Manufacturing apparatus and manufacturing method

Abstract

To provide manufacturing apparatus that can properly extrude even materials with high extrusion difficulty from the nozzle.SOLUTION: The forming apparatus (100) comprises a stage (2), a first nozzle (3) for extruding material for the formed object onto the stage to form the object, and a first nozzle temperature control device (23) for heating or cooling the material inside the nozzle to maintain its temperature within a predetermined range.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a manufacturing apparatus and a manufacturing method for manufacturing a shaped object. [Background technology]

[0002] Conventionally, there is known a technique for forming a three-dimensional object by depositing material for the object on a stage to form layers and laminating a plurality of such layers. Patent Document 1 discloses a modeling device that stirs and mixes an unvulcanized rubber composition in a screw-type extruder while heating it to a temperature below the vulcanization temperature, and extrudes the unvulcanized rubber composition onto a stage (modeling sheet) from an extrusion hole, thereby laminating the unvulcanized rubber composition with low fluidity on the stage to form a model. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-018440 Summary of the Invention [Problem to be solved by the invention]

[0004] The above-mentioned technology is not designed to be used with materials that are difficult to extrude. In other words, it is not possible to properly extrude materials that are difficult to extrude from the nozzle. A material that is difficult to extrude is one that generates shear heat (due to stirring inside the nozzle, etc.) when it is extruded from the nozzle's discharge hole, and this shear heat causes the material to harden.

[0005] Materials that are difficult to extrude include materials with high hardness (e.g., magnetic rubber compositions), materials with high viscosity, and unvulcanized rubber compositions containing a large amount of filler. Other examples include unvulcanized rubber compositions containing fluororubber. For example, when a magnetic rubber composition is extruded, the temperature of the magnetic rubber composition may rise to 100°C or higher due to shear heating. This may result in the magnetic rubber composition hardening due to an undesired vulcanization reaction.

[0006] One aspect of the present invention provides a manufacturing apparatus that can properly extrude a material from a nozzle, even if the material is difficult to extrude. [Means for solving the problem]

[0007] In order to solve the above problems, a manufacturing apparatus according to one aspect of the present invention is a manufacturing apparatus that forms a three-dimensional object by stacking multiple layers, and includes a stage, a nozzle that ejects material for the object onto the stage to form the object, and a temperature control unit that heats or cools the material inside the nozzle so that the temperature of the material inside the nozzle is within a predetermined range.

[0008] In order to solve the above problems, a manufacturing method according to one aspect of the present invention is a manufacturing method for forming a three-dimensional object by stacking multiple layers, and includes a preparation step of preparing a material inside a nozzle, a temperature control step of heating or cooling the material inside the nozzle so that the temperature of the material inside the nozzle is within a predetermined range, and a formation step of ejecting the material of the object onto a stage to form the object. [Effects of the Invention]

[0009] According to one aspect of the present invention, even a material that is difficult to extrude can be appropriately extruded from a nozzle. [Brief explanation of the drawings]

[0010] [Figure 1]1 is a block diagram showing a schematic configuration of a molding apparatus according to an embodiment of the present invention. [Figure 2] 1A to 1C are process diagrams illustrating a method for manufacturing a shaped object. [Figure 3] 10 is a flowchart showing a method for manufacturing a shaped object. DETAILED DESCRIPTION OF THE INVENTION

[0011] [Embodiment 1] (Schematic configuration of the molding device) 1 is a schematic diagram showing a modeling apparatus 100 according to one embodiment of the present invention. First, the modeling apparatus 100 (manufacturing apparatus) will be described below with reference to FIG.

[0012] As shown in FIG. 1, the modeling apparatus 100 includes a stage 2, a first nozzle 3 (nozzle), and a second nozzle 4. The modeling apparatus 100 manufactures a three-dimensional model P by stacking multiple layers L containing a model material (material of the model P) on the surface of the stage 2 (see FIG. 2). Furthermore, if the modeling apparatus 100 has a portion (a protruding portion) whose upper width is greater than its lower width, the modeling apparatus 100 manufactures a support body S that supports the protruding portion from below during modeling of the model P. The modeling apparatus 100 manufactures the support body S by stacking a support material (material of the support body S) on the surface of the stage 2 or the layer L.

[0013] 1, the modeling apparatus 100 includes a first nozzle driving device 13 and a second nozzle driving device 14 that drive the first nozzle 3 and the second nozzle 4, respectively. The modeling apparatus 100 also includes a first nozzle temperature adjusting device 23 (temperature adjusting unit) and a second nozzle temperature adjusting device 24 that adjust the temperatures of the first nozzle 3 and the second nozzle 4, respectively. The modeling apparatus 100 also includes a control device 15 that controls the first nozzle driving device 13 and the second nozzle driving device 14, respectively. The detailed configurations of the first nozzle temperature adjusting device 23 and the second nozzle temperature adjusting device 24 will be described later.

[0014] The stage 2 defines an area (specific plane) on which the unvulcanized rubber composition is laminated. The stage 2 is provided on a support base 21. The stage 2 is formed of a material that does not undergo chemical reactions with at least the material. For example, the stage 2 is a metal plate. The stage 2 may be heated by a heating device 22 (heater) built into the support base 21. The heating temperature by the heating device 22 is controlled by the control device 15.

[0015] The first nozzle 3 ejects the model material from above the stage 2 toward the stage 2. When ejecting the model material, the first nozzle 3 is heated by the first nozzle temperature regulator 23 to a predetermined temperature at which the model material has good fluidity. The unvulcanized rubber composition is vulcanized and hardened by a predetermined curing treatment (for example, irradiation with ultraviolet light) to form a layer L. The layers L are stacked to form the shaped object P. An opening 3a is provided on the side of the first nozzle 3. The model material is supplied to the first nozzle 3 through the opening 3a.

[0016] The second nozzle 4 ejects the support material from above the stage 2 toward the stage 2. When ejecting the support material, the second nozzle 4 is heated by the second nozzle temperature regulator 24 to a predetermined temperature that improves the fluidity of the support material. The support material is hardened by a predetermined hardening process (for example, by irradiation with ultraviolet light) to form a support layer SL. The support layers SL are stacked to form the support body S.

[0017] The first nozzle 3 and the second nozzle 4 are moved along the surface of the stage 2 by the first nozzle driving device 13 and the second nozzle driving device 14, respectively, while discharging the model material and the supporting material. As a result, the first nozzle 3 models the model material on a specific plane, and models the model material on the model material or supporting material that has been modeled on the specific plane (see Figure 2). The second nozzle 4 models the supporting material on the specific plane, and models the supporting material on the unvulcanized rubber composition or supporting material that has been modeled on the specific plane. Hereinafter, unless there is a need to particularly distinguish between the first nozzle 3 and the second nozzle 4, they will be simply referred to as nozzles 3 and 4.

[0018] The position, discharge timing, discharge amount, etc. of the nozzles 3, 4 may be controlled by the control device 15 according to the three-dimensional structure of the object P and the support S. Alternatively, the stage 2 may move instead of the nozzles 3, 4. The stage 2 or the nozzles 3, 4 may move in the planar direction and the stacking direction. Either the stage 2 or the nozzles 3, 4 may move only in the planar direction, while the other of the stage 2 or the nozzles 3, 4 may move in the stacking direction. Note that the planar direction refers to the direction in which the stage 2 or the nozzles 3, 4 move while maintaining a constant distance between the nozzles 3, 4 and the stage 2 (a direction parallel to the surface of the stage 2). Additionally, the stacking direction refers to the direction in which the stage 2 or the nozzles 3, 4 move toward and away from the stage 2 and the nozzles 3, 4 (a direction perpendicular to the surface of the stage).

[0019] The molding apparatus 100 does not necessarily have to include the second nozzle 4, the second nozzle driving device 14, and the second nozzle temperature adjusting device 24.

[0020] (Nozzle temperature control device) The first nozzle temperature regulator 23 heats or cools the material inside the first nozzle 3 so that the temperature of the material inside the first nozzle 3 is within a predetermined range (hereinafter referred to as the "appropriate temperature range"). The "appropriate temperature range" is a temperature range that allows the material to have sufficient fluidity to be appropriately discharged from the first nozzle 3. Typically, increasing the temperature of the material improves the material's fluidity (in other words, reduces its viscosity). However, some materials harden due to a vulcanization reaction above a certain temperature. When discharging such materials from the first nozzle 3, the material's temperature must be maintained at a temperature equal to or higher than a first threshold temperature at which the material has good fluidity and lower than a second threshold temperature at which a curing reaction occurs. For example, if the material is an unvulcanized rubber composition, the appropriate temperature range is typically between 50°C and 100°C. Unvulcanized rubber compositions typically harden due to a vulcanization reaction above 100°C.

[0021] Here, when a material that is difficult to extrude is extruded from the first nozzle 3, shear heating may occur (due to stirring inside the nozzle, etc.). If the modeling apparatus only has a heating function for heating the material inside the first nozzle 3, this shear heating makes it difficult to control the temperature of the material. As a result, the temperature of the material may fall outside the appropriate temperature range. On the other hand, the modeling apparatus 100 according to this embodiment is equipped with a first nozzle temperature adjustment device 23 that can not only heat but also cool the material inside the first nozzle 3. Therefore, according to the modeling apparatus 100 according to this embodiment, even if the above-mentioned shear heating occurs, the temperature of the material can be kept within the appropriate temperature range. Therefore, even a material that is difficult to extrude can be appropriately extruded from the nozzle.

[0022] The first nozzle temperature regulator 23 controls, for example, a circulation device that circulates a heat medium around the first nozzle 3. The heat medium is, for example, water or oil. The temperature of the heat medium is, for example, about 80°C. This allows the first nozzle temperature regulator 23 to maintain a constant temperature of the material inside the first nozzle 3 (heating material at room temperature and cooling material whose temperature has risen due to shear heating). The first nozzle temperature regulator 23 is equipped with input means that allows the user to set a target temperature, and controls the circulation device based on the temperature sensor so that the material discharged from the first nozzle 3 maintains the target temperature.

[0023] The second nozzle temperature regulator 24 may also have the same function as the first nozzle temperature regulator 23. Alternatively, the second nozzle temperature regulator 24 may only have a heating function.

[0024] (Nozzle diameter) The nozzle diameter of the first nozzle 3 is preferably 0.8 mm or less. Preferably, the nozzle diameter of the first nozzle 3 is 0.4 mm or less. By setting the nozzle diameter of the first nozzle 3 to less than 0.8 mm, the thickness of each layer L of the object P formed on the stage 2 can be reduced. This makes it possible to easily adjust the shape of the object.

[0025] Furthermore, the difficulty of extrusion caused by setting the nozzle diameter to less than 0.8 mm can be reduced by the first nozzle temperature regulator 23. That is, the degree of freedom in the shape of the shaped object P can be improved, while at the same time, the material can be appropriately extruded from the first nozzle 3.

[0026] (About the materials) As described above, the molding apparatus 100 is provided with the first nozzle temperature adjustment device 23, which makes it possible to apply materials that are difficult to extrude. Below, some examples of such materials that are difficult to extrude will be described.

[0027] As an example, an example of a material that is difficult to extrude is an unvulcanized rubber composition having a hardness of 60 degrees or more after vulcanization based on JIS K 6253. That is, an unvulcanized rubber composition having a hardness of 60 degrees or more after vulcanization may generate shear heat when extruded from the first nozzle 3. The first nozzle temperature regulator 23 maintains the temperature of the unvulcanized rubber composition constant (for example, at about 80°C) to suppress the progress of the vulcanization reaction of the unvulcanized rubber composition that accompanies such shear heat. Furthermore, since an unvulcanized rubber composition having a hardness of 70 degrees or more after vulcanization generates a large amount of shear heat when extruded from the first nozzle 3, it is even more important to maintain the temperature constant using the above-mentioned first nozzle temperature regulator 23.

[0028] In another example, a material that is difficult to extrude includes a magnetic rubber composition. The magnetic rubber composition is a material for a bonded magnet (e.g., a rubber magnet), which is an example of the shaped object P. The ability to manufacture a bonded magnet using the above-described molding apparatus 100 is of great significance in this technical field. That is, in conventional techniques for molding bonded magnets using a mold or the like, it has been difficult to mold a bonded magnet with a thickness or diameter greater than a certain level. This is because magnetic rubber compositions (especially those containing rubber) have low thermal conductivity, and molding a bonded magnet requires a long heating time, resulting in distortion of the bonded magnet. On the other hand, by manufacturing a bonded magnet using the above-described molding apparatus 100, it is possible to properly manufacture even bonded magnets with a thickness or diameter greater than a certain level.

[0029] In yet another example, the material that is difficult to extrude includes fluororubber. An unvulcanized rubber composition that includes fluororubber has a high viscosity, making it difficult to extrude.

[0030] (Method of manufacturing a molded object) FIG. 2 is a process diagram showing a method for manufacturing the object P. FIG. 3 is a flowchart showing a method for manufacturing the object P. Next, with reference to FIGS. 2 and 3, the method for manufacturing the object P using the modeling apparatus 100 will be described below. Hereinafter, the kth layer L will be referred to as layer Lk (1≦k≦n). Note that in FIGS. 2 and 3, the ejection of support material from the second nozzle 4 is omitted for simplicity.

[0031] First, the first nozzle temperature regulator 23 starts regulating the temperature of the first nozzle 3. The first nozzle temperature regulator 23 raises the temperature of the heat medium circulating around the first nozzle 3 to a predetermined temperature (temperature regulation preparation step S1 in FIG. 3). The predetermined temperature is, for example, a temperature (approximately 70°C) corresponding to the lower limit threshold of the appropriate temperature range. After the temperature of the heat medium has risen to the predetermined temperature, the first nozzle temperature regulator 23 continues regulating the temperature of the first nozzle 3 so that the temperature of the model material supplied inside the first nozzle 3 is within the appropriate temperature range (temperature regulation step S2).

[0032] After the temperature of the heat medium has risen to a predetermined temperature, the control device 15 starts forming the object P (S3 in FIG. 3). First, the control device 15 prepares a model material for the inside of the first nozzle 3 (model material preparation step S4 in FIG. 3). The model material is supplied into the inside of the first nozzle 3 via, for example, the opening 3a.

[0033] In the model material preparation step S4, the model material is heated in the temperature adjustment step S2 so that the temperature of the model material inside the first nozzle 3 falls within the appropriate temperature range. In other words, the first nozzle temperature adjustment device 23 heats the model material, which is at room temperature, to raise the temperature of the model material to within the appropriate temperature range (e.g., approximately 70 to 80°C). For example, the first nozzle temperature adjustment device 23 circulates a heat medium at approximately 80°C around the first nozzle 3 to heat the model material, which is at room temperature. The first nozzle temperature adjustment device 23 may monitor the temperature of the model material discharged from the first nozzle 3 using a temperature sensor. If the temperature of the model material exceeds the appropriate temperature range, the first nozzle temperature adjustment device 23 may cool the model material to lower the temperature of the model material to within the appropriate temperature range.

[0034] Next, the model material is discharged onto the stage 2 to form the modeled object P (modeling step S5 in FIG. 3). Specifically, as shown by reference numeral 2001 in FIG. 2, the first nozzle 3 is disposed above the stage 2, and the model material is discharged from the discharge hole of the first nozzle 3 toward the stage 2. Here, the first nozzle 3 moves along the surface of the stage 2 (in a planar direction) while discharging the model material. The first nozzle 3 moves, for example, in a circular motion, and causes the end of the unvulcanized rubber composition to merge with the beginning of the initially discharged model material. In this way, the model material is layered on the surface of the stage 2. Specifically, the first nozzle 3 discharges the model material onto a specific region on the surface of the stage 2 that is determined according to the three-dimensional structure of the modeled object P (more specifically, the cross-sectional shape corresponding to layer L1 of the three-dimensional structure).

[0035] In the modeling step S5, the model material is heated or cooled in the temperature adjustment step S2 so that the temperature of the model material inside the first nozzle 3 is within the appropriate temperature range. In other words, the first nozzle temperature adjustment device 23 maintains the temperature of the model material within the appropriate temperature range while the model material is being extruded from the first nozzle 3. For example, if the model material is a material that is difficult to extrude, shear heating may occur when the model material is extruded from the first nozzle 3. If such shear heating occurs, the first nozzle temperature adjustment device 23 cools the model material to lower the temperature of the model material to within the appropriate temperature range.

[0036] Next, since the modeling of the modeled object P is not complete, the process returns to modeling step S5 again (NO in S6 in FIG. 3). That is, as shown by reference numeral 2002 in FIG. 2, the first nozzle 3 is placed above the stage 2, and the model material is discharged from the discharge holes of the first nozzle 3 toward the upper surface of the layer L1. As a result, the model material is stacked on the upper surface of the layer L1. Specifically, the first nozzle 3 discharges the model material onto a specific region on the upper surface of the layer L1 that is determined according to the three-dimensional structure of the modeled object P (more specifically, the cross-sectional shape of the three-dimensional structure that corresponds to layer L2).

[0037] The above steps S2 and S3 are repeated until the formation of the object P is completed. When the top layer Ln is formed, the formation of the object P is completed (YES in S6 in FIG. 3). When the formation of the object P is completed, the temperature adjustment step S2 is also completed (S7).

[0038] The formation of the modeled object P is completed by heat-vulcanizing a laminate of multiple layers L1-Ln of the model material. For example, after the top layer Ln is formed, the multiple layers L1-Ln of the model material are heat-vulcanized collectively to form the modeled object P. In this way, when the model material is an unvulcanized rubber composition, by laminating the unvulcanized rubber together, the contact surfaces between the unvulcanized rubbers can be vulcanized and bonded during heat-vulcanization. Furthermore, because the layers are heat-vulcanized collectively, the time required for modeling can be shortened. Furthermore, the model material extruded from the first nozzle 3 is cooled by air, which reduces its viscosity and increases its hardness, thereby reducing deformation of the material after modeling. Note that if the hardness of the model material is lower than a predetermined hardness, each time one or more layers of the model material are formed, those layers may be heat-vulcanized.

[0039] (Advantages of the modeling apparatus 100) According to the molding apparatus 100 of this embodiment, even if shear heat occurs when extruding a material that is difficult to extrude, the temperature of the material can be kept within an appropriate temperature range. Therefore, even materials that are difficult to extrude can be properly extruded from the nozzle. This makes it possible to mold products (e.g., bonded magnets) that were previously unachievable due to the difficulty of extrusion.

[0040] Furthermore, the above manufacturing method in which layers are stacked in accordance with the three-dimensional structure of the shaped object P does not require a mold. This makes it possible to reduce the manufacturing cost of the shaped object P in small-lot production. Furthermore, if the shaped object P is a rubber product, there is no need to cut the rubber block material, so the shaped object P can be manufactured inexpensively and the environmental load can be reduced.

[0041] [Software implementation example] The functions of the control device 15 (hereinafter referred to as "device") can be realized by a program that causes a computer to function as the device, and a program that causes a computer to function as each control block of the device.

[0042] In this case, the device includes a computer having at least one control device (e.g., a processor) and at least one storage device (e.g., a memory) as hardware for executing the program. The control device and storage device execute the program, thereby realizing the functions described in each of the above embodiments.

[0043] The program may be non-transitory and may be recorded on one or more computer-readable recording media. The recording media may or may not be included in the device. In the latter case, the program may be supplied to the device via any wired or wireless transmission medium.

[0044] Furthermore, some or all of the functions of the control blocks can be realized by logic circuits. For example, an integrated circuit in which a logic circuit that functions as each of the control blocks is formed is also included in the scope of the present invention. In addition, the functions of the control blocks can also be realized by, for example, a quantum computer.

[0045] 〔summary〕 The manufacturing apparatus according to aspect 1 of the present invention is a manufacturing apparatus for forming a three-dimensional object by stacking multiple layers, and includes a stage, a nozzle for ejecting material for the object onto the stage to form the object, and a temperature control unit for heating or cooling the material inside the nozzle so that the temperature of the material inside the nozzle is within a predetermined range.

[0046] In the production method according to a second aspect of the present invention, in the first aspect, the material is an unvulcanized rubber composition having a hardness after vulcanization based on JIS K 6253 of 60 degrees or more.

[0047] A manufacturing method according to a third aspect of the present invention is the same as that of the first aspect, wherein the material includes a magnetic rubber composition.

[0048] A fourth aspect of the present invention relates to the manufacturing method of the first aspect, wherein the material includes fluororubber.

[0049] A fifth aspect of the present invention relates to the manufacturing method of the first aspect, wherein the nozzle has a nozzle diameter of 0.8 mm or less.

[0050] A manufacturing method according to aspect 6 of the present invention is a manufacturing method for forming a three-dimensional object by stacking multiple layers, and includes a preparation step of preparing a material inside a nozzle, a temperature control step of heating or cooling the material inside the nozzle so that the temperature of the material inside the nozzle is within a predetermined range, and a modeling step of ejecting the material of the object onto a stage to form the object.

[0051] The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present invention. [Explanation of symbols]

[0052] 2 Stage 3 No. 1 nozzle (nozzle) 23 First nozzle temperature control device (temperature control unit) 100 Molding equipment (manufacturing equipment)

Claims

1. A manufacturing apparatus for forming a three-dimensional object by stacking a plurality of layers, The stage and a nozzle that ejects a material of the object onto the stage to form the object; and a temperature control unit that heats or cools the material inside the nozzle so that the temperature of the material inside the nozzle is within a predetermined range.

2. 2. The manufacturing apparatus according to claim 1, wherein the material is an unvulcanized rubber composition having a hardness after vulcanization of 60 degrees or more according to JIS K 6253.

3. The manufacturing apparatus of claim 1 , wherein the material comprises a magnetic rubber composition.

4. The manufacturing apparatus according to claim 1 , wherein the material comprises fluororubber.

5. The manufacturing apparatus according to claim 1 , wherein the nozzle has a nozzle diameter of 0.8 mm or less.

6. A manufacturing method for forming a three-dimensional object by stacking a plurality of layers, comprising: a preparation step of preparing a material inside the nozzle; a temperature control step of heating or cooling the material inside the nozzle so that the temperature of the material inside the nozzle is within a predetermined range; and a modeling step of discharging a material of the object onto a stage to model the object.

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