a cloth-like touch, and has a comfortable touch.

[0099] Also, when the human skin 311 comes into contact with the flocked product 3, the human skin 311 can deflect the flock 303 with a weak force. Also, the human skin 311 only weakly contacts the surface of the flocked product 3, and the frictional force generated between the human skin 311 and the flocked product 3 is small. Thereby, the flocked product 3 has a soft touch.

[0100] The main body 301 contains a thermoplastic polymer. The thermoplastic polymer is preferably thermoplastic polyurethane. The properties of the main body 301 can be adjusted by the shaping material used in manufacturing.

[0101] The adhesive layer 302 is composed of a cured product of an adhesive.

[0102] The adhesive is adjusted to be compatible with the main body 301 and the flock 303.

[0103] The adhesive is a thermoplastic adhesive or a thermosetting adhesive, and preferably a thermosetting adhesive. When the adhesive is a thermosetting adhesive, the durability of the adhesive layer 302 can be improved. On the other hand, when the adhesive is a thermoplastic adhesive, the electrostatic deposition of the flock 303 can be easily performed.

[0104] The adhesive is a polymer adhesive, preferably a polyurethane-based adhesive or an acrylic-based adhesive, and more preferably a polyurethane-based adhesive. When the adhesive is a polyurethane-based adhesive, a flexible polyurethane is included in the adhesive layer 302, and it is possible to suppress the adhesive layer 302 from impairing the flexibility of the flocked product 3.

[0105] The polyurethane-based adhesive is, for example, an aqueous or solvent-based polyurethane dispersion, or a liquid polyurethane.

[0106] The flock 303 includes at least one selected from the group consisting of fibers and particles. The flock 303 includes at least one selected from the group consisting of natural products and synthetic products. The natural products include, for example, at least one selected from the group consisting of cotton, wool, and viscose. However, the natural products may contain substances other than cotton, wool, and viscose. The synthetic products include at least one selected from the group consisting of polyester, polyamide (nylon), polyurethane, polylactic acid (PLA), polyethylene, and polypropylene. The synthetic products may contain substances other than polyester, polyamide, polyurethane, polylactic acid, polyethylene, and polypropylene.

[0107] The flock fibers have, for example, a length of 0.1 mm or more and 5 mm or less, and preferably have a length of 0.4 mm or more and 0.8 mm or less. When the length of the flock fibers is shorter than these ranges, the flock fibers may be buried in the polymer and not protrude from the surface, and may not affect the surface touch feeling. Also, if the protruding portion of the flock fibers on the surface is too short, the fibers may stand upright, giving a prickly touch feeling. When the length of the flock fibers is longer than these ranges, the weight of the fibers becomes larger, and there is a possibility that the deposition of the fibers in the flocking process becomes insufficient. If the flock fibers are too long, the fibers may fall down, and there is a risk of losing the fluffy touch feeling.

[0108] The flock fibers have a diameter of, for example, several micrometers or more and several hundred micrometers or less. When the diameter of the flock fibers becomes thinner than this range, generally speaking, a large amount of dust is generated at the site during the manufacturing operation, and if these reach the lungs, there is a risk of causing lung diseases. In the case of the end-user of the product, since the flock fibers are attached to the surface of the printed cloth, the same problem cannot occur. Also, the strength of the fibers weakens and there are problems with durability. When the diameter of the flock fibers is thicker than this range, it may become difficult to flock (embed or disperse) the fibers into the polymer, not commensurate with the thickness of the sheath. Also, a fiber diameter that is too thick gives a rough feeling, losing softness and deteriorating the touch feeling.

[0109] In the first example, the main body 301 is manufactured using a monofilament made of TPU. Also, the adhesive is a polyurethane-based adhesive. Also, the flock 303 is cotton fiber. As a result, the main body 300 becomes soft, and the touch feeling on the surface of the flock product 3 becomes a comfortable touch feeling, so the flock product 3 can be made into comfortable clothing.

[0110] As shown in FIGS. 20 and 21, the flock product 3 includes a first linear body 331 and a second linear body 332.

[0111] Each first linear body 331 extends in the first direction D1 while meandering. The first linear bodies 331 are arranged in the second direction D2. There is a gap between adjacent first linear bodies 331. Each second linear body 332 extends in the second direction D2 while meandering. The second linear bodies 332 are arranged in the first direction D1. There is a gap between adjacent second linear bodies 332. The second direction D2 is perpendicular to the first direction D1. As a result, in plan view, the first linear bodies 331 intersect the second linear bodies 332. Also, the flock product 3 has a lattice-like planar shape.

[0112] The second linear body 332 is disposed on the first linear body 331. The second linear body 332 is in contact with the first linear body 331.

[0113] The flocked product 3 having the above-described characteristics has softness, comfort, breathability, wicking property, controlled coarseness and smoothness, has a cloth-like touch, and has a comfortable touch. That is, flocking can convert a shaped object printed by a 3D printer into a truly wearable textile or fabric. Also, the color of the flocked product 3 can be changed.

[0114] 3.3 Manufacturing method of flocked product FIG. 22 is a perspective view schematically showing an electrostatic deposition apparatus used for manufacturing a flocked product according to the third embodiment.

[0115] The electrostatic deposition apparatus 341 shown in FIG. 22 is an up-type electrostatic deposition apparatus that makes the flock 303 fly from vertically downward to vertically upward. The electrostatic deposition apparatus 341 may be an electrostatic deposition apparatus other than the up-type electrostatic deposition apparatus. For example, the electrostatic deposition apparatus 341 may be a down-type electrostatic deposition apparatus that makes the flock 303 fly from vertically upward to vertically downward.

[0116] As shown in FIG. 22, the electrostatic deposition apparatus 341 includes a first electrode 351, a second electrode 352, a chamber 353, and a power source 354.

[0117] The first electrode 351 has a flat plate shape. The first electrode 351 is installed horizontally.

[0118] The second electrode 352 has a flat plate grid shape. The second electrode 352 is disposed vertically above the first electrode. The second electrode 352 is installed horizontally. For this reason, the second electrode 352 is parallel to the first electrode 351. The second electrode 352 is grounded.

[0119] The chamber 353 houses the first electrode 351 and the second electrode 352.

[0120] The power supply 354 generates a high DC voltage. The positive electrode 361 of the power supply 354 is electrically connected to the first electrode 351. The negative electrode 362 of the power supply 354 is electrically connected to the second electrode 352 and grounded. Thereby, the generated high DC voltage is applied between the first electrode 351 and the second electrode 352.

[0121] When the flock 303 is electrostatically deposited on the workpiece 371, the flock 303 is placed on the upper surface 351S of the first electrode 351. Also, the workpiece 371 is installed above the second electrode 352. Thereafter, the power supply 354 applies a high DC voltage between the first electrode 351 and the second electrode 352. Thereby, the flock 303 is charged, and the charged flock 303 flies from above the upper surface 351S of the first electrode 351 to the workpiece 371 via the second electrode 352. At that time, the charged flock 303 passes through the gap formed in the second electrode 352. The flock 303 that has reached the workpiece 371 adheres to the workpiece 371. Thereby, the flock 303 is electrostatically deposited on the workpiece 371.

[0122] FIG. 23 is a flowchart showing the manufacturing process of the flock product of the third embodiment.

[0123] When the flock product 3 is manufactured, steps S101 to S106 shown in FIG. 23 are executed. Step S101 is a primary process of printing the main body 301 by a 3D printer. Steps S102 to S105 following step S101 are secondary processes for correcting the touch feeling and appearance of the surface of the printed main body 301 by electrostatic deposition, that is, electrostatic flocking.

[0124] In step S101, the main body 301 to be processed is manufactured. The main body 301 is manufactured by a 3D printer and by the FDM method. However, the main body 301 may be manufactured by a modeling device other than a 3D printer and by a modeling method other than the FDM method.

[0125] In the subsequent step S102, an adhesive layer 302 is disposed on the surface 301S of the main body 301. Thereby, a workpiece 371 composed of the main body 301 and the adhesive layer 302 is produced. At that time, a liquid adhesive is applied to the surface 301S of the main body 301 by a spraying method, a brushing method, a roller coating method, a doctor blade method, or the like. Thereby, a thin adhesive layer 302 that spreads over the entire surface 301S of the main body 301 is formed. The adhesive to be applied is selected to be compatible with electrostatic deposition. The disposed adhesive layer 302 promotes the adhesion between the flock 303 and the main body 301.

[0126] In the subsequent step S103, the flock 303 and the workpiece 371 are introduced into the chamber 353. At that time, the flock 303 is placed on the upper surface 351S of the first electrode 351. Further, the workpiece 371 is disposed vertically above the second electrode 352.

[0127] In the subsequent step S104, the flock 303 is pierced into the adhesive layer 302. The flock 303 is pierced into the adhesive layer 302 by electrostatic deposition. At that time, the power supply 354 applies a DC high voltage between the first electrode 351 and the second electrode 352. Thereby, the flock 303 is charged, and the charged flock 303 flies from above the upper surface 351S of the first electrode 351 to the workpiece 371 via the second electrode 352. The flock 303 that has reached the workpiece 371 adheres to the adhesive layer 302. Thereby, the flock 303 is adhered to the surface 301S of the main body 301 via the adhesive layer 302 and covers the surface 301S of the main body 301. Thereby, a new tactile sensation is brought about. One end of the attached flock 303 is buried in the adhesive layer 302 and fixed to the adhesive layer 302. The remaining portion of the attached flock 303 is disposed outside the adhesive layer 302. Thereby, the flock 303 protrudes from the adhesive layer 302. For this reason, the flock 303 is pierced into the adhesive layer 302 in a state where the flock 303 protrudes from the adhesive layer 302. When the flock 303 is a fiber, the flock 303 is pierced into the adhesive layer 302 in a state substantially perpendicular to the surface 301S of the main body 301.

[0128] In the subsequent step S105, the adhesive layer 302 is cured. At this time, the adhesive layer 302 is dried and sintered by heating or the like.

[0129] In the subsequent step S106, cleaning is performed. At this time, the excess flock 303 that is not adhered to the main body 301 by the adhesive layer 302 is removed. Thereby, the flock product 3 is completed.

[0130] Flocking may be performed manually using a handheld electrostatic coating device or the like.

[0131] FIG. 24 is a photograph of a prototype of the main body provided in the flock product of the third embodiment. FIG. 25 is a photograph of a prototype of the flock product of the third embodiment.

[0132] Comparing the main body 301 before flocking shown in FIG. 24 and the flock product 3 after flocking shown in FIG. 25, it can be understood that complex unevenness can be formed on the surface of the flock product 3 by performing flocking.

[0133] The step S102 of disposing the adhesive layer 302 on the surface 301S of the main body 301 and the step S104 of piercing the flock 303 into the adhesive layer 302 require only a very short time, for example, only 3 - 10 minutes. When the process is automated, further time reduction is possible. However, the step S105 of curing the adhesive layer 302 requires a long time, for example, several hours. However, it is possible to shorten the time required for step S105 by selecting an adhesive.

[0134] The coating state of the flock 303 on the surface 301S of the main body 301 can be adjusted by adjusting the parameters of the electrostatic deposition in step S104. For example, by adjusting the parameters, the entire surface 301S of the main body 301 can be uniformly coated with the flock 303, or the surface 301S of the main body 301 can be coated with the flock 303 such that the density of the flock 303 has a gradient.

[0135] The touch feeling of the flock product 3 can be adjusted by adjusting the type, dTex (deciTex), and length of the flock 303. The density of the flock 303 can be adjusted by adjusting the main body 301, the properties of the adhesive, the properties of the flock 303, and the process conditions.

[0136] The flock 303 is hardly affected by the material of the main body 301, but can be adjusted by the selection of the adhesive. By these means, the flock product 3 suitable for various applications can be manufactured.

[0137] The properties of the flock product 3 are hardly affected by the properties of the main body 301 and can be adjusted by the selection of the adhesive. This is because the adhesive layer 302 functions as an intermediate layer that connects the flock 303 to the main body 301.

[0138] In order to obtain the structure and properties of the flock product 3 that cannot be obtained with one type of flock 303, two or more types of flock 303 may be combined.

[0139] In order to execute the manufacturing method of the flock product described above, a factory that executes the above-described primary process and secondary process may be established according to the customer's requirements or seasonal limited collections. A factory that executes only the above-described secondary process according to the customer's requirements may be established. In this case, the main body 300 is provided by the customer.

[0140] The present disclosure is not limited to the above-described embodiments, and may be replaced with a configuration that is substantially the same as the configuration shown in the above-described embodiments, a configuration that exhibits the same operational effects, or a configuration that can achieve the same object.

Explanation of Signs

[0141] 1 Modeling material (filament), 101 Core / sheath structure, 111 Core, 112 Sheath, 121 First thermoplastic polymer, 122 Second thermoplastic polymer, 123 Fiber / particle, 1M Modeling material, 2 Modeled object, 201 First linear body, 202 Second linear body, 210 Linear body, 221 Core / sheath structure, 231 Core, 232 Sheath, 241 Linear body main body, 242 Protrusion, 251 Intersecting fiber / intersecting particle, 261 Human skin, 271 3D printer, 281 Filament spool, 282 Print head, 283 Driving mechanism, 284 Plate, 288 Melt, 3 Flocked product, 301 Main body, 302 Adhesive layer, 303 Flock, 311 Human skin, 331 First linear body, 332 Second linear body, 341 Electrostatic deposition device, 351 First electrode, 352 Second electrode, 353 Chamber, 354 Power supply, 361 Positive electrode, 362 Negative electrode.

Claims

1. A core / sheath structure that constitutes a modeling material that is melted and cured to manufacture a shaped object, a core having a linear shape, an outer peripheral surface, and containing a first thermoplastic polymer, a sheath that covers the outer peripheral surface and contains at least one of a second thermoplastic polymer and fibers or particles dispersed in the second thermoplastic polymer, The core / sheath structure is characterized by comprising.

2. The core / sheath structure according to claim 1, wherein at least one of the fibers or particles of the sheath forms a protrusion on the outer peripheral surface of the shaped object.

3. The core / sheath structure according to claim 1, wherein the first thermoplastic polymer and the second thermoplastic polymer are of the same type of thermoplastic polymer.

4. The core / sheath structure according to claim 1, wherein the first thermoplastic polymer and the second thermoplastic polymer are of different types of thermoplastic polymers.

5. The core / sheath structure constitutes a modeling material, The core / sheath structure according to claim 1, wherein at least one of the core and the sheath contains one or more of a foaming material and a foaming agent.

6. The core / sheath structure according to claim 1, wherein the sheath contains at least a hard component and a soft component.

7. The core / sheath structure according to claim 1, wherein the hard component contains a thermoplastic resin, The core / sheath structure according to claim 1, wherein the soft component contains a thermoplastic elastomer.

8. The core / sheath structure according to claim 1, wherein one or both of the fibers or particles are one or both of natural materials or synthetic materials.

9. The core / sheath structure according to claim 1, wherein the core is a porous body.

10. The core / sheath structure according to claim 1, wherein at least one of the core or the sheath contains a reinforcing component.

11. The core / sheath structure according to claim 10, wherein the reinforcing component contains a filler.

12. The core / sheath structure according to claim 11, wherein the filler contains at least one of fibers, particles, fine particle powder, nanoparticles, or nanofibers.

13. The core / sheath structure according to claim 11, wherein the filler contains at least one of natural materials or compounds.

14. The core / sheath structure according to claim 1, wherein one or both of the fibers or particles comprise at least one of llama, cotton, wool, silk, or chitosan.

15. The core / sheath structure according to claim 1, wherein one or both of the fibers or particles comprise cotton.

16. The core / sheath structure according to claim 1, wherein one or both of the fibers or particles comprise wool.

17. The core / sheath structure according to claim 1, wherein the core / sheath structure comprises a two-layer structure.

18. The core / sheath structure according to claim 1, wherein the core comprises at least one of a fiber or a particle.

19. The core / sheath structure according to claim 1, wherein the sheath comprises one or more additives for forming pores.

20. The core / sheath structure according to claim 1, wherein the sheath comprises a water-soluble material.

21. The core / sheath structure according to claim 20, wherein the water-soluble material comprises polyvinyl alcohol (PVA).

22. The core / sheath structure according to claim 20, wherein the sheath further comprises a thermoplastic polymer.

23. The core / sheath structure according to claim 1, wherein the core / sheath structure has at least a three-layer structure.

24. A shaped article having a core / sheath structure, wherein the shaped article has a linear shape, has an outer peripheral surface, and a core comprising a first thermoplastic polymer, a sheath covering the outer peripheral surface and comprising a second thermoplastic polymer and at least one of a fiber or a particle dispersed in the second thermoplastic polymer, and is provided with at least one of the fibers or particles of the sheath forms a protrusion on the outer peripheral surface of the shaped article

25. The shaped article according to claim 24, wherein the first thermoplastic polymer and the second thermoplastic polymer are of the same type of thermoplastic polymer.

26. The shaped article according to claim 24, wherein the first thermoplastic polymer and the second thermoplastic polymer are of different types of thermoplastic polymers.

27. The shaped article according to claim 24, wherein one or both of the fibers or particles are one or both of a natural material or a synthetic material.

28. The shaped article according to claim 24, wherein one or both of the fibers or particles contain at least one of llama, cotton, wool, silk, or chitosan.

29. The shaped article according to claim 24, wherein at least one of the core or the sheath contains a reinforcing component.

30. The shaped article according to claim 29, wherein the reinforcing component contains a filler.

31. The shaped article according to claim 30, wherein the filler contains at least one of fibers, particles, fine particle powder, nanoparticles, or nanofibers.

32. The shaped article according to claim 30, wherein the filler contains at least one of natural materials or compounds.

33. The shaped article according to claim 24, wherein the shaped article includes a fabric or a cloth.

34. The shaped article according to claim 24, wherein the shaped article includes clothing configured to contact the human skin.

35. The shaped article according to claim 24, wherein the shaped article includes articles other than clothing.

36. The shaped article according to claim 24, wherein one or more properties of the shaped article are determined based on at least one of the fibers or particles.

37. The shaped article according to claim 36, wherein one or more properties of the shaped article include elasticity, flexibility, strength, or breathability.

38. The shaped article according to claim 24, wherein the shaped article has a lattice-like planar shape.

39. The shaped article according to claim 24, wherein the surface roughness of the shaped article is controlled by at least one of the fibers or particles.

40. The shaped article according to claim 39, wherein the surface roughness of the shaped article is controlled by at least one of the shape or dimension of at least one of the fibers or particles.

41. The shaped article is configured to contact human skin, The shaped article according to claim 24, wherein the protrusions are configured to contact human skin.

42. The shaped article according to claim 41, wherein the protrusions are configured to contact human skin and give a cloth-like tactile sensation.

43. The shaped article according to claim 24, wherein the protrusions form irregular unevenness on the surface of the shaped article.

44. The shaped article according to claim 24, wherein at least one of the fibers or particles remains at least partially within the sheath and projects at least partially from the surface of the shaped article.

45. The shaped article according to claim 24, wherein at least one of the fibers or particles results in the shaped article having a color.

46. The shaped article according to claim 24, wherein at least one of the fibers or particles results in the shaped article having wicking properties.

47. The shaped article according to claim 24, wherein at least one of the fibers or particles results in the shaped article having a controlled roughness or smoothness.

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