Solid fiber formation system, solid fiber formation program, and solid fiber formation method

Abstract

To manufacture a high-quality solid-shaped fiber.SOLUTION: This invention relates to a solid fiber formation system. The solid fiber formation system of this invention is characterized by having a stage provided with a flat surface constituted of a net; a feeding mechanism that accommodates a molding material including a viscous liquid in which a fiber is floating and discharges the molding material onto the flat surface from an exhaust port for discharging the molding material; a positioning mechanism for positioning the exhaust port on the upper side of the stage; pattern data holding means for holding pattern data indicating a pattern for discharging the molding material onto the flat surface; and control means for controlling the positioning mechanism and the feeding mechanism to discharge the molding material onto the flat surface in accordance with the pattern data.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a three-dimensional fiber forming system, a three-dimensional fiber forming program, and a three-dimensional fiber forming method, and can be applied to a system for forming paper with a three-dimensional shape, for example. [Background technology]

[0002] Conventionally, as a technology for forming a three-dimensional shape, there is a system described in Patent Document 1, for example.

[0003] The system described in Patent Document 1 is configured to form a three-dimensional shape by layering a fluid material containing fibers. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Special Publication No. 2022-506320 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the system described in Patent Document 1 requires the addition of a hardening material that hardens when heated, etc., to the material, which means that the paper must contain ingredients different from those in regular paper, which could cause problems with the quality of the paper produced and problems with recycling. Also, the system described in Patent Document 1 makes it difficult to produce thin, flexible, high-quality paper because the manufacturing process includes a hardening step using heat, etc.

[0006] In view of the above problems, there is a demand for a three-dimensional fiber forming system, a three-dimensional fiber forming program, and a three-dimensional fiber forming method that can produce high-quality three-dimensionally shaped fibers. [Means for solving the problem]

[0007] The three-dimensional fiber forming system of the first invention is characterized by having a stage having a plane formed by a net, a supply mechanism that stores molding material containing mucus with suspended fibers and discharges the molding material onto the plane from an outlet that discharges the molding material, a positioning mechanism for positioning the outlet above the stage, pattern data holding means for holding pattern data indicating the pattern in which the molding material will be discharged onto the plane, and control means for controlling the positioning mechanism and the supply mechanism so as to discharge the molding material onto the plane in accordance with the pattern data.

[0008] The second three-dimensional fiber forming program of the present invention is characterized in that it functions as a computer mounted on a control device that controls a supply mechanism that stores a molding material containing mucus with suspended fibers and discharges the molding material from an outlet onto a stage having a flat surface formed by a mesh, and a positioning mechanism for positioning the outlet above the stage, and as a pattern data holding means that holds pattern data indicating the pattern in which the molding material is discharged onto the flat surface, and as a control means that controls the positioning mechanism and the supply mechanism so as to discharge the molding material onto the flat surface in accordance with the pattern data.

[0009] The third three-dimensional fiber formation method of the present invention is a three-dimensional fiber formation method performed by a three-dimensional fiber formation system comprising a stage having a plane formed by a net, a supply mechanism that stores molding material containing mucus with suspended fibers and discharges the molding material onto the plane from an outlet for discharging the molding material, a positioning mechanism for positioning the outlet above the stage, and a control device, wherein the control device comprises a pattern data holding means and a control means, the pattern data holding means holds pattern data indicating the pattern in which the molding material will be discharged onto the plane, and the control means controls the positioning mechanism and the supply mechanism so as to discharge the molding material onto the plane in accordance with the pattern data. [Effects of the Invention]

[0010] According to the present invention, a three-dimensional fiber forming system capable of producing high-quality three-dimensionally shaped fibers can be provided. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a diagram (perspective view) showing the overall configuration of a three-dimensional fiber forming system according to an embodiment. [Figure 2] 3A and 3B are diagrams showing examples of coordinate system models of the XY plane in the positioning device and papermaking stage according to the embodiment. [Figure 3] 1 is a diagram (image) showing the steps of a papermaking process in a three-dimensional fiber forming system according to an embodiment. [Figure 4] 1 is a diagram (image) showing the steps of papermaking and drying in a three-dimensional fiber forming system according to an embodiment. FIG. [Figure 5] FIG. 2 is a block diagram showing the functional configuration of a control terminal according to the embodiment. [Figure 6] 10A and 10B are diagrams illustrating the operation of a papermaking control processing unit according to the embodiment to control discharge to desired coordinates on an XY plane. [Figure 7] FIG. 1 is a diagram (part 1) showing the relationship between the diffusion radius and the fiber diffusion area over the entire XY plane in the papermaking process of the three-dimensional fiber formation system according to the embodiment. [Figure 8] FIG. 10 is a diagram (part 2) showing the relationship between the diffusion radius and the fiber diffusion area over the entire XY plane in the papermaking process of the three-dimensional fiber formation system according to the embodiment. [Figure 9] 10A and 10B are diagrams showing changes in the shape of a fiber portion when the number of times discharge processing is performed on a target coordinate is changed in a papermaking process of a three-dimensional fiber forming system according to an embodiment. [Figure 10] 10 is a diagram showing the change in the shape of the fiber portion when the number of times of discharge processing in the X direction from the target coordinate is changed in the papermaking process of the three-dimensional fiber formation system according to the embodiment. FIG. [Figure 11]1 is a diagram (part 1) showing an example of papermaking pattern data and the shape of a three-dimensional fiber in a papermaking process of a three-dimensional fiber forming system according to an embodiment. FIG. [Figure 12] FIG. 2 is a diagram (part 2) showing an example of papermaking pattern data and the shape of a three-dimensional fiber in the papermaking process of the three-dimensional fiber forming system according to the embodiment. [Figure 13] 1 is a flowchart showing each step of a process in which a user forms a three-dimensional fiber using a three-dimensional fiber forming system according to an embodiment. [Figure 14] 4 is a flowchart showing the contents of a paper making control process (paper making control program) by a control terminal (paper making control processing unit) according to the embodiment. [Figure 15] 1 is a photograph (a drawing substitute photograph) taken of a three-dimensional fiber formed using a three-dimensional fiber forming system according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0012] (A) Main embodiment Hereinafter, an embodiment of a three-dimensional fiber forming system, a three-dimensional fiber forming program, and a three-dimensional fiber forming method according to the present invention will be described in detail with reference to the drawings.

[0013] (A-1) Configuration of the embodiment FIG. 1 is a diagram (perspective view) showing the overall configuration of a three-dimensional fiber forming system 1. As shown in FIG.

[0014] The three-dimensional fiber forming system 1 includes a positioning device 10, a papermaking stage 20, a molding material storage section 30 for storing (accumulating) molding material 31, a tube 40, a pump device 50, and a control terminal 60.

[0015] The three-dimensional fiber forming system 1 is a system for obtaining a molded product (hereinafter also referred to as "three-dimensional fiber") B in which fibers contained in a molding material 31 composed of a viscous liquid containing fibers are formed (formed by additive manufacturing) into a shape according to the control of a control terminal 60.

[0016] The molding material storage section 30 has the function of storing a viscous molding material 31. The shape of the molding material storage section 30 is not limited, but the molding material storage section 30 shown in Fig. 1 is configured as a cylindrical container with an opening formed on the upper side.

[0017] The papermaking stage 20 receives the discharged forming material 31 on its upper surface and forms three-dimensional fibers B through a process similar to papermaking (e.g., Japanese papermaking). The papermaking stage 20 is configured with a ring-shaped (or rectangular) frame 21 and a papermaking net 22 stretched over it. The shape of the frame 21 is not limited, but in this embodiment, it is rectangular (or square-shaped). Various metals, wood, and other materials can be used for the frame 21. In this embodiment, the frame 21 is described as being made of wood. When the papermaking net 22 receives the discharged forming material 31 from above, it receives the fibers contained in the forming material 31 while allowing most of the liquid to fall to the bottom (i.e., a process similar to papermaking, hereinafter also referred to as the "papermaking process"), forming a fiber layer on its upper surface. The fiber layer formed on the upper surface of the papermaking net 22 will form three-dimensional fibers B when it dries. The specifications of the papermaking net 22 (e.g., material and mesh specifications) must be suitable for the papermaking process (a process that receives the fibers of the molding material 31 while allowing most of the liquid to pass through). The material of the papermaking net 22 is preferably one that peels easily after the fibers dry. For example, nets made of vinyl chloride, polyethylene, or stainless steel can be used as the material for the papermaking net 22. Furthermore, for example, the mesh specifications (distribution, density) of the papermaking net 22 are preferably approximately 40 to 80 meshes. "Mesh" is a unit that indicates the mesh specifications of the net and indicates the number of openings per inch (25.4 mm). For example, 60 mesh indicates that there are 60 openings per inch. For example, 60 mesh has a mesh pitch of approximately 0.423 mm and a porosity of 37.78%. In this embodiment, the papermaking net 22 is a 60-mesh vinyl chloride net.

[0018] The tube 40 is a pipe (transport path) for transporting the molding material 31 stored in the molding material storage section 30 to the papermaking stage 20. The tube 40 is a pipe with a predetermined inner diameter made of a flexible (elastic) material, and the material and inner diameter are not limited. In this embodiment, the tube 40 is described as a polyvinyl chloride tube with an inner diameter of 6 mm. One end (inlet 41) of the tube 40 is immersed in the molding material 31 (viscous liquid) in the molding material storage section 30, and the other end (outlet 42) is attached to the positioning device 10.

[0019] The pump device 50 applies stress to the tube 40 to change the pressure inside the tube 40, thereby pumping the molding material 31 through the tube 40. In other words, the pump device 50 draws the molding material 31 through the suction port 41 of the tube 40 and discharges it through the discharge port 42. Although the type of pump device 50 is not limited, in this embodiment, a so-called roller type is applied. The pump device 50 is equipped with a roller 51 that rotates (driven by a motor, not shown) while squeezing the tube 40, and is configured to apply negative pressure to the suction port 41 side and positive pressure to the discharge port 42 side as the roller 51 rotates. The pump device 50 rotates the roller 51 at a predetermined angular velocity and by a predetermined rotation angle under the control of the control terminal 60.

[0020] An existing pump can be applied to the pump device 50. The connection configuration between the control terminal 60 and the pump device 50 is not limited, and may be configured using a serial bus cable such as a USB (Universal Serial Bus), for example.

[0021] The positioning device 10 is a device for positioning the position of the discharge outlet 42 of the tube 40 (the position where the molding material 31 is discharged and discharged) above the papermaking stage 20. The positioning device 10 determines the position (XY coordinates) of the discharge outlet 42 when the upper surface of the papermaking stage 20 (the upper surface of the papermaking net 22) is a two-dimensional plane (XY plane) defined by the X axis and the Y axis, in accordance with the control of the control terminal 60. The positioning device 10 is equipped with a head 14 for holding (fixing) the discharge outlet 42, and when coordinates on the XY plane are input from the control terminal 60, the head 14 is moved to a position corresponding to the input coordinates.

[0022] An existing device can be applied to the positioning device 10. The connection configuration between the control terminal 60 and the positioning device 10 is not limited, and may be configured using, for example, a serial bus cable such as a USB.

[0023] In this embodiment, the papermaking stage 20 is placed on a horizontal or approximately horizontal surface (hereinafter referred to as the "ground surface"), and the upper surface (XY plane) of the papermaking stage 20 is also assumed to be a surface parallel to the ground surface. Figure 1 illustrates the X-axis and Y-axis directions on the upper surface of the papermaking stage 20 (the upper surface of the papermaking net 22). In the following, the direction perpendicular to the upper surface (XY plane) of the papermaking stage 20 (i.e., the vertical direction or approximately vertical direction, height direction) is referred to as the Z-axis.

[0024] In positioning device 10, the configuration for moving head 14 along the XY plane is not limited, and various configurations can be applied. In this embodiment, positioning device 10 includes X-slider 13, which is a linear slider (linear guide) for holding head 14 and moving it in the X-axis direction, and a pair of Y-sliders 11 and 12, which are linear sliders (linear guides) for holding X-slider 13 and moving it in the Y-axis direction. In positioning device 10, the movement of head 14 (movement on X-slider 13) and the movement of X-slider 13 (movement on Y-sliders 11 and 12) are realized by a drive mechanism such as a motor or belt (not shown). In other words, when coordinates on the XY plane are input from control terminal 60, positioning device 10 controls the drive mechanism to move head 14 to a position corresponding to the input coordinates.

[0025] FIG. 2 is a diagram showing an example of a coordinate system model of the XY plane in the positioning device 10 and the papermaking stage 20. As shown in FIG.

[0026] The XY plane shown in Fig. 2 is represented by an X axis gridded (divided) by N coordinates 0 to N, and a Y axis gridded (divided) by M coordinates 0 to M. In Fig. 2, the origin of the XY plane (the position where X = 0, Y = 0) is shown as P0. Here, as shown in Fig. 1, the explanation will be given assuming that the inner corner of the rectangular frame 21 (the corner of the papermaking net 22; the corner on the far left side when viewed from the direction of Fig. 1) is the origin P0.

[0027] FIG. 3 is a diagram (image) showing the steps of the papermaking process in the three-dimensional fiber forming system 1.

[0028] FIG. 4 is a diagram (image) showing the steps of papermaking and drying in the three-dimensional fiber forming system 1.

[0029] 3 shows a cross-sectional view of the papermaking stage 20 cut along the ZX plane (a plane represented by the Z axis and the X axis). As shown in FIG. 3, in the papermaking stage 20 of this embodiment, the papermaking net 22 is slightly larger than the frame 21, and the outer edge of the papermaking net 22 is fixed to the frame 21 with a plurality of staplers 23. Note that the number and arrangement of the staplers 23 are not limited as long as the papermaking net 22 can be stretched over the frame 21 with a tension sufficient to withstand the papermaking process. Furthermore, the method of fixing the papermaking net 22 to the frame 21 is not limited as long as the papermaking net 22 can be stretched over the frame 21 with a tension sufficient to withstand the papermaking process. Furthermore, if the papermaking net 22 can be stretched over the frame 21 with a tension sufficient to withstand the papermaking process, there is no need to use the frame 21.

[0030] 3, when the molding material 31 discharged from the discharge port 42 of the tube 40 falls onto the papermaking net 22, a fibrous portion B101 of the molding material 31 remains on the upper surface of the papermaking net 22, and a liquid portion B102 of the molding material 31 falls below the papermaking net 22. In other words, the papermaking net 22 separates the discharged molding material 31 into the fibrous portion B101 (including mucus adhering to the fibers) and the liquid portion 102, and only the fibrous portion remains above the papermaking net 22.

[0031] FIG. 4 is a diagram (image) showing the steps of papermaking and drying in the three-dimensional fiber forming system 1.

[0032] FIG. 4(a) shows the papermaking process, and FIG. 4(b) shows the drying process. FIG. 4(a) also shows the fiber portion B101 remaining on the upper surface of the papermaking stage 20 after the papermaking process and the liquid portion B102 that falls to the lower side. After the papermaking process, the water contained in the fiber portion B101 is removed by the drying process, and when it dries, it turns into three-dimensional fiber B. Finally, this three-dimensional fiber B is obtained by peeling it off from the papermaking stage 20. The three-dimensional fiber B may be peeled off from the papermaking stage 20 by an operator's fingers, or a peeling tool (such as a scraper) may be used.

[0033] Through the above steps, the three-dimensional fiber forming system 1 forms a three-dimensional fiber.

[0034] FIG. 5 is a block diagram showing the functional configuration of the control terminal 60. As shown in FIG.

[0035] As shown in FIG. 5, the control terminal 60 has a papermaking control processing unit 61, a pump control unit 62, a positioning control unit 63, and a papermaking pattern data storage unit 64.

[0036] The control terminal 60 may be realized by hardware (for example, a dedicated chip) or software (a computer program). For example, the control terminal 60 may be realized by installing a program (including the three-dimensional fiber forming program according to the embodiment) in a computer equipped with a processor and memory (not shown). The three-dimensional fiber forming program according to this embodiment is realized by elements (subprograms) including a papermaking control processing unit 61, a pump control unit 62, a positioning control unit 63, and a papermaking pattern data storage unit 64.

[0037] The pump control unit 62 has a function of controlling the pump device 50 in accordance with instructions from the papermaking control processing unit 61. For example, the pump control unit 62 controls the ON / OFF state of the pump device 50 in accordance with instructions from the papermaking control processing unit 61.

[0038] The positioning control unit 63 has the function of controlling the positioning device 10 in accordance with the control of the papermaking control processing unit 61. For example, when information of XY coordinates (coordinates on the XY plane) is input from the papermaking control processing unit 61, the positioning control unit 63 controls the positioning device 10 to move the head 14 (discharge outlet 42) to a position corresponding to the XY coordinates.

[0039] The papermaking pattern data storage unit 64 has the function of storing data (hereinafter referred to as "papermaking pattern data") indicating a collection (pattern) of positional information (coordinates) for discharging the forming material 31 on the XY plane in the papermaking process of the three-dimensional fiber forming system 1. The papermaking pattern data may be information that sets values ​​(hereinafter also referred to as "coordinate values") indicating the content of discharging the forming material 31 for each coordinate, and the specific data format is not limited. For example, the papermaking pattern data may be configured using an N x M array formula or structure to describe the coordinate values ​​of each coordinate on the XY plane. The method of expressing each coordinate value is also not limited. For example, a value indicating whether or not to discharge (e.g., "1" for discharge and "0" for not discharge) or a value indicating the number of times to discharge (e.g., "1" for discharge once and "2" for discharge twice) may be set.

[0040] In other words, if the molded product formed on the XY plane is viewed as an image, each coordinate value can also be viewed as a pixel value, and the papermaking pattern data (a collection of coordinate values / pixel values) can also be viewed as image data showing the papermaking pattern (hereinafter also referred to as "papermaking image data").

[0041] The papermaking control processing unit 61 acquires papermaking pattern data from the papermaking pattern data storage unit 64, and controls the positioning device 10 and the pump device 50 so that papermaking processing is performed according to the acquired papermaking pattern data, thereby performing processing to form three-dimensional fibers according to the papermaking pattern data on the papermaking stage 20. At this time, the papermaking control processing unit 61 controls the pump device 50 via the pump control unit 62, and controls the positioning device 10 via the positioning control unit 63. Specifically, the papermaking control processing unit 61 performs processing to control the positioning control unit 63 and the pump device 50 so that the formed material 31 is discharged to coordinates according to the papermaking pattern data (hereinafter also referred to as "discharge control processing" or "papermaking control processing").

[0042] Next, the details of the discharge control process performed by the papermaking control processor 61 will be described.

[0043] FIG. 6 is a diagram showing the operation of the papermaking control processor 61 to perform discharge control processing at a desired coordinate (hereinafter referred to as "target coordinate") P2 (X=n, Y=m) on the XY plane.

[0044] FIG. 6(a) shows the area (hereinafter referred to as the "fiber-diffused area") where the fiber portion B101 diffuses, centered on the target coordinate P2, when the fiber portion B101 is positioned at the target coordinate P2 and discharged. As shown in FIG. 6(a), the fiber-diffused area spreads concentrically around the target coordinate P2. In FIG. 6(a), the radius of this circular fiber-diffused area (hereinafter referred to as the "diffused radius") is denoted as rs. Hereinafter, the X direction will also be referred to as the horizontal direction, and the Y direction will also be referred to as the vertical direction. Furthermore, below, the direction intersecting the X and Y directions will also be referred to as the diagonal direction. For example, when viewed from the target coordinate P2 (X=n, Y=m), the coordinates of (X=n+1, Y=m), (X=n-1, Y=m), (X=n, Y=m+1), and (X=n, Y=m-1) are either vertical or horizontal. Also, for example, when viewed from the target coordinate P2 (X=n, Y=m), the coordinates (X=n+1, Y=m+1), (X=n+1, Y=m-1), (X=n-1, Y=m+1), and (X=n-1, Y=m-1) are diagonal coordinates. In the following, the distance between adjacent coordinates in the vertical and horizontal directions (X and Y directions) (hereinafter also referred to as "grid width") is represented as D1, and the distance between adjacent coordinates in the diagonal direction (hereinafter also referred to as "diagonal grid width") is represented as D2. Here, since the grid width in both the X and Y directions is D1, D2 is obtained by multiplying D1 by 2. -1 The value is multiplied by (the square root of 2).

[0045] The larger the amount of molding material 31 discharged in one go (hereinafter referred to as "one-time discharge amount") in the discharge process controlled by the papermaking control processing unit 61, the longer this diffusion radius rs becomes. In other words, the larger the one-time discharge amount, the larger the area of ​​the fiber diffusion region. The one-time discharge amount is proportional to the period during which the papermaking control processing unit 61 keeps the pump device 50 in the ON state in one discharge process (hereinafter referred to as "one-time discharge period").

[0046] In this embodiment, the one-time discharge amount (i.e., one-time discharge period) and the like are adjusted so that the diffusion radius rs becomes a predetermined target value (hereinafter referred to as the "target diffusion radius") R1 that has been designed in advance.

[0047] Here, the relationship between the diffusion radius rs for each coordinate and the fiber diffusion area over the entire XY plane will be explained.

[0048] 7 and 8 are diagrams showing the relationship between the diffusion radius rs and the fiber diffusion area over the entire XY plane.

[0049] Figures 7(a), 7(b), and 8 are diagrams showing the fiber-dispersed region when rs satisfies the following formulas (1) to (3). In Figures 7 and 8, the fiber-dispersed region is shown with hatching (diagonal line pattern). rs <D1 / 2…(1) D1 / 2≦rs <D2 / 2…(2) D2 / 2≦rs <D1…(3)

[0050] As shown in Figure 7(a), when rs satisfies formula (1) (when rs is less than half the grid width D1), the fiber-dispersed regions of adjacent coordinates do not overlap. Also, as shown in Figure 7(b), when rs satisfies formula (2) (when rs is greater than or equal to D1 / 2 and less than D2 / 2), the fiber-dispersed regions of adjacent coordinates in both the vertical and horizontal directions overlap, but the fiber-dispersed regions of adjacent coordinates in both diagonal directions overlap. Furthermore, as shown in Figure 8, when rs satisfies formula (3) (when rs is greater than or equal to D2 / 2 and less than D1), the fiber-dispersed regions of adjacent coordinates not only in the vertical and horizontal directions but also in the diagonal directions overlap. Furthermore, when rs is greater than or equal to D1, the fiber-dispersed regions of adjacent coordinates overlap not only in the vertical and horizontal directions but also in the diagonal directions. To achieve a uniform fiber-dispersed region, it is desirable to set the diffusion radius rs within the range of formula (3).

[0051] In other words, the shape and texture of the final fiber portion B101 (three-dimensional fiber B) will differ depending on the spreading radius rs (target spreading radius R1). For example, if the user determines the single discharge period corresponding to the desired target spreading radius R1 and sets the determined single discharge period in the papermaking control processor 61, the user can obtain the fiber portion B101 (three-dimensional fiber B) with the desired shape and texture. In other words, it is desirable that the papermaking control processor 61 be able to set this single discharge period as a variable parameter (for example, settable in response to user operation).

[0052] Next, a specific example of the grid width D1 and the discharge amount per one time will be described.

[0053] In an experiment conducted by the inventors (hereinafter referred to as "this experiment"), the grid width D1 was varied from 6 mm to 10 mm and the discharge amount per discharge was varied from 5 ml to 20 ml, and the change in the diffusion radius rs was confirmed. In this experiment, when the grid width D1 was 9 mm and the discharge amount per discharge was 10 cc, the diffusion radius rs fell within the range of the above formula (3). In other words, this experiment found that when the grid width D1 was 9 mm, the single discharge period should be set so that the discharge amount per discharge is 10 cc in order to bring the target diffusion radius R1 within the range of the above formula (3). Note that if the pump device 50 is capable of discharging the molding material 31 of a single discharge amount in response to an input of the discharge amount per discharge, it is necessary to input the discharge amount per discharge (e.g., 10 cc) rather than the single discharge period.

[0054] Next, the thickness (height direction) distribution in the fiber portion B101 (fiber dispersion region) will be described with reference to FIGS.

[0055] FIG. 9 is a diagram (cross-sectional view including the papermaking stage 20 and the fiber portion 101) showing the change in the shape of the fiber portion B101 when the number of times the discharge process is performed on the target coordinate P2 (X=n, Y=m) is changed.

[0056] 9(a) to 9(c) show the shape (thickness distribution; cross-sectional view) of the fiber portion B101 when the number of discharge processes is increased to once, twice, and three times at the target coordinate P2 (X=n, Y=m). As shown in Fig. 9, the thickness of the fiber portion B101 increases (the height increases) as the number of discharge processes increases.

[0057] Figure 10 is a diagram (cross-sectional view including the papermaking stage 20 and the fiber part 101) showing the change in shape of the fiber part B101 (change in shape in the X direction) when the number of times the discharge process is performed in the X direction from the target coordinate P2 (X = n, Y = m) is changed.

[0058] As shown in FIG. 10, by changing the number of times the discharge process is performed for each coordinate, it is possible to control the distribution of the thickness (height) of the fiber portion B101 for each coordinate.

[0059] 11 and 12 are diagrams showing examples of papermaking pattern data and the shape of the fiber portion B101 obtained as a result of the papermaking process.

[0060] 11(a) and 12(a) each show an example of papermaking pattern data, and FIG. 11(b) and 12(b) each show an example of the shape (distribution) of the fiber portion B101 obtained as a result of the papermaking process.

[0061] In Fig. 11(a) and Fig. 12(a), for ease of explanation, the papermaking pattern data is shown as matrix data represented by a 9x9 (N=M=9) coordinate system (X: 1 to 9, Y: 1 to 9). In the papermaking pattern data shown in Fig. 11(a) and Fig. 12(a), a value for the number of times the discharge process is to be performed is set for each coordinate. For example, in Fig. 11(a) and Fig. 12(a), coordinates set to a value of 0 indicate that the discharge process is not to be performed, and coordinates set to a value of 1 or greater indicate that the discharge process is to be performed the number of times indicated by that value. In Fig. 11(b) and Fig. 12(b), areas where the discharge process has been performed once are shown as B101a, and areas where the discharge process has been performed twice are shown as B101b, with different hatching (diagonal line patterns).

[0062] The order in which the papermaking control processing unit 61 performs the discharge process according to the papermaking pattern data is not limited, as long as the discharge process is performed the number of times corresponding to the coordinate value at the position corresponding to each coordinate. For example, for coordinates with a coordinate value of two or more, the papermaking control processing unit 61 may perform the discharge process multiple times at once, or may perform the discharge process at intervals. For example, the papermaking control processing unit 61 may perform the discharge process by dividing each coordinate into layers according to the height corresponding to the coordinate value. Hereinafter, the pattern for each coordinate value (height) in the papermaking pattern data will also be referred to as a "layer." For example, in the papermaking pattern data shown in FIG. 11(a), the maximum coordinate value is 1, so the papermaking pattern data is composed of one layer with a coordinate value of 1. For example, in the papermaking pattern data shown in FIG. 12(a), the maximum coordinate value is 2, so the papermaking pattern data is composed of two layers: a first layer with a coordinate value of 1 and a second layer with a coordinate value of 2. In other words, the papermaking pattern data includes layer images (hereinafter referred to as "layer images") equal to the number of maximum coordinate values.

[0063] As described above, the papermaking control processing unit 61 may perform the discharge process for each layer of the papermaking pattern data. For example, in the case of the papermaking pattern data shown in Fig. 12(a), the papermaking control processing unit 61 may first acquire a coordinate group having a coordinate value of 1 or more (1 or 2) as a first layer image and discharge the same, and then acquire a coordinate group having a coordinate value of 2 or more (2) as a second layer image and discharge the same.

[0064] In addition, in this embodiment, even if the papermaking pattern data has a structure including multiple layer images, it is expressed as one matrix data as shown in Figures 11 and 12, but it may be expressed as different matrix data (matrix image) for each layer image. In other words, the papermaking pattern data is not limited to the format of Figures 11 and 12, and layer images may be expressed in various formats.

[0065] Next, an example of the configuration of the molding material 31 will be described.

[0066] The composition of the forming material 31 can be the same as that of the raw material liquid generally used in producing Japanese paper (papermaking). Therefore, the fiber portion B101 and the three-dimensional fiber B have the same composition as that of Japanese paper.

[0067] Generally, the raw material liquid for Japanese paper is obtained by adding fibers (e.g., fibers from plants such as paper mulberry, Mitsumata, and gampi) to a viscous liquid made by mixing water and a substance called "neri" (e.g., a substance derived from the roots of plants such as Abelmoschus tschonoskii) and stirring the mixture. The Neri used in the forming material 31 may be a plant-derived substance such as Abelmoschus tschonoskii, or a chemical substance (e.g., polyethylene oxide or polyacrylamide). The fibers used in the forming material 31 may also be plant-derived or synthetic fibers (e.g., recycled fibers such as rayon or cupra, or various flame-retardant fibers). Adding Neri to the raw material liquid for Japanese paper helps to maintain a uniform distribution of fibers in the liquid.

[0068] (A-2) Operation of the embodiment Next, the operation of the three-dimensional fiber formation system 1 according to this embodiment (the three-dimensional fiber formation method according to this embodiment) will be described.

[0069] FIG. 13 is a diagram showing each step of the process in which a user (operator) forms a three-dimensional fiber using the three-dimensional fiber forming system 1.

[0070] First, it is assumed that the molding material 31 is prepared by the user and placed in the molding material storage unit 30 (S101).

[0071] Next, it is assumed that the papermaking pattern data used in the papermaking process is set in the papermaking pattern data storage unit 64 of the control terminal 60 by user operation (S102). Note that the method for storing the papermaking pattern data used in the papermaking process in the control terminal 60 (papermaking pattern data storage unit 64) is not limited, and the control terminal 60 may accept online or offline uploads or downloads, or may accept direct input from the user (for example, input by operating a keyboard, etc.).

[0072] Next, the user operates the control terminal 60 (papermaking control processing unit 61) and starts (executes) the program for the discharge control process (papermaking control process) (S103). The papermaking control processing unit 61 controls the positioning device 10 and the pump device 50 according to the set papermaking pattern data, discharges the formed material 31 on the papermaking stage 20 according to the papermaking pattern data, and forms a fiber portion B101 on the papermaking stage 20 in a shape according to the papermaking pattern data.

[0073] Next, when the fiber portion B101 formed on the papermaking stage 20 is dried for a predetermined time (for example, by natural drying by leaving it for a predetermined time or by drying with heat, air, etc.) (S104), the fiber portion B101 is dehydrated and becomes three-dimensional fiber B. Furthermore, the fiber portion B101 may be squeezed (pressurized) before drying, as in the manufacturing process of Japanese paper. Then, when this three-dimensional fiber B is peeled off from the papermaking stage 20 (S105), the three-dimensional fiber B is completed. The obtained three-dimensional fiber B may be used as is, or may be further pressed (for example, by a roller or press) and processed into paper (for example, paper for writing brushes). Note that the three-dimensional fiber B does not necessarily have to function as paper.

[0074] By applying pressure to the three-dimensional fiber B (fiber part B101) before and after the drying process, the thickness (dimension in the Z direction; height) of the three-dimensional fiber B (fiber part B101) becomes roughly uniform throughout, but the density becomes higher (stronger; more rigid) in the parts that are discharged more frequently.

[0075] Next, a specific example of the discharge control process (papermaking control process) by the control terminal 60 (papermaking control processing unit 61) in step S103 will be described.

[0076] FIG. 14 is a flowchart showing the contents of the paper making control process (paper making control program) by the control terminal 60 (paper making control processing unit 61).

[0077] When the papermaking control processing unit 61 starts its operation, it first reads all of the papermaking pattern data set in the papermaking pattern data storage unit 64 (S201).

[0078] Next, the papermaking control processing unit 61 acquires a layer image for one layer of the read papermaking pattern data (S202), and controls the discharge process for one layer (S203).

[0079] Next, the paper making control processing unit 61 checks whether there is an unprocessed layer (S204), and if there is an unprocessed layer, the operation returns to step S202 described above, and if not, the process ends.

[0080] Next, the results of an experiment (hereinafter referred to as "this experiment") in which the inventor of the present application actually constructed a three-dimensional fiber forming system 1 and produced three-dimensional fiber B (three-dimensional fiber B) will be described.

[0081] In this experiment, paper mulberry fibers (commonly processed for washi paper production) were used as the fiber, and a mixed powder of polyethylene oxide and polyacrylamide (commonly sold for washi paper production) was used as the adhesive (neri). Specifically, a papermaking adhesive manufactured by Awagami Factory (Awa Handmade Washi Commerce and Industry Cooperative) (https: / / awagami.jp / collections / material / products / 8822110) was used. Furthermore, in this experiment, a mixture of 1000 ml of water, 10 g of paper mulberry fibers, and 0.5 g of adhesive (neri) was used as the molding material 31. The above mixture ratio in the molding material 31 is the same as the raw material liquid used in general washi paper production.

[0082] In this experiment, the grid width D1 was 9 mm and the discharge volume per cycle was 10 cc. In this case, the thickness of the three-dimensional fiber B (molded product) obtained by one discharge process was approximately 12 μm, and the diffusion radius rs was within the range satisfying equation (3) (the range shown in Figure 8). In this experiment, the thickness of the three-dimensional fiber B obtained increased in proportion to the number of discharge processes (the number of discharge processes for the same coordinate). In other words, the thickness of the three-dimensional fiber B obtained by 10 discharge processes for each coordinate was approximately 120 μm. In this way, the three-dimensional fiber forming system 1 can adjust the thickness distribution of the three-dimensional fiber B obtained by adjusting the number of discharge processes (the number of layers) based on the papermaking pattern data.

[0083] FIG. 15 is a photograph (a drawing substitute photograph) of the three-dimensional fiber B actually formed in this experiment, taken obliquely from above.

[0084] The photograph shown in Figure 15, which serves as a substitute for a drawing, shows the white three-dimensional fiber B against a black background. The three-dimensional fiber B shown in Figure 15 has not been subjected to any particular pressing or welding, and therefore has a very light texture (the texture of a low-density fiber).

[0085] (A-3) Effects of the embodiment According to this embodiment, the following effects can be achieved.

[0086] In the three-dimensional fiber forming system 1, three-dimensional fiber B having a shape according to the papermaking pattern data can be formed on the papermaking stage 20 by performing papermaking processing (discharge processing of molding material 31) according to the papermaking pattern data on the papermaking stage 20 under the control of the control terminal 60 (papermaking control processing unit 61).

[0087] In addition, in the three-dimensional fiber forming system 1, the diffusion radius rs can be controlled according to the one-time discharge amount (one-time discharge period) applied during the papermaking process (discharge process of the molding material 31), and the shape and texture of the three-dimensional fiber B can be adjusted.

[0088] Furthermore, in the three-dimensional fiber formation system 1, the thickness distribution of the three-dimensional fiber B can be adjusted by adjusting the number of discharge processes for each coordinate during the papermaking process (discharge process of the molding material 31). In normal papermaking to produce Japanese paper, it is difficult to change the thickness (fiber density, hereinafter simply referred to as "density") for each region, but in the three-dimensional fiber formation system 1, the thickness (density) for each region of the three-dimensional fiber B can be easily adjusted simply by adjusting the number of discharge processes for each coordinate as described above.

[0089] Furthermore, the high-density portions of the three-dimensional fiber B have increased strength (for example, tear strength and tensile strength) and rigidity. In other words, the strength and rigidity of each region of the three-dimensional fiber B can be adjusted by adjusting the number of discharge processes for each region (coordinate). This means that when bending or rolling the three-dimensional fiber B to form a structure (for example, a lighting fixture cover), the structure can be easily formed without the need for a separate core material or the like. In other words, the three-dimensional fiber formation system 1 of this embodiment (the three-dimensional fiber formation method of this embodiment) can easily form the three-dimensional fiber B that forms the structure without the need for a separate core material or the like.

[0090] Furthermore, in the denser portions of the three-dimensional fiber B, the translucency (light transmittance) decreases (light blocking properties increase). By utilizing these characteristics, the three-dimensional fiber forming system 1 of this embodiment (the three-dimensional fiber forming method of this embodiment) adjusts the number of discharge processes for each region (coordinate), thereby controlling the translucency (light blocking properties) for each region (coordinate), facilitating processing such as making a watermark (a watermark with a pattern corresponding to the papermaking pattern data) appear on the three-dimensional fiber B. For example, a suitable application example is to apply the three-dimensional fiber B to a lighting fixture cover.

[0091] (B) Other embodiments The present invention is not limited to the above-described embodiments, and may include modified embodiments such as those exemplified below.

[0092] (B-1) In the above embodiment, the positioning device 10 is provided with one supply mechanism (molding material storage unit 30, tube 40, and pump device 50) for the molding material 31. However, multiple supply mechanisms may be provided. For example, different colors of fibers may be fed into the first supply mechanism and the second supply mechanism to adjust the distribution of the two colors in one fiber portion B101 (three-dimensional fiber B) (i.e., to produce a two-color image). In this case, the papermaking pattern data storage unit 64 must store papermaking pattern data for each supply mechanism (each color of molding material 31). Alternatively, the positioning device 10 may be provided with supply mechanisms for each of the three primary colors, red (R), green (G), and blue (B), to produce a color image on one fiber portion B101 (three-dimensional fiber B) (i.e., a color printer configuration).

[0093] (B-2) In the above embodiment, as shown in FIG. 12, a single papermaking process based on one papermaking pattern data is performed to form three-dimensional fiber B (fiber portion B101). However, a single three-dimensional fiber B (fiber portion B101) may be formed by multiple consecutive papermaking processes (two or more consecutive times) based on one or more papermaking pattern data. For example, after a first papermaking process based on first papermaking pattern data, a second papermaking process based on the first papermaking pattern data or second papermaking pattern data different from the first papermaking pattern data may be performed to form one three-dimensional fiber B (fiber portion B101). After the first papermaking process and before the second papermaking process, an object other than fiber (e.g., a foreign object such as a decorative film or metal part) may be placed (e.g., by the user) on fiber portion B101, and then a second papermaking process may be performed to form three-dimensional fiber B with the foreign object sandwiched between two layers of fiber portion B101. By sandwiching a foreign substance between two layers of fiber portion B101, the range of expression when molding three-dimensional fiber B is expanded. [Explanation of symbols]

[0094] 1...3D fiber forming system, 10...positioning device, 11, 12...Y slider, 13...X slider, 14...head, 20...papermaking stage, 21...frame, 22...papermaking net, 23...stapler, 30...molding material storage section, 31...molding material, 40...tube, 41...suction port, 42...discharge port, 50...pump device, 51...roller, 60...control terminal, 61...papermaking control processing section, 62...pump control section, 63...positioning control section, 64...papermaking pattern data storage section, 101...fiber portion, 102...liquid portion, B...3D fiber, B101...fiber portion, B102...liquid portion, B...3D fiber, D1...grid width, D2...diagonal grid width

Claims

1. a stage having a plane formed by a net; a supply mechanism that stores a molding material containing a viscous liquid with suspended fibers and discharges the molding material onto the flat surface from a discharge port that discharges the molding material; a positioning mechanism for positioning the outlet above the stage; and a pattern data storage means for storing pattern data indicating a pattern for discharging the molding material onto the plane; a control means for controlling the positioning mechanism and the supply mechanism so as to discharge the molding material onto the plane in accordance with the pattern data; A three-dimensional fiber forming system comprising:

2. a computer mounted on a control device that controls a supply mechanism that stores a molding material containing a viscous liquid with suspended fibers and discharges the molding material from an outlet that discharges the molding material onto a stage having a flat surface formed by a net, and a positioning mechanism that positions the outlet above the stage; a pattern data storage means for storing pattern data indicating a pattern for discharging the molding material onto the plane; a control means for controlling the positioning mechanism and the supply mechanism so as to discharge the molding material onto the plane in accordance with the pattern data; A three-dimensional fiber formation program characterized by functioning as follows.

3. A three-dimensional fiber forming method performed by a three-dimensional fiber forming system comprising: a stage having a plane formed by a net; a supply mechanism that stores a molding material containing a viscous liquid with suspended fibers and discharges the molding material from a discharge port onto the plane; a positioning mechanism for positioning the discharge port above the stage; and a control device, the control device includes a pattern data storage means and a control means; the pattern data holding means holds pattern data indicating a pattern for discharging the molding material onto the plane; The control means controls the positioning mechanism and the supply mechanism so as to discharge the molding material onto the plane in accordance with the pattern data. A method for forming a three-dimensional fiber.

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