Method for manufacturing three-dimensional object, intermediate structure, and molding system

Abstract

To provide a method for manufacturing a three-dimensional object, an intermediate structure, and a molding system that can be easily manufactured.SOLUTION: A method for manufacturing a three-dimensional object includes a coating step and a bending step. In the coating step, a coating material 13 containing a conversion component that converts electromagnetic waves into heat is applied to a linear application position on a surface of a molded sheet 10. In the bending step, electromagnetic waves are irradiated onto the molded sheet 10 from a side of the surface to which the coating material 13 was applied in the coating step, thereby bending the molded sheet 10 at the application position. The molded sheet 10 has a first layer that shrinks when heated and a second layer that shrinks less when heated than the first layer.SELECTED DRAWING: Figure 9

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a three-dimensional object, an intermediate structure, and a modeling system. [Background technology]

[0002] There are known techniques for manufacturing three-dimensional objects. For example, Patent Document 1 discloses a technique for manufacturing a three-dimensional synthetic resin molded product using a synthetic resin sheet material. Also, Patent Document 2 discloses a technique for manufacturing a bellows-shaped cover. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6166304 [Patent Document 2] Japanese Patent Application Laid-Open No. 2016-198969 Summary of the Invention [Problem to be solved by the invention]

[0004] In the technology for manufacturing the above-mentioned three-dimensional objects, there is a demand for an easier method for manufacturing the three-dimensional objects.

[0005] The present invention has been made to solve the above-mentioned problems, and has an object to provide a method for manufacturing a three-dimensional object that can be easily manufactured, an intermediate structure, and a modeling system. [Means for solving the problem]

[0006] In order to achieve the above object, the method for manufacturing a three-dimensional object according to the present invention includes a coating step of applying a coating material containing a conversion component that converts electromagnetic waves into heat to a linear coating position on the surface of a molded sheet, and a bending step of bending the molded sheet at the coating position by irradiating the electromagnetic waves onto the molded sheet from the side of the surface to which the coating material has been applied in the coating step, wherein the molded sheet has a first layer that shrinks when heated and a second layer whose shrinkage due to heating is smaller than that of the first layer. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a method for manufacturing a three-dimensional object, an intermediate structure, and a modeling system that can be easily manufactured. [Brief explanation of the drawings]

[0008] [Figure 1A] 1 is an external view of a three-dimensional object according to a first embodiment. [Figure 1B] 1A and 1B are diagrams illustrating the developed shape of a three-dimensional object according to the first embodiment. [Figure 1C] 1A to 1C are diagrams illustrating an example of assembling a three-dimensional object according to the first embodiment from molding sheets. [Figure 2] FIG. 2 is a cross-sectional view of a molded sheet according to the first embodiment. [Figure 3] FIG. 1 is a block diagram showing a configuration of a modeling system according to a first embodiment. [Figure 4] FIG. 2 is a cross-sectional view of an intermediate structure according to the first embodiment. [Figure 5] 3 is a diagram showing the front surface of the intermediate structural body according to the first embodiment. FIG. [Figure 6] 6 is a diagram showing an example in which the intermediate structure shown in FIG. 5 is cut out into a developed shape of a three-dimensional object. FIG. [Figure 7A] 1 is a side view of an irradiation device according to a first embodiment. [Figure 7B] 1 is a top view of an irradiation device according to a first embodiment. [Figure 8] 4A and 4B are diagrams illustrating an example in which an intermediate structure according to the first embodiment is irradiated with electromagnetic waves. [Figure 9] 10A and 10B are diagrams showing an example of a bent intermediate structure according to the first embodiment. [Figure 10] 1 is a flowchart showing the flow of a method for manufacturing a three-dimensional object according to the first embodiment. [Figure 11A] FIG. 10 is an external view of a three-dimensional object according to a second embodiment. [Figure 11B] FIG. 10 is a diagram showing the developed shape of a three-dimensional object according to the second embodiment. [Figure 12] FIG. 6 is a cross-sectional view of a molded sheet according to a second embodiment. [Figure 13] FIG. 10 is a cross-sectional view of an intermediate structure according to a second embodiment. [Figure 14A] FIG. 10 is a diagram showing the front surface of an intermediate structural body according to a second embodiment. [Figure 14B] FIG. 10 is a diagram showing the back surface of the intermediate structural body according to the second embodiment. [Figure 15A] FIG. 10 is a side view of the irradiation device according to the second embodiment. [Figure 15B] FIG. 10 is a view of an irradiation device according to a second embodiment as seen obliquely from above. [Figure 16] 10A and 10B are diagrams illustrating an example in which an intermediate structure according to the second embodiment is irradiated with electromagnetic waves. [Figure 17] 10A and 10B are diagrams showing an example of a bent intermediate structure according to the second embodiment. [Figure 18A] FIG. 10 is a cross-sectional view of a molded sheet according to a modified example. [Figure 18B] 18B is a diagram showing an example of the molded sheet shown in FIG. 18A being bent. FIG. [Figure 19A] FIG. 10 is a cross-sectional view of a molded sheet according to a modified example. [Figure 19B] 19B is a diagram showing an example of the molded sheet shown in FIG. 19A being bent. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals. A three-dimensional object 1 according to embodiment 1 is an article having a three-dimensional outer shape, which is manufactured by bending a flat sheet of uniform thickness. Here, "bending a sheet" means folding or curving the sheet.

[0010] In the following, a case will be described in which the three-dimensional object 1 manufactured in the first embodiment is a rectangular parallelepiped box as shown in Fig. 1A. The three-dimensional object 1 is a packaging container used, for example, for gift boxes. Such a three-dimensional object 1 is manufactured by bending a molded sheet 10 cut into the shape of the three-dimensional object 1 when unfolded as shown in Fig. 1B along bending line L1, and assembling it three-dimensionally as shown in Fig. 1C.

[0011] More specifically, the three-dimensional object 1 has a square bottom A1, four rectangular side surfaces A2, four top surfaces (lids) A3 shaped like a combination of a triangle and a circle, and four trapezoidal flaps A4. Each side surface A2 is connected to one of the four sides of the bottom A1. Each top surface A3 is connected to the side of the corresponding side surface A2 facing the bottom A1. Each flap A4 is connected to the other side of the corresponding side surface A2 and is folded toward the inner surface of the adjacent side surface A2 so as to eliminate gaps between them. Bend lines L1 are set at the boundaries between the bottom A1 and each side surface A2, the boundaries between each side surface A2 and the corresponding top surface A3, and the boundaries between each side surface A2 and the corresponding flap A4. The bend lines L1 are also referred to as "fold lines" or "ridge lines," and are lines for bending the molded sheet 10 along the bend lines L1. The three-dimensional object 1 is fixed to the box by folding the molded sheet 10 at a right angle along the bending line L1 and interlocking the four top surfaces A3 with each other. Note that in Figures 1A to 1C, the reference numerals A1 to A4, L1, etc. are only used for some of the relevant parts to avoid complication. This also applies to the subsequent figures.

[0012] The molding sheet 10 used to manufacture such a three-dimensional object 1 is a flat plate-like member of uniform thickness. As shown in FIG. 2, the molding sheet 10 has a substrate 11 and an ink-receiving layer 12 laminated on one side of the substrate 11. The substrate 11 and the ink-receiving layer 12 each have a uniform thickness. Hereinafter, the side of the molding sheet 10 on which the ink-receiving layer 12 is formed will be referred to as the front side of the molding sheet 10, and the side on which the ink-receiving layer 12 is not laminated will be referred to as the back side of the molding sheet 10.

[0013] The substrate 11 is a main element of the three-dimensional object 1. The substrate 11 is a flexible sheet-like member that has the rigidity required to maintain the three-dimensional shape of the three-dimensional object 1. The substrate 11 is made of a thermoplastic resin and has the property of shrinking when heated to a predetermined temperature range. The substrate 11 is an example of a first layer that shrinks when heated. Specifically, a stretched film such as a biaxially stretched film or a uniaxially stretched film can be used as the substrate 11. Examples of materials for the substrate 11 include polyvinyl chloride (PVC), polyethylene terephthalate (PET), and polypropylene (PP). The thicker the substrate 11, the greater its rigidity becomes, but it becomes more difficult to bend it and its flexibility decreases, making it difficult to form a curved surface. Therefore, the thickness of the substrate 11 is designed to be, for example, several tens to several hundreds of μm so that the substrate 11 has appropriate rigidity and portability.

[0014] The ink-receiving layer 12 is a layer laminated on the substrate 11. The ink-receiving layer 12 is provided on the outermost surface of the molded sheet 10 to allow the application of the coating material 13, which will be described later. The thickness of the ink-receiving layer 12 is, for example, approximately 10 to several tens of μm. The ink-receiving layer 12 can be made of a material used for printing paper in general inkjet printers. More specifically, the ink-receiving layer 12 is formed of an appropriate material so as to have less shrinkage than the substrate 11 when heated to a predetermined temperature range at which the substrate 11 begins to shrink. As an example, the ink-receiving layer 12 is formed by using an inorganic filler such as silica as a main component and bonding the filler with an ink fixer and a crosslinking agent. The ink-receiving layer 12 is an example of a second layer that has less shrinkage upon heating than the substrate 11.

[0015] Any material may be used for the combination of substrate 11 and ink-receiving layer 12, as long as substrate 11 shrinks when heated to a predetermined temperature range and the shrinkage of ink-receiving layer 12 is less than that of substrate 11. As an example, inkjet recording paper disclosed in JP-A-2001-253166 or JP-A-2002-46350 can be used as molded sheet 10. Note that, when substrate 11 is a stretched film, the predetermined temperature range is a temperature of, for example, several tens of degrees Celsius to 200 degrees Celsius at which the stretched film unwinds.

[0016] Next, a modeling system 50 for producing a three-dimensional object 1 from the above-described molded sheet 10 will be described. As shown in FIG. 3, the modeling system 50 includes a printing device (applicator) 60 and an irradiation device 70. The printing device 60 is capable of performing a printing process using a known printing method such as an offset method or an inkjet method. Specifically, as shown in FIG. 4, the printing device 60 applies a coating material 13 to a linear application position along a bending line L1 on the surface of the ink-receiving layer 12 of the molded sheet 10 through a printing process. Note that FIG. 4 shows a cross section of one of the multiple bending lines L1 set on the molded sheet 10, viewed from the direction along the bending line L1. The printing device 60 is an example of an applicator that applies the coating material 13 to the surface of the molded sheet 10.

[0017] The coating material 13 is a member containing a conversion component that converts electromagnetic waves into heat. The coating material 13 absorbs electromagnetic waves in a specific wavelength range, such as near-infrared rays (wavelengths of 780 nm to 2.5 μm), converts them into heat, and emits the heat. Specifically, the coating material 13 contains, as a main component, black (K) ink for general printing that contains carbon black. Note that the electromagnetic waves are not limited to near-infrared rays as long as they are converted into heat in the coating material 13; they may also be radio waves, visible light, or the like. Furthermore, the coating material 13 is not limited to carbon black, and may be made of any material that can convert electromagnetic waves into heat and emit the heat. For example, the coating material 13 may be made of a near-infrared light-absorbing material such as phthalocyanine or naphthalocyanine.

[0018] The printing device 60 applies the coating material 13 to the surface of the ink-receiving layer 12 of the molding sheet 10 (the front surface of the molding sheet 10) at coating positions indicated by the application image data. Here, the coating positions where the coating material 13 is applied correspond to the linear positions where the molding sheet 10 is bent when manufacturing the three-dimensional object 1 from the molding sheet 10. Specifically, as shown by the bold lines in Fig. 5, the coating positions are positions along bending lines L1 on the surface of the ink-receiving layer 12 of the molding sheet 10. The bending lines L1 are set at the boundary portions between the bottom surface A1 and each side surface A2, the boundary portions between each side surface A2 and the corresponding top surface A3, and the boundary portions between each side surface A2 and the corresponding flap A4.

[0019] The application image data is data that indicates such application positions. The user selects application image data that corresponds to the three-dimensional object 1 to be manufactured, and sets a molding sheet 10 that is larger than the developed shape of the three-dimensional object 1 in the printing device 60. In accordance with the user's operation, the printing device 60 applies the application material 13 to the application positions indicated by the selected application image data on the surface of the set molding sheet 10. As a result, the application material 13 is applied along the bending line L1 on the surface of the molding sheet 10, as shown in FIGS. 4 and 5.

[0020] Hereinafter, the structure in the state where the coating material 13 is applied to the molding sheet 10 will be referred to as the "intermediate structure 15." The intermediate structure 15 is a structure at an intermediate stage when producing the three-dimensional object 1 from the molding sheet 10. The intermediate structure 15 has the molding sheet 10 and the coating material 13 applied to the surface of the molding sheet 10 at a coating position along the bending line L1.

[0021] Once the intermediate structure 15 is generated, it is cut by a processing tool (not shown) along the outline shown by the dashed line in Fig. 5. As a result, the intermediate structure 15 is cut out into the developed shape of the three-dimensional object 1, as shown in Fig. 6. The processing tool is a known tool capable of cutting the molded sheet 10, such as scissors, a cutter knife, a punching machine, or an electric jigsaw.

[0022] Returning to FIG. 3, the irradiation device 70 is a device that irradiates the intermediate structure 15 with electromagnetic waves. The irradiation device 70 irradiates the surface of the formed sheet 10 on which the coating material 13 is applied (the coating surface) with near-infrared rays (hereinafter simply referred to as "light"), which are electromagnetic waves. In this way, the irradiation device 70 heats the coating material 13 and bends the formed sheet 10. Specifically, as shown in FIGS. 7A and 7B, the irradiation device 70 includes an irradiation section 71, a cooler 72, a protective plate 73, and a conveying mechanism 80.

[0023] The irradiation unit 71 irradiates light onto the intermediate structure 15, which has been coated with the coating material 13 by the printing device 60 and cut out by a processing tool. The irradiation unit 71 is provided above a transport mechanism 80 that transports the intermediate structure 15 so as to irradiate the upper surface of the intermediate structure 15 with light. The irradiation unit 71 irradiates light over the entire length (full width) of the intermediate structure 15 in the width direction (Y direction in FIGS. 7A and 7B ). More specifically, the irradiation unit 71 includes a light source 7a and a reflector 7b. The light source 7a is, for example, a halogen lamp, and emits light including near-infrared rays that are converted into heat by the coating material 13. The reflector 7b is provided to cover the upper side of the light source 7a and reflects the light emitted from the light source 7a toward the intermediate structure 15.

[0024] The cooler 72 is an air-cooled fan, a water-cooled radiator, or the like, and is provided near the reflector 7b. The cooler 72 cools the irradiation unit 71, which irradiates light, so that the temperature of the irradiation unit 71 does not rise too high. The protective plate 73 is a flat plate material that is horizontally arranged directly below the irradiation unit 71. The protective plate 73 is provided as necessary to prevent the intermediate structure 15 from coming into contact with the reflector 7b or the light source 7a if it floats up from the transport path, and to prevent the intermediate structure 15 from generating excessive heat due to its proximity to the light source 7a. The protective plate 73 is made of a material with high light (near-infrared) transmittance, such as a glass plate, so as not to block the light from the irradiation unit 71.

[0025] The transport mechanism 80 transports the intermediate structure 15 at a constant speed in one horizontal direction (the X direction in FIGS. 7A and 7B ). The transport mechanism 80 is, for example, a belt conveyor, and includes a belt 81, a head pulley (drive pulley) 82, a tail pulley 83, and a motor (not shown) that rotates and drives the head pulley 82. The intermediate structure 15 is placed on the belt 81 with the surface on which the coating material 13 is applied, i.e., the surface of the ink-receiving layer 12, facing the direction of the irradiation unit 71. The transport mechanism 80 drives the motor to transport the intermediate structure 15 placed on the belt 81. The belt 81 is made of rubber or the like with low thermal conductivity so as to prevent heat from propagating in the surface direction in the intermediate structure 15.

[0026] When the intermediate structure 15 is transported by the transport mechanism 80 and enters the irradiation area of ​​the irradiation device 70, the irradiation device 70 irradiates light (electromagnetic waves) from the side of the intermediate structure 15 on which the coating material 13 is applied, i.e., the side of the ink-receiving layer 12, as shown in Fig. 8. When the light is irradiated onto the coating material 13, the light is converted into heat, causing the coating material 13 to generate heat. The generated heat then propagates from the surface of the ink-receiving layer 12 in the thickness direction, heating the ink-receiving layer 12 and the substrate 11.

[0027] When the substrate 11 is heated to a predetermined temperature range by heat emitted from the coating material 13, the stretched film unwinds and shrinks. On the other hand, the ink-receiving layer 12 has less shrinkage than the substrate 11, and therefore does not shrink relatively as much as the substrate 11, even when heated to a predetermined temperature range. Because of this difference in shrinkage, the degree of shrinkage in the in-plane direction differs between the portion of the substrate 11 close to the ink-receiving layer 12 and the portion far from it.

[0028] Specifically, even if a portion of the substrate 11 close to the ink receiving layer 12 attempts to shrink due to heating, it is protected by the ink receiving layer 12, which has low shrinkage, and therefore the degree of shrinkage in the in-plane direction is relatively small, as shown by the solid arrow in Figure 8. In contrast, a portion of the substrate 11 farther from the ink receiving layer 12 is less affected by the ink receiving layer 12, and therefore the degree of shrinkage in the in-plane direction due to heating is relatively large.

[0029] As such, the degree of shrinkage varies in the thickness direction of the substrate 11, and so when the substrate 11 shrinks due to heating, the molded sheet 10 bends toward the side where the ink-receiving layer 12 is not laminated, i.e., the side where the substrate 11 is not protected by the ink-receiving layer 12. As a result, as shown in Figure 9, the molded sheet 10 bends along bending line L1, which is the application position where the coating material 13 is applied, so that the side where the ink-receiving layer 12 is present becomes convex and the side opposite the ink-receiving layer 12 becomes concave. In other words, the molded sheet 10 bends in a mountain fold at the application position, with the application position where the coating material 13 is applied as a mountain crease (mountain fold line), so that the side where the coating material 13 is applied becomes the mountain side (convex).

[0030] 9 shows an example in which the molded sheet 10 is bent along one bending line L1, but when the coating material 13 is applied along multiple bending lines L1 as shown in FIGS. 5 and 6, the molded sheet 10 and the intermediate structure 15 are bent with each of the multiple bending lines L1 forming a mountain crease (mountain fold line). Specifically, as shown in FIGS. 7A and 7B, the intermediate structure 15 was flat before entering the irradiation area of ​​the irradiation unit 71, but after being irradiated with electromagnetic waves by the irradiation unit 71, it rises three-dimensionally on the belt 81. This results in a molded sheet 10 that is bent in a mountain fold along the multiple bending lines L1.

[0031] The formed sheet 10 bent by the irradiation device 70 is manually assembled by the user into a box as needed, as shown in FIG. 1C, to complete the three-dimensional object 1 shown in FIG. 1A. At this time, the user applies a certain amount of external force to the portion bent by the irradiation device 70, bending it further to increase the bending angle, or widening it to decrease the bending angle. Because the bending line L1 is creased by the processing of the irradiation device 70, misalignment of the bending line L1 and the occurrence of cracks in the base material 11 are suppressed. Because the three-dimensional object 1 has creases along the bending line L1 and is fixed into a three-dimensional shape without gluing or the like, it can be easily assembled manually to form a packaging container such as a gift box.

[0032] Next, the flow of a method for manufacturing the three-dimensional object 1 will be described with reference to FIG. 10. The method for manufacturing the three-dimensional object 1 includes a sheet manufacturing process S1, a coating process S2, a cutting process S3, and a bending process S4. In the sheet manufacturing process S1, an ink-receiving layer 12 is formed on one side of a substrate 11. Specifically, the material for the ink-receiving layer 12 is applied to the substrate 11 and dried to form a predetermined thickness. This produces a molded sheet 10 in which the ink-receiving layer 12 is laminated on the substrate 11, as shown in FIG. 2. The manufactured molded sheet 10 is then cut to a size compatible with the printing device 60, as necessary.

[0033] In the coating step S2, a printing device 60 applies coating material 13 to a coating position along bending line L1 on the ink receiving layer 12 of the molding sheet 10. As a result, an intermediate structure 15 is produced in which the coating material 13 is applied to the molding sheet 10, as shown in Figures 4 and 5. In the cutting step S3, the intermediate structure 15 to which the coating material 13 has been applied is cut along the outline shown by the dashed line in Figure 5 using a processing tool. As a result, the developed shape of the three-dimensional object 1 is cut out, as shown in Figure 6.

[0034] In the bending step S4, an irradiation device 70 irradiates the cut intermediate structure 15 with light on the side on which the coating material 13 is applied. As a result, as shown in FIG. 9, the molded sheet 10 is bent along the bending line L1 on which the coating material 13 is applied, so that the ink-receiving layer 12 side becomes convex and the side opposite the ink-receiving layer 12 becomes concave. The molded sheet 10 bent in the bending step S4 is assembled into a box by the user's manual work, etc., as necessary. This completes the three-dimensional object 1 shown in FIG. 1A.

[0035] As described above, the method for producing a three-dimensional object 1 according to the first embodiment involves applying a coating material 13 containing a conversion component that converts electromagnetic waves into heat to a linear application position on the surface of a molding sheet 10 having a substrate 11 that shrinks when heated and an ink-receiving layer 12 that has a smaller shrinkage when heated than the substrate 11. The molding sheet 10 coated with the coating material 13 is then irradiated with electromagnetic waves, thereby bending the molding sheet 10 at the application position. In this way, the three-dimensional object 1 according to the first embodiment is produced by bending the molding sheet 10 by irradiating the molding sheet 10 coated with the coating material 13 with electromagnetic waves. This eliminates the need for a mold or for the user to manually bend the molding sheet 10. This allows the three-dimensional object 1 to be easily produced.

[0036] In particular, the three-dimensional object 1 according to the first embodiment can be easily manufactured without using a mold, making it suitable for small-scale production or prototyping. Furthermore, since the user does not need to manually bend the molded sheet 10, the molded sheet 10 can be accurately bent even when the bend line L1 is complex, such as when the bend line L1 is curved or stops midway rather than extending to the end of the molded sheet 10. Furthermore, even when the molded sheet 10 is thick or has a large rigidity, the molded sheet 10 can be bent without cracking or breaking.

[0037] Next, a second embodiment will be described. The same configurations and functions as those of the first embodiment will be omitted where appropriate. The following description will be given taking as an example the case where the three-dimensional object 2 manufactured in the second embodiment is the article shown in FIG. 11A. The three-dimensional object 2 is, for example, a decorative item such as a lampshade, and has a cylindrical shape with its sides folded in an accordion-like manner and tapered top and bottom ends. Such a three-dimensional object 2 is manufactured by bending a molded sheet 20 cut into the unfolded shape of the three-dimensional object 2 as shown in FIG. 11B along bending lines L2 and L3, and assembling it into a three-dimensional shape.

[0038] More specifically, the three-dimensional object 2 has six square-shaped first surfaces B1, twelve large trapezoidal second surfaces B2, twelve small trapezoidal third surfaces B3, and two overlap margins B4. In the three-dimensional object 2, each first surface B1 is connected to an adjacent first surface B1 at a vertex and arranged in a horizontal ring. Two upper sides of each first surface B1 are connected to second surfaces B2, and two lower sides of each first surface B1 are connected to third surfaces B3. Bending lines L2, shown by dashed lines in FIG. 11B, are set on the four sides of each first surface B1, the short sides of each second surface B2, and the short sides of each third surface B3. Bending lines L3, shown by solid lines in FIG. 11B, are set on the long sides of each second surface B2 and the long sides of each third surface B3. When bending the formed sheet 20, the bending lines L2 and L3 are used as valley lines (valley fold lines) and mountain lines (mountain fold lines), respectively, when viewed from one side (front side) of the formed sheet 20.

[0039] As shown in Fig. 12, a molding sheet 20 for manufacturing such a three-dimensional object 2 has a base material 11 and a pair of ink-receiving layers 12 sandwiching the base material 11. While the molding sheet 10 according to the first embodiment has the ink-receiving layer 12 on one side of the base material 11, the molding sheet 20 according to the second embodiment has the ink-receiving layer 12 on both sides of the base material 11. Hereinafter, one side of the molding sheet 20 (the upper side in Fig. 12) will be referred to as the front side, and the other side (the lower side in Fig. 12) will be referred to as the back side. A modeling system 50 according to the second embodiment manufactures a three-dimensional object 2 using such a molding sheet 20.

[0040] In the modeling system 50 according to the second embodiment, the printing device 60 applies the coating material 13 to each surface of the pair of ink receiving layers 12 of the molded sheet 20, as shown in FIG. 13 . In other words, whereas the printing device 60 applies the coating material 13 to only one surface of the molded sheet 10 in the first embodiment, the printing device 60 applies the coating material 13 to both surfaces of the molded sheet 20 in the second embodiment. Specifically, the printing device 60 applies the coating material 13 to a first linear application position along the bending line L2 on the front surface of the molded sheet 20 (the surface of the ink receiving layer 12 on one side), and further applies the coating material 13 to a second linear application position along the bending line L3 on the back surface of the molded sheet 20 (the surface of the ink receiving layer 12 on the other side). Note that FIG. 13 shows a cross section of one bending line L2 and one bending line L3 of the multiple bending lines L2 and L3 set on the molded sheet 20, viewed from the direction along the bending lines L2 and L3.

[0041] The user selects application image data corresponding to the three-dimensional object 2 to be manufactured and sets a molding sheet 20 larger than the developed shape of the three-dimensional object 2 in the printing device 60. The application image data includes image data for the front side indicating a first application position along the bending line L2 and image data for the back side indicating a second application position along the bending line L3. In accordance with the user's operation, the printing device 60 applies the application material 13 to the front side of the set molding sheet 20 at the application position indicated by the image data for the front side of the selected application image data. Furthermore, the printing device 60 applies the application material 13 to the back side of the set molding sheet 20 at the application position indicated by the image data for the back side of the selected application image data. The molding sheet 20 is then cut out into the developed shape of the three-dimensional object 2 using a processing tool.

[0042] As a result, as shown by the thick line in Fig. 14A, coating material 13 is applied to a first application position along bending line L2 on the front surface of molded sheet 20. Furthermore, as shown by the thick line in Fig. 14B, coating material 13 is applied to a second application position along bending line L3 on the back surface of molded sheet 20. This produces intermediate structure 25, which is a structure in which coating material 13 is applied to molded sheet 20. Intermediate structure 25 has molded sheet 20 and coating material 13 applied to linear application positions on both surfaces of molded sheet 20.

[0043] The modeling system 50 according to the second embodiment includes an irradiation device 70a instead of the irradiation device 70 described in the first embodiment. The irradiation device 70 according to the first embodiment irradiates electromagnetic waves onto one surface of the intermediate structure 15, on which the coating material 13 is applied. In contrast, the irradiation device 70a according to the second embodiment irradiates electromagnetic waves onto both surfaces of the intermediate structure 25. Specifically, as shown in FIGS. 15A and 15B , the irradiation device 70a includes two irradiation units 71 and two coolers 72, as well as a protective plate 73, a stage 77, and a transport mechanism 80a. The irradiation units 71, the coolers 72, and the protective plate 73 are the same as those of the irradiation device 70 described in the first embodiment (see FIGS. 7A and 7B ).

[0044] The first irradiation unit 71 and the first cooler 72 are installed above the stage 77. The first irradiation unit 71 irradiates light onto the upper surface of the intermediate structure 25 placed on the stage 77. In contrast, the second irradiation unit 71 and the second cooler 72 are installed below the stage 77 and are the first irradiation unit 71 and the first cooler 72 inverted upside down. The second irradiation unit 71 irradiates light onto the lower surface of the intermediate structure 25 placed on the stage 77. The two irradiation units 71 are arranged in opposing positions so that their irradiation areas coincide, and irradiate light simultaneously onto both surfaces of the intermediate structure 25. The two irradiation units 71 are also arranged in positions so that the amount of light passing through the protective plate 73 or the stage 77 and incident on the upper and lower surfaces of the intermediate structure 25 is equal.

[0045] The stage 77 is a flat plate-like member on which the intermediate structure 25 is placed, and is transported together with the intermediate structure 25 by the transport mechanism 80a. The stage 77 is, for example, a glass plate, and is made of a material with high light transmittance and low thermal conductivity so that the light from the second irradiation unit 71 is irradiated onto the underside of the intermediate structure 25. The transport mechanism 80a transports the stage 77 together with the intermediate structure 25 placed thereon at a constant speed in one horizontal direction. The transport mechanism 80a is, for example, a roller conveyor, and includes a plurality of carrier rollers 86 arranged in the transport direction, a motor (not shown) for rotating the plurality of carrier rollers 86 at the same rotational speed (circumferential speed), and a transmission mechanism (not shown) such as a belt or chain. The plurality of carrier rollers 86 are arranged to avoid the irradiation area (directly above the second irradiation unit 71).

[0046] When the intermediate structure 25 is transported by the transport mechanism 80a and enters the irradiation area of ​​the irradiation device 70a, light (electromagnetic waves) is irradiated from both the front and back sides of the intermediate structure 25 by the irradiation device 70a, as shown in FIG. 16 . When the coating material 13 is irradiated with light, the light is converted into heat, causing the coating material 13 to generate heat. The generated heat then propagates from the surface of the ink-receiving layer 12 in the thickness direction, heating the ink-receiving layer 12 and the substrate 11. When the substrate 11 is heated to a predetermined temperature range by the heat emitted from the coating material 13, the stretching of the stretched film unwinds and the substrate 11 shrinks. On the other hand, the ink-receiving layer 12 has less shrinkage than the substrate 11, and therefore does not shrink relatively as much as the substrate 11, even when heated to a predetermined temperature range.

[0047] Here, in the molded sheet 20 according to the second embodiment, unlike the molded sheet 10 according to the first embodiment, both sides of the substrate 11 are guarded by the ink-receiving layer 12. Therefore, in the second embodiment, there is no difference in shrinkage due to the guarding of the ink-receiving layer 12. On the other hand, among positions in the thickness direction of the substrate 11, the closer to the coating material 13 the greater the heating, and the farther from the coating material 13 the less the degree of heating. Therefore, as shown by the solid arrows in FIG. 16 , the degree of shrinkage becomes relatively greater at positions closer to the coating material 13 and relatively smaller at positions farther from the coating material 13. As a result, as shown in FIG. 17 , the molded sheet 20 bends toward the side coated with the coating material 13, so that the side coated with the coating material 13 becomes concave and the side not coated with the coating material 13 becomes convex. Specifically, when viewed from the front side of the molded sheet 20, the bending line L2 forms a valley line (valley fold line) and the bending line L3 forms a mountain line (mountain fold line).

[0048] In this way, in the second embodiment, the molded sheet 20 is bent due to the temperature difference that occurs in the thickness direction of the substrate 11 when it is heated to a predetermined temperature range. Therefore, the thickness of the substrate 11 needs to be designed to a thickness that will cause a temperature difference in the thickness direction.

[0049] 16 shows an example in which the molded sheet 20 is bent along one bending line L2 and one bending line L3, but when the coating material 13 is applied along multiple bending lines L2 and multiple bending lines L3 as shown in FIGS. 14A and 14B, the molded sheet 20 is bent with each of the multiple bending lines L2 as a valley line and each of the multiple bending lines L3 as a mountain line. Specifically, as shown in FIGS. 15A and 15B, the intermediate structure 25 was flat before entering the irradiation area of ​​the irradiation unit 71, but after being irradiated with electromagnetic waves by the irradiation unit 71, it rises three-dimensionally on the stage 77. As a result, the molded sheet 20 is obtained in a state in which mountain folds and valley folds are repeated and the molded sheet 20 is folded into an accordion-like shape.

[0050] The formed sheet 20 bent by the irradiation device 70a is manually assembled by the user as necessary to complete the three-dimensional object 2 shown in FIG. 11A. At this time, the user applies a certain amount of external force to the portions bent by the irradiation device 70a into mountain folds or valley folds, either bending them further to increase the bending angle or widening them to decrease the bending angle. The user then uses the overlap B4 as a glue tab and glues the front surface of the overlap B4 to the back surface of the end opposite the overlap B4 with an adhesive, thereby forming the cylindrical shape shown in FIG. 11A. Since the three-dimensional object 2 has creases along the bending lines L2 and L3, it can be easily assembled manually.

[0051] The method for manufacturing a three-dimensional object 2 according to the second embodiment includes a sheet manufacturing step S1, a coating step S2, a cutting step S3, and a bending step S4, similar to the method according to the first embodiment (see FIG. 10 ). In the sheet manufacturing step S1, an ink-receiving layer 12 is formed on both the front and back surfaces of a substrate 11. Specifically, a material for the ink-receiving layer 12 is applied to the front surface of the substrate 11 and dried to form a layer with a predetermined thickness. The material for the ink-receiving layer 12 is similarly applied to the back surface of the substrate 11 and dried to form a layer with a predetermined thickness. This produces a molded sheet 20 in which ink-receiving layers 12 are laminated on both sides of the substrate 11, as shown in FIG. 12 . The manufactured molded sheet 20 is then cut to a size compatible with the printing device 60, as necessary.

[0052] In the coating step S2, the printing device 60 applies the coating material 13 to a first coating position along the bending line L2 on the front surface of the molding sheet 20. Furthermore, the printing device 60 applies the coating material 13 to a second coating position along the bending line L3 on the back surface of the molding sheet 20. As a result, an intermediate structure 25 is produced in which the coating material 13 is applied to both sides of the molding sheet 20, as shown in FIG. 13. In the cutting step S3, the intermediate structure 25 to which the coating material 13 has been applied is cut with a processing tool. As a result, the developed shape of the three-dimensional object 2 is cut out, as shown in FIGS. 14A and 14B.

[0053] In the bending step S4, the irradiation device 70a irradiates light onto both the front and back surfaces of the cut intermediate structure 25. Specifically, the irradiation device 70a irradiates light onto the intermediate structure 25 from the front side, thereby bending the molded sheet 20 at a first application position along the bending line L2 so that the front side becomes concave. Furthermore, the irradiation device 70a irradiates light onto the intermediate structure 25 from the back side, thereby bending the molded sheet 20 at a second application position along the bending line L3 so that the front side becomes convex. As a result, as shown in FIG. 17, the molded sheet 20 is bent along the bending line L2 as a valley line and along the bending line L3 as a mountain line. The molded sheet 20 bent in the bending step S4 is manually assembled by the user as necessary. This completes the three-dimensional object 2 shown in FIG. 11A.

[0054] As described above, the method for producing a three-dimensional object 2 according to the second embodiment involves applying a coating material 13 containing a conversion component that converts electromagnetic waves into heat to linear application positions on the surface of a molded sheet 20 having a substrate 11 that shrinks upon heating and a pair of ink-receiving layers 12 sandwiching the substrate 11 and having a smaller shrinkage upon heating than the substrate 11. The molded sheet 10 coated with the coating material 13 is then irradiated with electromagnetic waves, thereby bending the molded sheet 10 with the coating positions forming valleys. In this way, in the second embodiment, the ink-receiving layers 12 are laminated on both sides of the substrate 11, so that the coating material 13 can be applied to both surfaces of the molded sheet 10. This allows the molded sheet 10 to bend in both mountain and valley folds when viewed from one side of the molded sheet 10. As a result, a three-dimensional object 2 with a more complex shape can be easily produced compared to the first embodiment.

[0055] Although the embodiments of the present invention have been described above, the above embodiments are merely examples, and the scope of application of the present invention is not limited to these. In other words, the embodiments of the present invention are applicable to various applications, and all embodiments are included in the scope of the present invention.

[0056] For example, in the above embodiments, the molded sheets 10 and 20 include the substrate 11 as the first layer that shrinks upon heating, and the ink-receiving layer 12 as the second layer that shrinks less upon heating than the first layer. However, the first and second layers are not limited to the substrate 11 or the ink-receiving layer 12, and may be layers formed of other materials as long as they have different shrinkage upon heating. The molded sheets 10 and 20 may also include layers other than the first and second layers. For example, the molded sheets 10 and 20 may include a peelable release layer between the substrate 11 and the ink-receiving layer 12. Then, after bending the molded sheets 10 and 20, the release layer may be peeled off from the substrate 11 together with the ink-receiving layer 12 and the coating material 13.

[0057] Furthermore, the configurations of the irradiation devices 70, 70a in the above-described embodiments are merely examples, and the irradiation devices 70, 70a may have any configuration as long as they are capable of irradiating electromagnetic waves onto the coating material 13 applied to the molded sheets 10, 20. For example, in the above-described first embodiment, the irradiation unit 71 was provided above the transport mechanism 80, and electromagnetic waves were irradiated from above the intermediate structure 15. However, the irradiation unit 71 may be provided below the intermediate structure 15, like the second irradiation unit 71 in the second embodiment, and electromagnetic waves may be irradiated from below the stage 77 on which the intermediate structure 15 is placed. In this case, the intermediate structure 15 is placed on the stage 77 with the side (front side) of the ink-receiving layer 12 facing downward and is transported. Furthermore, in the above-described second embodiment, two irradiation units 71 were disposed at opposing positions, and electromagnetic waves were irradiated simultaneously onto both surfaces of the intermediate structure 25. However, after one irradiation unit 71 irradiates one surface of the intermediate structure 25 with electromagnetic waves, the same or another irradiation unit 71 may irradiate the other surface with electromagnetic waves. However, because the intermediate structure 25 is bent by the first irradiation of electromagnetic waves, it is necessary to ensure that the bent intermediate structure 25 can be appropriately irradiated with electromagnetic waves in the second irradiation of electromagnetic waves.

[0058] Furthermore, the conveying mechanism 80, 80a is not limited to a configuration in which the intermediate structures 15, 25 are placed and conveyed, such as a belt conveyor, but may be configured to sandwich the intermediate structures 15, 25 between a pair of conveying rollers for conveying. In the case where the intermediate structures 15, 25 are sandwiched between a pair of conveying rollers for conveying, the pair of conveying rollers may be configured to sandwich both edges of the intermediate structures 15, 25 in the width direction (Y direction) so as not to hinder bending of the intermediate structures 15, 25 during conveyance. Furthermore, as long as the conveying mechanism 80, 80a can move the intermediate structures 15, 25 and the irradiation unit 71 relative to each other, it is not limited to a configuration in which the intermediate structures 15, 25 are conveyed, but may also be configured to move the irradiation unit 71 in one direction. Furthermore, if the irradiation unit 71 has a configuration in which light is irradiated in a planar manner from multiple light sources 7a and can simultaneously irradiate the entire surface of the intermediate structures 15, 25 with light, the irradiation device 70, 70a does not need to include the conveying mechanism 80, 80a.

[0059] In the above embodiment, the cutting step S3 of cutting the molded sheets 10, 20 into the developed shapes of the three-dimensional objects 1, 2 is performed between the coating step S2 and the bending step S4. However, the cutting step S3 may be performed before the coating step S2 as long as the printing device 60 can appropriately apply the coating material 13 to the molded sheets 10, 20 after they have been cut into the developed shapes. Furthermore, the cutting step S3 may be performed after the bending step S4 as long as the irradiation device 70, 70a can appropriately bend the molded sheets 10, 20 (intermediate structures 15, 25) before they are cut into the developed shapes.

[0060] In the above embodiment, the coating material 13, which converts electromagnetic waves into heat, is applied to the surface of the ink-receiving layer 12, and the substrate 11 is heated by irradiating it with electromagnetic waves using the irradiation device 70, 70a, thereby bending the molded sheets 10, 20 at the application positions where the coating material 13 is applied. However, instead of irradiating it with electromagnetic waves, the substrate 11 may be heated using a thermal head 30. In this case, the modeling system 50 includes a printing device having a thermal head 30 instead of the printing device 60 that applies the coating material 13 and the irradiation device 70, 70a that irradiates it with electromagnetic waves. When the thermal head 30 is used, the coating material 13 is not applied, and therefore the molded sheets 10a, 20a include a coating layer 14 instead of the ink-receiving layer 12 of the molded sheets 10, 20, as shown in FIGS. 18A and 19A . The coating layer 14, like the ink-receiving layer 12, is formed of an appropriate material that shrinks less when heated than the substrate 11.

[0061] When a coating layer 14 is laminated on one side of a substrate 11, as in the case of the molded sheet 10a shown in FIG. 18A, the thermal head 30 heats the substrate 11 from the side of the coating layer 14. When heated by the thermal head 30, the molded sheet 10a bends toward the side opposite the heated side, so that the heated side becomes convex and the side opposite the heated side becomes concave. Specifically, the thermal head 30 contacts the surface of the coating layer 14 and heats a linear position along the bending line L1 on the surface of the coating layer 14. As a result, the molded sheet 10a bends, with the position heated by the thermal head 30 forming a mountain crease (mountain fold line), as shown in FIG. 18B. In other words, just as the molded sheet 10 in embodiment 1 bends so that the ink receiving layer 12 side becomes convex, the molded sheet 10a bends so that the coating layer 14 side becomes convex.

[0062] On the other hand, when the coating layer 14 is laminated on both sides of the substrate 11, as in the case of the molded sheet 20a shown in FIG. 19A, the thermal head 30 can heat the substrate 11 from both sides. When heated by the thermal head 30, the molded sheet 20a bends toward the heated side, so that the heated side becomes concave and the opposite side becomes convex. Specifically, the thermal head 30 contacts the surface of the coating layer 14 on the front side of the molded sheet 20a and heats a linear position along the bending line L2. Furthermore, the thermal head 30 contacts the surface of the coating layer 14 on the back side of the molded sheet 20a and heats a linear position along the bending line L3. As a result, the molded sheet 20a bends, forming valley lines (valley fold lines) at the positions heated by the thermal head 30, as shown in FIG. 19B. In other words, similar to the molded sheet 20 in the second embodiment, the molded sheet 20a is bent with the bending lines L2 as valley lines (valley fold lines) and the bending lines L3 as mountain lines (mountain fold lines) when viewed from the front side of the molded sheet 20a.

[0063] In this way, instead of applying the coating material 13 and irradiating it with electromagnetic waves, the substrate 11 can be heated along the bending lines L1, L2, and L3 by using the thermal head 30. This allows the molded sheets 10a and 20a to bend in the same way as the molded sheets 10 and 20 described in the first and second embodiments. As a result, the three-dimensionally shaped objects 1 and 2 can be easily manufactured.

[0064] The above describes preferred embodiments of the present invention, but the present invention is not limited to the above-described embodiments, and various modifications and substitutions can be made to the above-described embodiments without departing from the scope of the claims. [Explanation of symbols]

[0065] 1, 2... Three-dimensional object, 10, 10a, 20, 20a... Molded sheet, 11... Substrate, 12... Ink receiving layer, 13... Coating material, 14... Coating layer, 15, 25... Intermediate structure, 30... Thermal head, 50... Modeling system, 60... Printing device, 70, 70a... Irradiation device, 80, 80a... Conveyance mechanism

Claims

1. A method for manufacturing a three-dimensional object, comprising: A coating step of applying a coating material containing a conversion component that converts electromagnetic waves into heat to a linear coating position on the surface of a molded sheet; A bending step of bending the molded sheet at the application position by irradiating the electromagnetic waves to the molded sheet from the side of the surface to which the coating material is applied in the application step, The molded sheet has a first layer that shrinks when heated and a second layer that has a shrinkage when heated that is smaller than that of the first layer. A method for manufacturing a three-dimensional object, comprising:

2. In the molded sheet, the second layer is laminated on one side of the first layer, In the coating step, the coating material is applied to the surface of the molded sheet on the side of the second layer, In the bending step, the molded sheet is bent with the application position as a mountain line. The method for manufacturing a three-dimensional object according to claim 1 .

3. A method for manufacturing a three-dimensional object, comprising: A coating step of applying a coating material containing a conversion component that converts electromagnetic waves into heat to a linear coating position on the surface of a molded sheet; A bending process in which the molding sheet is bent with the application position as a valley by irradiating the electromagnetic wave to the molding sheet from the side of the surface to which the coating material is applied in the application process, The molded sheet has a first layer that shrinks when heated, and a pair of second layers sandwiching the first layer, the second layers having a shrinkage when heated that is smaller than that of the first layer. A method for manufacturing a three-dimensional object, comprising:

4. In the coating step, the coating material is applied to a first linear coating position on the front surface of the molded sheet and a second linear coating position on the back surface of the molded sheet, In the bending step, the electromagnetic waves are applied to the molded sheet from the front side, thereby bending the molded sheet at the first application position so that the front side becomes concave, and the electromagnetic waves are applied to the molded sheet from the back side, thereby bending the molded sheet at the second application position so that the front side becomes convex. The method for manufacturing a three-dimensional object according to claim 3 .

5. An intermediate structure for producing a three-dimensional object, a molded sheet having a first layer that shrinks when heated and a second layer that has a shrinkage when heated that is smaller than that of the first layer; a coating material containing a conversion component that converts electromagnetic waves into heat, The coating material is applied to a linear application position on the surface of the molded sheet that bends the molded sheet. An intermediate structure characterized by:

6. An intermediate structure for producing a three-dimensional object, a molded sheet having a first layer that shrinks when heated and a pair of second layers sandwiching the first layer, the second layers having a shrinkage when heated smaller than that of the first layer; a coating material containing a conversion component that converts electromagnetic waves into heat, The coating material is applied to a linear application position on the surface of the molded sheet that bends the molded sheet, The application position is a position where the molded sheet is bent with the application position as a valley line. An intermediate structure characterized by:

7. A modeling system including a coating device and an irradiation device, The coating device applies a coating material containing a conversion component that converts electromagnetic waves into heat to a linear coating position on the surface of the molded sheet, The irradiation device irradiates the electromagnetic waves onto the molded sheet from the side of the surface to which the coating material is applied by the coating device, thereby bending the molded sheet at the coating position, The molded sheet has a first layer that shrinks when heated and a second layer that has a shrinkage when heated that is smaller than that of the first layer. A molding system characterized by:

8. A modeling system including a coating device and an irradiation device, The coating device applies a coating material containing a conversion component that converts electromagnetic waves into heat to a linear coating position on the surface of the molded sheet, The irradiation device irradiates the electromagnetic waves onto the molded sheet from the side of the surface to which the coating material is applied by the coating device, thereby bending the molded sheet with the application position as a valley, The molded sheet has a first layer that shrinks when heated, and a pair of second layers sandwiching the first layer, the second layers having a shrinkage when heated that is smaller than that of the first layer. A molding system characterized by:

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