Three-dimensional structures

Abstract

This invention provides a three-dimensional structure that allows for easy removal of uncured resin remaining in the gaps of a lattice structure, even when manufacturing a three-dimensional resin structure with a lattice structure using a 3D printer. [Solution] The three-dimensional structure 1 is composed of a resin surface layer 2 on which a design surface 2a is formed, and a resin base layer 3 that overlaps with the surface layer 2. The base layer 3 is composed of a lattice structure 5 and a plurality of connecting members 6 that connect the ends of the lattice structure 5 on the side opposite the surface layer. A plurality of openings are formed on the surface of the base layer 3 on the side opposite the surface layer.

Description

Technical Field

[0001] The present invention relates to a three-dimensional structure.

Background Art

[0002] Conventionally, a three-dimensional structural component having a first base, a lattice structure portion, and a second base has been known (see Patent Document 1). In the three-dimensional structural component of Patent Document 1, the first base and the second base are formed in a plate shape. The lattice structure portion is provided between the first base and the second base.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When manufacturing a resin three-dimensional structural component having a lattice structure portion by a 3D printer, uncured resin remains in the gaps in the lattice structure portion. Therefore, in this case, it is necessary to remove the uncured resin remaining in the gaps of the lattice structure portion. However, when the lattice structure portion is sandwiched and arranged between the first base and the second base formed in a plate shape as in the three-dimensional structural component of Patent Document 1, it becomes difficult to remove the uncured resin remaining in the gaps of the lattice structure portion, and the productivity of the three-dimensional structural component decreases.

[0005] An object of the present invention is to provide a three-dimensional structure capable of easily removing uncured resin remaining in the gaps of a lattice structure even when manufacturing a resin three-dimensional structure having a lattice structure by a 3D printer.

Means for Solving the Problems

[0006] A three-dimensional structure according to one aspect of the present invention is composed of a resin surface layer and a resin base layer that overlaps the surface layer. The base layer is composed of a lattice structure and a plurality of connecting members that connect the ends of the lattice structure on the side opposite the surface layer. A plurality of openings are formed on the surface of the base layer on the side opposite the surface layer. [Effects of the Invention]

[0007] According to the present invention, even when manufacturing a three-dimensional resin structure having a lattice structure using a 3D printer, it becomes possible to easily remove uncured resin remaining in the gaps of the lattice structure. [Brief explanation of the drawing]

[0008] [Figure 1] This is a side view of a three-dimensional structure according to an embodiment. [Figure 2] Figure 1 is a bottom view of the multiple interconnected structures shown. [Figure 3] Figure 1 is a perspective view of a portion of the lattice structure shown. [Figure 4] Figure 3 is a schematic diagram illustrating the structure of the unit cell shown. [Figure 5] This is a bottom view of a connecting body according to another embodiment. [Figure 6] This is a bottom view of a connecting body according to another embodiment. [Modes for carrying out the invention]

[0009] The embodiments will be described below with reference to the drawings.

[0010] <Embodiment> Figure 1 is a side view of a three-dimensional structure 1 according to an embodiment. Figure 2 is a bottom view of the multiple interconnected bodies 6 shown in Figure 1. Figure 3 is a perspective view of a part of the lattice structure 5 shown in Figure 1. Figure 4 is a schematic diagram illustrating the structure of the unit cell 7 shown in Figure 3. In Figure 2, the multiple interconnected bodies 6 are shown from the EE direction of Figure 1.

[0011] The three-dimensional structure 1 of this embodiment is a resin structural component used, for example, as an interior part of an automobile. The three-dimensional structure 1 is manufactured by a 3D printer. The three-dimensional structure 1 consists of a resin surface layer 2 on which a design surface 2a is formed, and a resin base layer 3 that overlaps with the surface layer 2. In the following description, the thickness direction of the base layer 3 (up and down direction in Figure 1) is referred to as the up and down direction, the side of the thickness direction of the base layer 3 on which the surface layer 2 is placed (upper side in Figure 1) is referred to as the upper side, and the opposite side (lower side in Figure 1) is referred to as the lower side. In this embodiment, the lower side is the anti-surface layer side, which is the side of the thickness direction of the base layer 3 on which the surface layer 2 is placed.

[0012] The surface layer 2 is formed, for example, in a flat plate shape. The upper surface of the surface layer 2 is a design surface 2a. The surface layer 2 may also be formed in a curved plate shape. The base layer 3 consists of a lattice structure 5 and a plurality of connecting members 6 that connect the lower end of the lattice structure 5. Specifically, the base layer 3 consists of a lattice structure 5 and a number of connecting members 6. The upper end of the lattice structure 5 is connected to the surface layer 2.

[0013] As shown in Figure 3, the lattice structure 5 is formed by repeatedly arranging multiple unit cell bodies 7 having a three-dimensional lattice structure. Specifically, the lattice structure 5 is formed by repeatedly arranging a large number of unit cell bodies 7. The unit cell body 7 is composed of multiple element bodies 8 formed in a rod shape. In this embodiment, the unit cell body 7 is composed of eight element bodies 8. The element bodies 8 are formed, for example, in a cylindrical shape.

[0014] As shown in Figure 4, one end of each of the eight element bodies 8 is connected at one point. If the other ends 8a of the element bodies 8 are connected by imaginary lines, a cube is formed with the eight other ends 8a as vertices. The one ends of each of the eight element bodies 8 are connected at the center C of this cube. The other ends 8a of the element bodies 8 of a unit cell body 7 are connected to the other ends 8a of the element bodies 8 of adjacent unit cell bodies 7. If the point where the other ends 8a of the element bodies 8 of the lowermost multiple unit cell bodies 7 are connected is defined as the vertex 9, then at the vertex 9, two or four other ends 8a are connected. Note that the element bodies 8 may be formed in a rod shape other than a cylindrical shape. Also, the unit cell body 7 may be composed of seven or fewer element bodies 8, or it may be composed of nine or more element bodies 8.

[0015] The connecting body 6 is formed in the shape of a rod with the same thickness as the element body 8. The connecting body 6 is formed in the same way as the element body 8, for example, in the shape of a cylinder. In the base layer 3, the other end 8a of the element body 8 of the unit cell body 7 located at the bottommost position becomes the lower end of the lattice structure 5. That is, the vertex 9 is the lower end of the lattice structure 5. The connecting body 6 connects the other ends 8a of the element body 8. That is, the connecting body 6 connects the vertex 9.

[0016] Specifically, the connecting body 6 connects the two other ends 8a of the unit cell 7 that are positioned on the diagonal (the diagonal passing through the center C) when viewed from above (see Figure 2). In other words, two connecting bodies 6 are connected to one unit cell 7. The two connecting bodies 6 connected to one unit cell 7 are connected to each other at the center of the connecting body 6. In this embodiment, the entire space between the two other ends 8a positioned on the diagonal of the unit cell 7 when viewed from above is connected by the connecting body 6. However, there may be other ends 8a among the two other ends 8a positioned on the diagonal of the unit cell 7 that are not connected by the connecting body 6.

[0017] The portion of the lower surface of the base layer 3 where the connecting body 6 is not disposed is an opening 3a that leads to the inside of the lattice structure 5. That is, a plurality of openings 3a that lead to the inside of the lattice structure 5 are formed on the lower surface of the base layer 3. In the present embodiment, a large number of square-shaped openings 3a are formed on the lower surface of the base layer 3. The porosity of the lower surface of the base layer 3 is 50% or more and 80% or less. That is, the ratio of the area of the portion of the lower surface of the base layer 3 where the plurality of openings 3a are formed to the entire area of the lower surface of the base layer 3 is 50% or more and 80% or less.

[0018] The three-dimensional structure 1 is formed by sequentially laminating resins discharged from an inkjet head of a 3D printer in the thickness direction of the three-dimensional structure 1. When manufacturing the three-dimensional structure 1, the lattice structure 5 may be supported by a support material. When the skin layer 2 and the base layer 3 are shaped by a 3D printer, uncured resin (for example, a support material) remaining in the gaps in the lattice structure 5 is removed by cleaning using a solvent or the like.

[0019] Hereinafter, the operation and effect of the three-dimensional structure 1 will be described.

[0020] (1) The three-dimensional structure 1 is composed of a resin-made skin layer 2 on which a design surface 2a is formed and a resin-made base layer 3 that overlaps the skin layer 2. The base layer 3 is composed of a lattice structure 5 formed by repeatedly arranging a plurality of unit lattice bodies 7 having a three-dimensional lattice-like structure and connected to the skin layer 2, and a plurality of connecting bodies 6 that connect between the lower end portions of the lattice structure 5. A plurality of openings 3a that lead to the inside of the lattice structure 5 are formed on the lower surface of the base layer 3.

[0021] In this embodiment, since multiple openings 3a leading to the interior of the lattice structure 5 are formed on the lower surface of the base layer 3, after the surface layer 2 and base layer 3 are fabricated by the 3D printer, it becomes possible to easily remove any uncured resin remaining in the gaps within the lattice structure 5 through the openings 3a. Furthermore, since the lower ends of the lattice structure 5 are connected by multiple connecting members 6, it becomes possible to ensure the rigidity of the three-dimensional structure 1. In other words, even though it is possible to easily remove any uncured resin remaining in the gaps of the lattice structure 5, it is possible to ensure the rigidity of the three-dimensional structure 1. In addition, since the base layer 3 includes the lattice structure 5, it becomes possible to enhance the impact resistance of the three-dimensional structure 1.

[0022] (2) The unit cell 7 is composed of multiple element bodies 8 formed in a rod shape. If the points where the other ends 8a of the element bodies 8 of the lowermost unit cell 7 are connected are called the vertices 9, then the vertices 9 are the lower ends of the lattice structure 5. The connecting body 6 connects the vertices 9. Therefore, it is possible to effectively increase the rigidity of the three-dimensional structure 1.

[0023] (3) The connecting body 6 is formed in the shape of a rod with the same thickness as the element body 8. Therefore, it is possible to make the opening 3a relatively large, and thus it becomes easier to remove the uncured resin remaining in the gaps of the lattice structure 5.

[0024] (4) The porosity of the lower surface of the base layer 3 is 50% or more and 80% or less. Since the porosity of the lower surface of the base layer 3 is 50% or more, it becomes possible to easily remove the uncured resin remaining in the gaps of the lattice structure 5. Also, since the porosity of the lower surface of the base layer 3 is 80% or less, it becomes possible to ensure the rigidity of the three-dimensional structure 1. In other words, it becomes possible to balance the ease of removing the uncured resin remaining in the gaps of the lattice structure 5 with the rigidity of the three-dimensional structure 1.

[0025] <Variation> Figure 5 is a bottom view of the connecting body 16 according to another embodiment. Figure 6 is a bottom view of the connecting bodies 6 and 16 according to another embodiment. In Figures 5 and 6, the same reference numerals are used for components that are the same as those in the embodiments described above.

[0026] The base layer 3 may have a connecting body 16 instead of the connecting body 6, the connecting body 16 having a width wider than the thickness of the element body 8 when viewed from above. In this case, for example, as shown in Figure 5, the connecting body 16 may connect two adjacent other ends 8a in the circumferential direction of the unit cell body 7 centered on the center C when viewed from above. In the modified example shown in Figure 5, all of the space between two adjacent other ends 8a in the circumferential direction of the unit cell body 7 when viewed from above is connected by the connecting body 16. However, there may be an other end 8a among the two adjacent other ends 8a in the circumferential direction of the unit cell body 7 that is not connected by the connecting body 16.

[0027] In the modified example shown in Figure 5, the width of the connecting body 16 when viewed from above is wider than the thickness of the element body 8, which makes it possible to effectively increase the rigidity of the three-dimensional structure 1. Alternatively, the connecting body 16 may connect the two other ends 8a that are located on the diagonal of the unit cell body 7 when viewed from above.

[0028] Furthermore, as shown in Figure 6, the base layer 3 may also include a first connecting body 6 formed in the shape of a rod with the same thickness as the element body 8, and a second connecting body 16 whose width when viewed from above is wider than the thickness of the element body 8. In the modified example shown in Figure 6, the connecting body 6 connects two other ends 8a that are arranged on the diagonal of the unit cell body 7 when viewed from above, and the connecting body 16 connects two other ends 8a that are adjacent in the circumferential direction of the unit cell body 7 when viewed from above.

[0029] In the modified example shown in Figure 6, all of the other ends 8a of the unit cell 7, which are located on the diagonal, are connected by the connecting body 6. However, there may be other ends 8a among the two other ends 8a of the unit cell 7 that are located on the diagonal, but they may be connected by the connecting body 6. Also, in the modified example shown in Figure 6, there may be other ends 8a among the two adjacent other ends 8a of the unit cell 7 in the circumferential direction that are not connected by the connecting body 16. However, all of the other ends 8a between two adjacent other ends 8a of the unit cell 7 in the circumferential direction may be connected by the connecting body 16.

[0030] In the modified example shown in Figure 6, the base layer 3 includes a connecting body 6 formed in the shape of a rod with the same thickness as the element body 8, and a connecting body 16 whose width when viewed from above is wider than the thickness of the element body 8. This makes it possible to effectively increase the rigidity of the three-dimensional structure 1.

[0031] The embodiments and modifications described above are merely illustrative examples provided to facilitate understanding of the invention. The technical scope of the invention is not limited to the specific technical matters disclosed in the embodiments, etc., but also includes various modifications, changes, and alternative technologies that can be easily derived therefrom. [Explanation of Symbols]

[0032] 1 Three-dimensional structure 2 Epidermal layer 2a Design surface 3. Substratum 3a opening 5 Lattice Structures 6 Connected body (1st connected body) 7 Unit lattice 8 element body 9 Vertices 16 Concatenation body (second concatenation body)

Claims

1. It consists of a resin surface layer on which a design surface is formed, and a resin base layer that overlaps with the surface layer. If we define the side of the substrate layer's thickness direction opposite to the side where the epidermal layer is located as the side opposite the epidermal layer, The substrate layer is composed of a lattice structure formed by repeatedly arranging multiple unit cell bodies having a three-dimensional lattice structure and connected to the epidermal layer, and a plurality of connecting members that connect the ends of the lattice structure on the side opposite the epidermal layer. A three-dimensional structure having a plurality of openings formed on the surface of the substrate layer opposite the surface of the skin layer, which lead to the interior of the lattice structure.

2. The unit cell is composed of a plurality of element bodies formed in a rod shape, If we define the vertex as the point where the ends of the element bodies of the multiple unit cells located furthest towards the anti-skin layer are connected, The aforementioned vertex portion is the end of the lattice structure on the side opposite the epidermal layer, The three-dimensional structure according to claim 1, wherein the connecting body connects the vertices.

3. The three-dimensional structure according to claim 2, wherein the connecting body is formed in the shape of a rod with the same thickness as the element body.

4. The three-dimensional structure according to claim 2, wherein the width of the connecting body when viewed from the thickness direction of the base layer is wider than the thickness of the element body.

5. The three-dimensional structure according to claim 2, wherein the base layer comprises, as the connecting body, a first connecting body formed in the shape of a rod with the same thickness as the element body, and a second connecting body whose width when viewed from the thickness direction of the base layer is wider than the thickness of the element body.

6. The three-dimensional structure according to any one of claims 1 to 5, wherein the porosity of the surface of the substrate layer opposite the surface layer is 50% or more and 80% or less.

Images