Resin-containing member, method for manufacturing resin-containing member, and method for manufacturing fired body

Abstract

To provide a resin-containing member that allows a formable three-dimensional structure to have an expanded range and attains improved handling properties, a method for producing the resin-containing member, and a method for producing a calcined body.SOLUTION: A mixture obtained by mixing a calcinable powder material and a liquid binder containing a photocurable resin is prepared (step S101). The mixture prepared is used for the fabrication of a sheet-like member by stereolithography (step S102). In stereolithography, a sheet-like member is formed by laminating photocured layers each containing the photocurable resin in a vertical direction. At this time, at least one of an energy of light applied on the photocurable resin and an irradiation position of the light is adjusted. In the fabricated sheet-like member, a soft part composed of the photocurable resin in at least one of a semi-cured state and an uncured state exists.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a resin-containing member made using a photocurable resin, a method for manufacturing a resin-containing member, and a method for manufacturing a fired body. [Background technology]

[0002] Ceramic green sheets are used to manufacture various products such as substrates and artificial bones (see, for example, Patent Document 1). Ceramic green sheets are produced by forming a slurry containing ceramic powder and a binder into a sheet and drying it. The binder is made of, for example, a resin. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2012-029760 Summary of the Invention [Problem to be solved by the invention]

[0004] It is desirable for ceramic green sheets to have a three-dimensional structure to achieve functions according to their applications. Examples of such three-dimensional structures include a lattice structure, a moth-eye structure, a gyroid structure, a mesh structure, an embossed structure, and a concave-convex structure. Meanwhile, ceramic green sheets are generally processed using a processing machine (a laser processing machine or a mechanical processing machine). While processing methods using a processing machine can form simple three-dimensional structures, it is difficult to form complex three-dimensional structures such as the lattice structure, the moth-eye structure, the gyroid structure, the mesh structure, the embossed structure, and the concave-convex structure.

[0005] Furthermore, it is desirable for ceramic green sheets to be bendable, foldable, etc., to increase the degree of freedom in the three-dimensional shape of the sintered body that can be produced. In this regard, some ceramic green sheets have a certain degree of flexibility in their unsintered state. However, even if such ceramic green sheets are deformed into a predetermined three-dimensional shape by being bent or folded, they do not have the strength to maintain the three-dimensional shape. Therefore, it is difficult to produce a sintered body having a predetermined three-dimensional shape from such ceramic green sheets.

[0006] On the other hand, some ceramic green sheets have relatively high rigidity in an unsintered state. However, such ceramic green sheets are difficult to deform. Therefore, the applicable uses of ceramic green sheets have been limited by the target three-dimensional shape. Thus, ceramic green sheets are difficult to handle due to deformation.

[0007] An object of the present disclosure is to provide a resin-containing member that can be formed in a wider range of three-dimensional structures and has improved handleability, a method for manufacturing a resin-containing member, and a method for manufacturing a fired body. [Means for solving the problem]

[0008] (1) The resin-containing member according to the first disclosure has a three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and includes a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state. The photocurable resin contains bakeable powder material.

[0009] Because the resin-containing member contains a photocurable resin, it can be formed using a stereolithography method. This expands the range of three-dimensional structures that can be formed. Furthermore, because the resin-containing member contains a soft portion, it can be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed resin-containing member with light or applying heat, the resin-containing member can be completely cured. Therefore, the range of three-dimensional structures that can be formed as a resin-containing member is expanded and the handleability of the resin-containing member is improved.

[0010] light The curable resin is added with powdered material that can be baked. There are In this case, fired bodies of various shapes can be produced, which widens the range of three-dimensional shapes that can be formed into fired bodies.

[0011] ( 2 ) The resin-containing member according to the second disclosure has a three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and includes a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state; Multiple through holes are distributed This In this case, the weight of the resin-containing member is reduced and the flexibility of the resin-containing member is improved.

[0012] ( 3 ) The resin-containing member according to the third disclosure has a three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and includes a soft portion made of the photocurable resin in at least one of a semi-cured state and an uncured state; The soft portion includes a first soft portion made of a photocurable resin in a first semi-cured state, and a second soft portion made of a photocurable resin in a second semi-cured state or an uncured state that is closer to an uncured state than the first semi-cured state. nothing.

[0013] In this case, the second soft portion has higher flexibility than the first soft portion, and therefore, by selectively providing the first soft portion and the second soft portion in multiple portions of the resin-containing member, it is possible to easily adjust the flexibility distribution in the resin-containing member.

[0014] ( 4The second soft portion may be formed so as to be present inside the first soft portion. In this case, since the second soft portion is present inside the first soft portion, it is possible to prevent the resin-containing member from losing its outer shape due to exposure of the uncured photocurable resin.

[0015] ( 5 ) A resin-containing member according to a fourth disclosure has a three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and includes a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state; The three-dimensional structure includes at least one selected from the group consisting of a lattice structure, a moth-eye structure, a gyroid structure, a mesh structure, an embossed structure, and a concave-convex structure. nothing. In this case, functions specific to various structures, such as a weight reduction function, an anti-reflection function, and a strength ensuring function, can be added to the photocurable resin.

[0018] ( 6 ) A method for producing a resin-containing member according to a fifth disclosure includes: The method includes a step of fabricating a resin-containing member by a stereolithography method in which photocured layers containing a photocurable resin are stacked in the vertical direction, and the step of fabricating the resin-containing member includes forming a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state by adjusting at least one of the energy of light irradiated onto the photocurable resin and the irradiation position of the light in the stereolithography method. and forming the soft portion includes, in the stereolithography method, forming a soft portion made of a photocurable resin in a first semi-cured state as the first soft portion, and forming a soft portion made of a photocurable resin in a second semi-cured state or an uncured state that is closer to an uncured state than the first semi-cured state as the second soft portion so as to be present inside the first soft portion. nothing.

[0019] In the method for manufacturing a resin-containing member, the resin-containing member is produced using stereolithography. This expands the range of three-dimensional structures that can be formed. Furthermore, since the produced resin-containing member contains a soft portion, it can be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed resin-containing member with light or applying heat, the resin-containing member can be completely cured. Therefore, the range of three-dimensional structures that can be formed as a resin-containing member is expanded and the handleability of the resin-containing member is improved.

[0021] AlsoThe second soft portion has higher flexibility than the first soft portion. Therefore, by selectively providing the first soft portion and the second soft portion in multiple portions of the resin-containing member, the distribution of flexibility in the resin-containing portion can be easily adjusted.

[0022] ( 7 ) A method for producing a resin-containing member according to a sixth disclosure includes a step of producing a resin-containing member by a stereolithography method in which photocured layers containing a photocurable resin are stacked in a vertical direction, and the step of producing the resin-containing member includes forming a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state by adjusting at least one of the energy of light irradiated to the photocurable resin and the irradiation position of the light in the stereolithography method; The method for manufacturing a resin-containing member includes: Fabrication In the process of Fabrication The method further includes a step of curing the resin-containing member, the step of curing the resin-containing member including deforming the resin-containing member and applying light energy or thermal energy to the deformed resin-containing member to cure the deformed resin-containing member. Includes:

[0023] In this case, the resin-containing member that has been cured into a three-dimensional shape corresponding to the reference shape can be subjected to a desired process.

[0024] ( 8 The step of curing the resin-containing member may further include bonding the resin-containing member to the surface of another member that will serve as a molding surface while deforming the soft portion. In this case, an integrally molded product of the member that includes the molding surface and the resin-containing member can be easily produced.

[0027] ( 9 ) No. 7 The method for producing a sintered body according to the disclosure includes the method for producing the resin-containing member described above, and a sinterable powder material is added to the photocurable resin, and the method for producing the sintered body includes: Resin-containing materials The method further includes a step of firing the resin-containing member cured by the manufacturing method. The method for manufacturing a fired body allows for the production of fired bodies having a variety of three-dimensional shapes. [Effects of the Invention]

[0028] According to the present disclosure, the range of three-dimensional structures that can be formed as a resin-containing component is expanded and the handleability is improved, and the range of three-dimensional shapes that can be formed as a fired body is also expanded. [Brief explanation of the drawings]

[0029] [Figure 1] 1 is a flowchart illustrating a method for manufacturing a sintered body according to an embodiment of the present disclosure. [Figure 2] 1A to 1C are schematic diagrams illustrating an example of a process for producing a sheet-like member by a stereolithography method. [Figure 3] 10A and 10B are diagrams illustrating an example of cleaning of a sheet-like member. [Figure 4] FIG. 2 is a plan view of a sheet-like member produced by steps S101 to S103 in FIG. [Figure 5] FIG. 5 is a partially enlarged cross-sectional view taken along line AA in FIG. 4. [Figure 6] FIG. 2 is a diagram showing an example of post-cure in step S105 of FIG. [Figure 7] FIG. 10 is a plan view of a sheet-like member according to a first modified example. [Figure 8] FIG. 8 is a partially enlarged cross-sectional view taken along line BB in FIG. 7. [Figure 9] FIG. 10 is a plan view of a sheet-like member according to a second modified example. [Figure 10] FIG. 10 is a partially enlarged cross-sectional view taken along line CC in FIG. 9. [Figure 11] FIG. 10 is a plan view of a sheet-like member according to a third modified example. [Figure 12] FIG. 12 is a partially enlarged cross-sectional view taken along line DD in FIG. [Figure 13] FIG. 10 is a plan view of a sheet-like member according to a fourth modified example. [Figure 14] FIG. 14 is a partially enlarged cross-sectional view taken along line EE in FIG. [Figure 15] 10A to 10C are diagrams for explaining a method for manufacturing a fired body according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0030] [1] Manufacturing method of resin-containing member and fired body Hereinafter, a resin-containing member, a method for manufacturing a resin-containing member, and a method for manufacturing a sintered body according to an embodiment of the present disclosure will be described with reference to the drawings. Fig. 1 is a flowchart showing the method for manufacturing a sintered body according to an embodiment of the present disclosure.

[0031] In the method for manufacturing a sintered body according to this embodiment, first, a mixture is prepared by mixing a sinterable powder material with a liquid binder containing a photocurable resin (step S101). The sinterable powder material includes, for example, at least one of a ceramic powder and a metal powder. The mixture prepared in step S101 has fluidity. Therefore, in the following description, the mixture prepared in step S101 is referred to as a fluid mixture. The fluid mixture is, for example, a slurry.

[0032] Next, a sheet-like member is produced by stereolithography using the prepared fluid mixture (step S102). FIG. 2 is a schematic diagram showing an example of a process for producing a sheet-like member by stereolithography. As shown in the upper part of FIG. 2, in the process for producing a sheet-like member by stereolithography, the fluid mixture 10 prepared in step S101 is applied to a predetermined thickness on the upper surface of a table (not shown). Exposure light (hereinafter referred to as exposure light) is irradiated from an exposure device 1 onto the applied fluid mixture 10. The exposure light is, for example, laser light having a wavelength in the photosensitive wavelength range of the photocurable resin used in the fluid mixture 10. The laser light is generated from a laser diode. Note that light generated from another light source, such as an LED (light emitting diode), may be used as the exposure light instead of laser light.

[0033] At this time, the exposure light is scanned over the surface of the fluid mixture along a predetermined pattern. As a result, the portion X of the fluid mixture 10 irradiated with the exposure light is cured, and becomes a fully cured state or a semi-cured state, which will be described later. In the upper part of Figure 2, the portions of the fluid mixture 10 other than the portion X are in an uncured state, which will be described later.

[0034] Thereafter, a new layer of the fluid mixture 10 is formed by applying a predetermined thickness of the fluid mixture 10 onto the partially cured layer of the fluid mixture 10. The new layer of the fluid mixture 10 is irradiated with exposure light in a predetermined pattern. As a result, the portion X of the fluid mixture 10 irradiated with the exposure light is cured.

[0035] By repeating the above series of operations, a laminate consisting of multiple layers of the hardened fluid mixture 10 is produced, as shown in the lower part of Figure 2. This laminate includes a sheet-like member 10X formed by stacking hardened portions X in a predetermined pattern.

[0036] The degree of hardening of a photocurable resin due to irradiation with exposure light varies depending on the amount of energy of the irradiated exposure light. Here, the minimum amount of energy required for a photocurable resin to completely harden is called the required energy amount. If a photocurable resin is irradiated with exposure light with an energy amount less than the required energy amount, the photocurable resin will not completely harden and will retain flexibility. In this case, the greater the amount of energy imparted to the photocurable resin by exposure, the greater the degree of hardening of the photocurable resin and the lower its flexibility. On the other hand, the smaller the amount of energy imparted to the photocurable resin by exposure, the lower the degree of hardening of the photocurable resin and the higher its flexibility.

[0037] In the following description, the state of a photocurable resin that has not been exposed to light is referred to as an uncured state, and the state of a photocurable resin that has been exposed to the required amount of energy is referred to as a fully cured state. Furthermore, the state of a photocurable resin that has been exposed to an energy amount lower than the required amount, i.e., a state of a photocurable resin between the uncured state and the fully cured state, is referred to as a semi-cured state. The photocurable resin according to this embodiment may have a certain degree of elasticity and flexibility even when it is in a fully cured state.

[0038] In this embodiment, the output power and scanning speed of the exposure light irradiated onto the fluid mixture 10 are adjusted so that the sheet-like member 10X to be produced contains a photocurable resin in at least one of a semi-cured state and an uncured state. Also, the irradiation position of the exposure light irradiated onto the fluid mixture 10 is adjusted. As a result, at least a portion of the sheet-like member 10X produced in step S102 is flexible.

[0039] When a portion of the sheet-like member 10X contains uncured photocurable resin, the output and scanning speed of the exposure light irradiated onto the fluid mixture 10 are adjusted so that the uncured portion is contained within an enclosed space formed by the semi-cured photocurable resin. Also, the irradiation position of the exposure light irradiated onto the fluid mixture 10 is adjusted.

[0040] As described above, after a laminate including the sheet-shaped member 10X is produced in step S102, the sheet-shaped member 10X is washed (step S103). FIG. 3 is a diagram showing an example of washing the sheet-shaped member 10X. As shown in FIG. 3, a spray nozzle 2 that sprays, for example, ethanol is directed toward the laminate including the sheet-shaped member 10X. Then, atomized ethanol is sprayed from the spray nozzle 2 onto the sheet-shaped member 10X, thereby removing uncured portions of the sheet-shaped member 10X from the sheet-shaped member 10X. The sheet-shaped member 10X obtained in this manner is an example of a resin-containing member of the present disclosure. Therefore, steps S101 to S103 of FIG. 1 are an example of a method for producing a resin-containing member of the present disclosure.

[0041] When the sheet-shaped member 10X containing the uncured photocurable resin is produced in step S102, the uncured portion of the produced sheet-shaped member 10X is contained in an enclosed space formed by the semi-cured photocurable resin, thereby preventing the uncured portion constituting the sheet-shaped member 10X from being removed together with unnecessary photocurable resin during cleaning in step S103.

[0042] FIG. 4 is a plan view of a sheet-shaped member 10X produced by steps S101 to S103 of FIG. 1. FIG. 5 is a partially enlarged cross-sectional view taken along line AA of FIG. 4. As shown in FIG. 4, the sheet-shaped member 10X of this example has a circular plate shape. The sheet-shaped member 10X may have other shapes, such as a rectangular plate shape. Furthermore, the sheet-shaped member 10X of this example has a large number of through holes 10h formed therein. The large number of through holes 10h are dispersed throughout the entire sheet-shaped member 10X. While each through hole 10h in FIG. 4 has a circular shape in plan view, each through hole 10h may have an elliptical shape or a rectangular shape in plan view. Alternatively, the through holes 10h may have other shapes, such as a triangular shape in plan view. Furthermore, the distance between each two adjacent through holes 10h may be smaller or larger than that in the example of FIG. 4.

[0043] In the cross-sectional view of FIG. 5, each of the multiple layers of the fluid mixture 10 formed by stacking using the stereolithography method is indicated by a dotted line. In the sheet-like member 10X of FIG. 5, the hatched portions of the sheet-like member 10X are assumed to be in a semi-cured state. Therefore, the sheet-like member 10X has a predetermined flexibility corresponding to the amount of energy of the exposure light applied to the fluid mixture 10 in step S102. Furthermore, in the sheet-like member 10X of this example, multiple through holes 10h are formed throughout the sheet-like member 10X, thereby reducing the weight of the sheet-like member 10X and improving the flexibility of the sheet-like member 10X. The sheet-like member 10X has a thickness of, for example, about 0.1 mm to 1.0 mm.

[0044] Next, the sheet-like member 10X cleaned in step S103 of FIG. 1 is pressed against a molding surface having a predetermined reference shape (step S104). This reference shape corresponds to the three-dimensional shape of the sintered body to be finally produced (hereinafter referred to as the target shape). The molding surface is formed of a material that is at least harder than the photocurable resin in a fully cured state and has excellent heat resistance. In this case, as described above, the sheet-like member 10X is flexible, and when pressed against the molding surface, it deforms into the three-dimensional shape corresponding to the reference shape, i.e., the target shape.

[0045] Next, while the sheet-shaped member 10X is pressed against the molding surface, the entire sheet-shaped member 10X is irradiated with exposure light to promote complete curing of the photocurable resin, a so-called post-cure (step S105). In the post-cure, the output of the exposure light is adjusted so that the entire photocurable resin forming the sheet-shaped member 10X is completely cured.

[0046] Note that some photocurable resins can be cured by applying heat instead of irradiating them with exposure light. Therefore, depending on the type of photocurable resin used, the entire sheet-shaped member 10X may be cured by applying heat (thermal energy) to the sheet-shaped member 10X in step S105.

[0047] FIG. 6 shows an example of the post-cure process in step S105 of FIG. 1. In the example of FIG. 6, as shown in the upper part, a cylindrical mold 9 is prepared, and a sheet-like member 10X is pressed against the outer peripheral surface 9S of the mold 9, which serves as a molding surface. At this time, the sheet-like member 10X is flexible and therefore deformed into a target shape corresponding to the shape (reference shape) of the outer peripheral surface 9S. In this state, exposure light is irradiated from the exposure device 3 toward the entire sheet-like member 10X so that each part of the sheet-like member 10X is given an amount of energy greater than or equal to the required amount. This completely cures all of the photocurable resin contained in the sheet-like member 10X. The cured sheet-like member 10X is then peeled off from the mold 9. As a result, a sheet-like member 10X cured to the target shape is obtained, as indicated by the white arrows in FIG. 6.

[0048] Finally, the sheet-shaped member 10X that has been hardened into the target shape by post-cure is fired (step S106), thereby producing a fired body made mainly of the powder material that was contained in the fluid mixture.

[0049] [2] First Modification of Sheet-Like Member 10X In the above example, the sheet-like member 10X is formed in a semi-hardened state and has multiple dispersed through holes 10h, but the configuration of the sheet-like member 10X produced using the stereolithography method is not limited to the above example.

[0050] Fig. 7 is a plan view of a sheet-shaped member 10X according to a first modified example. Fig. 8 is a partially enlarged cross-sectional view taken along line BB in Fig. 7. In the cross-sectional view of Fig. 8, each of the multiple layers of the fluid mixture 10 formed by stacking using the stereolithography method is indicated by a dotted line. Differences between the sheet-shaped member 10X in Fig. 7 and the sheet-shaped member 10X in Fig. 4 will be described.

[0051] As shown in the plan view of Fig. 7 and the partially enlarged cross-sectional view of Fig. 8, in this example, the sheet-like member 10X includes a semi-cured portion 11a and multiple uncured portions 11b. The semi-cured portion 11a is a portion made of a photocurable resin in a semi-cured state, and the uncured portion 11b is a portion made of a photocurable resin in an uncured state. In the partially enlarged cross-sectional view of Fig. 8, the semi-cured portion 11a is hatched, and the multiple uncured portions 11b are marked with a dot pattern.

[0052] The plurality of uncured portions 11b are formed inside the semi-cured portion 11a. The plurality of uncured portions 11b are also dispersed throughout the entire sheet-shaped member 10X in a plan view. The plurality of uncured portions 11b are also dispersed in the thickness direction of the sheet-shaped member 10X (the stacking direction of the plurality of layers of the fluid mixture 10 formed in the stereolithography method). In this way, in the sheet-shaped member 10X according to the first modification, the plurality of uncured portions 11b are further present inside the flexible semi-cured portion 11a. This ensures the strength of the fired body obtained by firing the sheet-shaped member 10X and also improves the flexibility of the sheet-shaped member 10X.

[0053] 7, each uncured portion 11b has a circular shape in plan view, but each uncured portion 11b may have an elliptical shape in plan view or a rectangular shape in plan view. Alternatively, each uncured portion 11b may have another shape, such as a triangular shape in plan view. Furthermore, in the sheet-like member 10X of this example, one or more through holes may be formed in the area excluding the uncured portions 11b in plan view.

[0054] Furthermore, in the examples of Figures 7 and 8, instead of the uncured portion 11b, a portion in a semi-cured state (an example of a second semi-cured state of the present disclosure) that is closer to an uncured state than the semi-cured state of the semi-cured portion 11a (an example of a first semi-cured state of the present disclosure) may be provided inside the semi-cured portion 11a.

[0055] [3] Second Modification of Sheet-Like Member 10X Fig. 9 is a plan view of a sheet-shaped member 10X according to a second modified example. Fig. 10 is a partially enlarged cross-sectional view taken along line CC in Fig. 9. In the cross-sectional view of Fig. 10, each of the multiple layers of the fluid mixture 10 formed by stacking using the stereolithography method is indicated by a dotted line. Differences between the sheet-shaped member 10X in Fig. 9 and the sheet-shaped member 10X in Fig. 4 will be described.

[0056] As shown in the plan view of Fig. 9 and the partially enlarged cross-sectional view of Fig. 10, in this example, the sheet-like member 10X includes a fully cured portion 12a and multiple uncured portions 12b. The fully cured portion 12a is a portion made of photocurable resin in a fully cured state, and the uncured portion 12b is a portion made of photocurable resin in an uncured state. In the partially enlarged cross-sectional view of Fig. 10, the fully cured portion 12a is densely hatched, and the multiple uncured portions 12b are made of dotted patterns.

[0057] The plurality of uncured portions 12b are formed inside the fully cured portion 12a. The plurality of uncured portions 12b are dispersed throughout the entire sheet-shaped member 10X in a plan view. The plurality of uncured portions 12b are also dispersed in the thickness direction of the sheet-shaped member 10X (the stacking direction of the plurality of layers of the fluid mixture 10 formed in the stereolithography method). In other words, the fully cured portion 12a forms a three-dimensional structure surrounding the plurality of uncured portions 12b.

[0058] In order to form the above three-dimensional structure, when the sheet-like member 10X according to the second modified example is produced, each time a layer of the fluid mixture 10 is formed by stereolithography, exposure light is irradiated onto a portion of the formed layer that corresponds to the fully cured portion 12a. As a result, the fully cured portion 12a is formed at the portion irradiated with the exposure light. Furthermore, the exposure light is not irradiated onto a portion of the layer of the fluid mixture 10 that corresponds to the uncured portion 12b. As a result, the uncured portion 12b is formed at the portion not irradiated with the exposure light.

[0059] Thus, in the sheet-like member 10X according to the second modification, multiple uncured portions 12b exist within the inflexible fully cured portion 12a. In this configuration, each of the multiple uncured portions 12b is formed at a fine level with high density, so that distortion in each part of the fully cured portion 12a is absorbed by the multiple uncured portions 12b. As a result, a certain level of flexibility is ensured despite the presence of the fully cured portions 12a.

[0060] 9, as in the example of FIG. 7, each uncured portion 12b has a circular shape in plan view, but each uncured portion 12b may have an elliptical shape or a rectangular shape in plan view. Alternatively, each uncured portion 12b may have another shape, such as a triangular shape, in plan view. Furthermore, one or more through holes may be formed in the sheet-like member 10X of this example in a region excluding the uncured portions 12b in plan view.

[0061] 9 and 10, semi-cured portions may be provided inside the fully cured portion 12a instead of the uncured portions 12b. Even in this case, each of the semi-cured portions is densely formed at a fine level, so that distortions in each part of the fully cured portion 12a are absorbed by the semi-cured portions. This ensures a certain level of flexibility despite the presence of the fully cured portions 12a.

[0062] [4] Third Modification of Sheet-Like Member 10X Fig. 11 is a plan view of a sheet-shaped member 10X according to a third modified example. Fig. 12 is an enlarged cross-sectional view of a portion taken along line DD in Fig. 11. Differences between the sheet-shaped member 10X in Fig. 11 and the sheet-shaped member 10X in Fig. 4 will be described.

[0063] As shown in the plan view and partially enlarged cross-sectional view of FIG. 11, in this example, the sheet-shaped member 10X is composed of only a single layer of the fluid mixture 10 formed by layering using a stereolithography method. The entire sheet-shaped member 10X is made of a photocurable resin in a semi-cured state. In this configuration, the three-dimensional structure of the sheet-shaped member 10X is simple, making it easy to fabricate the sheet-shaped member 10X. Furthermore, the thickness of the sheet-shaped member 10X can be made sufficiently small, thereby reducing the weight of the sheet-shaped member 10X and improving the flexibility of the sheet-shaped member 10X.

[0064] 11 and 12, the thickness of the sheet-shaped member 10X may be adjusted to such an extent that the flexibility required for the sheet-shaped member 10X is not impaired. In this case, the sheet-shaped member 10X may be formed of multiple layers of the fluid mixture 10 by a stereolithography method.

[0065] [5] Fourth Modification of Sheet-Like Member 10X Fig. 13 is a plan view of a sheet-shaped member 10X according to a fourth modified example. Fig. 14 is a partially enlarged cross-sectional view taken along line EE in Fig. 13. In the cross-sectional view of Fig. 14, each of the multiple layers of the fluid mixture 10 formed by stacking using the stereolithography method is indicated by a dotted line. Differences between the sheet-shaped member 10X in Fig. 13 and the sheet-shaped member 10X in Fig. 4 will be described.

[0066] As shown in the plan view of FIG. 13 and the partially enlarged cross-sectional view of FIG. 14, in this example, the sheet-like member 10X includes a base portion 13a and multiple ridge portions 13b. The base portion 13a has a disk shape with a constant thickness. Alternatively, the base portion 13a may have another shape, such as a rectangle. The multiple ridge portions 13b are formed on one surface of the base portion 13a so as to protrude upward and be aligned at regular intervals in one direction. Furthermore, each ridge portion 13b is formed so as to extend in another direction that intersects with the one direction in which the multiple ridge portions 13b are aligned. As a result, the sheet-like member 10X has a wave-shaped structure on one surface. Furthermore, the sheet-like member 10X in this example is entirely made of a photocurable resin in a semi-cured state.

[0067] The sheet-shaped member 10X is fabricated by a stereolithography method, and therefore, the above-described wave-shaped structure can be easily formed as the structure of the sheet-shaped member 10X, despite having a complex shape.

[0068] Instead of the corrugated structure, the sheet-like member 10X may have a three-dimensional structure such as a moth-eye structure, a lattice structure, a gyroid structure, a mesh structure, an embossed structure, or a concave-convex structure on one surface. Alternatively, the entire sheet-like member 10X may be formed with a three-dimensional structure such as a moth-eye structure, a lattice structure, a gyroid structure, a mesh structure, an embossed structure, or a concave-convex structure. These three-dimensional structures can also be easily formed as the structure of the sheet-like member 10X using stereolithography. In this case, functions specific to various structures, such as a lightweight function, an anti-reflection function, and a strength-ensuring function, can be added to the sheet-like member 10X.

[0069] [6] Effects (1) The sheet-like member 10X contains a photocurable resin and can be formed using a stereolithography method. This expands the range of three-dimensional structures that can be formed. Furthermore, since the sheet-like member 10X contains a soft portion, it can be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed sheet-like member 10X with exposure light or by applying heat, the sheet-like member 10X can be completely cured. Therefore, the range of three-dimensional structures that can be formed as the sheet-like member 10X is expanded and the handleability of the sheet-like member 10X is improved. Furthermore, by adding a sinterable powder material to the sheet-like member 10X, sintered bodies of various three-dimensional shapes can be produced, thereby expanding the range of three-dimensional shapes that can be formed as sintered bodies.

[0070] (2) In the sheet-shaped member 10X according to the first modified example of Fig. 7, the uncured portions 11b are more flexible than the semi-cured portions 11a. Therefore, by selectively providing the semi-cured portions 11a and the uncured portions 11b in multiple portions of the sheet-shaped member 10X, the distribution of flexibility in the sheet-shaped member 10X can be easily adjusted.

[0071] (3) In addition, in the sheet-shaped member 10X according to the first modification in Fig. 7, the uncured portion 11b is present inside the semi-cured portion 11a, which prevents the uncured photocurable resin from being exposed and thus causing the outer shape of the sheet-shaped member 10X to be lost. In the sheet-shaped member 10X according to the second modification in Fig. 9, similarly to the sheet-shaped member 10X according to the first modification in Fig. 7, the uncured portion 12b is present inside the fully cured portion 12a, which prevents the uncured photocurable resin from being exposed and thus causing the outer shape of the sheet-shaped member 10X to be lost.

[0072] [7] Other embodiments (1) In the above embodiment, in step S104, the sheet-shaped member 10X is pressed against the outer peripheral surface 9S of the mold 9, which serves as a molding surface. In step S105, the sheet-shaped member 10X that has been hardened by post-cure is peeled off from the mold 9. However, the present disclosure is not limited to this.

[0073] The mold 9 may be formed of a material that can withstand the baking environment of the sheet-shaped member 10X, and the sheet-shaped member 10X may be attached to the mold 9 in step S104. Fig. 15 is a diagram for explaining a method for producing a baked body according to another embodiment. Fig. 15 shows, one above the other, a cross-sectional view of the sheet-shaped member 10X being pressed against the mold 9 and attached to the mold 9, and a cross-sectional view of the sheet-shaped member 10X being post-cured.

[0074] 15, the sheet-shaped member 10X of this example includes a semi-cured portion 14a and an uncured portion 14b. Furthermore, a moth-eye structure including a plurality of minute protrusions is formed on one surface of the sheet-shaped member 10X of this example.

[0075] First, a mold 9 is prepared having an attachment surface SS to which the sheet-like member 10X is to be attached. A liquid photocurable resin 8 is applied to the attachment surface SS as an adhesive. The photocurable resin 8 is preferably the same as the photocurable resin that constitutes the fluid mixture 10. Thereafter, the sheet-like member 10X is attached onto the attachment surface SS of the mold 9 via the photocurable resin 8.

[0076] In this state, post-curing is performed. As a result, as shown in the lower part of Fig. 15, the entire sheet-shaped member 10X and the entire photocurable resin 8 are completely cured, and the mold 9 and the sheet-shaped member 10X are bonded together. Thereafter, the sheet-shaped member 10X is baked. Thus, according to the example of Fig. 15, by bonding the sheet-shaped member 10X before baking to another member, the range of baked bodies that can be produced is expanded.

[0077] (2) In the above embodiment, the sheet-shaped member 10X is used to produce a sintered body, but the present disclosure is not limited thereto. The sheet-shaped member 10X can also be used for purposes other than producing a sintered body. In this case, the sheet-shaped member 10X does not need to contain a sinterable powder material.

[0078] For example, the sheet-like member 10X may be formed as a diffraction grating. In this case, in the example of Fig. 15, a lens is prepared as the mold 9, and the sheet-like member 10X is attached to one surface of the prepared lens, followed by post-curing, whereby an optical member having desired optical properties can be easily produced.

[0079] (3) In the above embodiment, the sheet-shaped member 10X that is cured by post-curing does not necessarily have to have a sheet shape. As long as the entire member can be completely cured by post-curing, the flexible resin-containing member may have a rectangular parallelepiped shape, a cylindrical shape, or a spherical shape. In this case, too, the above-described structure can suppress surface cracks.

[0080] [8] Correspondence between each element of the claims and each element of the embodiment Below, examples of correspondence between each element of the claims and each element of the embodiments will be described, but the present disclosure is not limited to the following examples. Various other elements having the configuration or function described in the claims can also be used as each element of the claims.

[0081] In the above embodiment, sheet-like member 10X is an example of a resin-containing member, the entire sheet-like member 10X shown in Figures 4, 7, 11, 13 and the upper part of Figure 15 and unhardened portion 12b in Figure 9 are examples of soft portions, semi-hardened portion 11a in Figure 7 and semi-hardened portion 14a in the upper part of Figure 15 are examples of a first soft portion, and unhardened portion 11b in Figure 7 and unhardened portion 14b in the upper part of Figure 15 are examples of a second soft portion.

[0082] Further, the fully hardened portion 12a in FIG. 9 is an example of a hard portion, the unhardened portion 12b in FIG. 9 is an example of a soft portion, and the outer peripheral surface 9S of the mold 9 in FIG. 6 and the surface SS to be attached in FIG. 15 are examples of molding surfaces. [9] Reference form (1) The resin-containing member according to the first embodiment has a three-dimensional structure that can be formed using a photopolymerization method in which photocured layers containing a photocurable resin are stacked in an up-down direction, and includes a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state. Because the resin-containing member contains a photocurable resin, it can be formed using a stereolithography method. This expands the range of three-dimensional structures that can be formed. Furthermore, because the resin-containing member contains a soft portion, it can be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed resin-containing member with light or applying heat, the resin-containing member can be completely cured. Therefore, the range of three-dimensional structures that can be formed as a resin-containing member is expanded and the handleability of the resin-containing member is improved. (2) A sinterable powder material may be added to the photocurable resin, which allows for the production of sintered bodies in a variety of shapes, thereby expanding the range of three-dimensional shapes that can be formed into sintered bodies. (3) The resin-containing member may have a plurality of through holes dispersed therein, which reduces the weight of the resin-containing member and improves the flexibility of the resin-containing member. (4) The soft portion may include a first soft portion made of a photocurable resin in a first semi-cured state, and a second soft portion made of a photocurable resin in a second semi-cured state or an uncured state that is closer to an uncured state than the first semi-cured state. In this case, the second soft portion has higher flexibility than the first soft portion, and therefore, by selectively providing the first soft portion and the second soft portion in multiple portions of the resin-containing member, it is possible to easily adjust the flexibility distribution in the resin-containing member. (5) The second soft portion may be formed so as to be present inside the first soft portion. In this case, since the second soft portion is present inside the first soft portion, it is possible to prevent the resin-containing member from losing its outer shape due to exposure of the uncured photocurable resin. (6) The three-dimensional structure may include at least one selected from the group consisting of a lattice structure, a moth-eye structure, a gyroid structure, a mesh structure, an embossed structure, and a concave-convex structure. In this case, the photocurable resin can be provided with functions specific to each structure, such as a lightweight function, an anti-reflection function, and a strength function. (7) The resin-containing member according to the second reference embodiment has a three-dimensional structure that can be formed using a photo-lithography method in which photo-cured layers containing photo-curable resin are stacked in the vertical direction, and includes a hard portion made of photo-curable resin in a fully cured state and a soft portion made of photo-curable resin in a semi-cured or uncured state, and the soft portion is formed so as to exist inside the hard portion. Because the resin-containing member contains a photocurable resin, it can be formed using a stereolithography method. This expands the range of three-dimensional structures that can be formed. Furthermore, because the resin-containing member contains a soft portion, even if distortion occurs in the hard portion, the distortion is absorbed by the soft portion. This allows the resin-containing member to be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed resin-containing member with light or applying heat, the resin-containing member can be completely cured. Therefore, the range of three-dimensional structures that can be formed as a resin-containing member is expanded and the handleability of the resin-containing member is improved. (8) A method for manufacturing a resin-containing member according to a third reference embodiment includes a step of producing a resin-containing member by a photo-lithography method in which photo-cured layers containing a photo-curable resin are stacked in an up-down direction, and the step of producing the resin-containing member includes forming a soft portion made of a photo-curable resin in at least one of a semi-cured state and an uncured state by adjusting at least one of the energy of light irradiated to the photo-curable resin and the irradiation position of the light in the photo-lithography method. In the method for manufacturing a resin-containing member, the resin-containing member is produced using stereolithography. This expands the range of three-dimensional structures that can be formed. Furthermore, since the produced resin-containing member contains a soft portion, it can be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed resin-containing member with light or applying heat, the resin-containing member can be completely cured. Therefore, the range of three-dimensional structures that can be formed as a resin-containing member is expanded and the handleability of the resin-containing member is improved. (9) The process of forming the resin-containing member may include, in a photopolymerization method, forming a soft portion made of a photocurable resin in a first semi-cured state as the first soft portion, and forming a soft portion made of a photocurable resin in a second semi-cured state or an uncured state that is closer to an uncured state than the first semi-cured state as the second soft portion so as to be present inside the first soft portion. In this case, the second soft portion has higher flexibility than the first soft portion, and therefore, by selectively providing the first soft portion and the second soft portion in multiple portions of the resin-containing member, it is possible to easily adjust the flexibility distribution in the resin-containing portion. (10) The method for manufacturing a resin-containing member may further include a step of curing the resin-containing member formed in the step of forming the resin-containing member, and the step of curing the resin-containing member may further include deforming the resin-containing member and curing the deformed resin-containing member by applying light energy or thermal energy to the deformed resin-containing member. In this case, the resin-containing member that has been cured into a three-dimensional shape corresponding to the reference shape can be subjected to a desired process. (11) The step of curing the resin-containing member may further include bonding the resin-containing member to the surface of another member that will serve as a molding surface while deforming the soft portion. In this case, an integrally molded product of the member that includes the molding surface and the resin-containing member can be easily produced. (12) A method for manufacturing a resin-containing member according to a fourth embodiment includes a step of forming a resin-containing member by a photo-lithography method in which photo-cured layers containing a photo-curable resin are stacked in an up-down direction, and the step of forming the resin-containing member includes forming a hard portion made of a photo-curable resin in a fully cured state in the photo-lithography method, and forming a soft portion made of a photo-curable resin in a semi-cured or uncured state inside the hard portion. In the method for manufacturing a resin-containing member, the resin-containing member is produced using a photolithography system. This expands the range of three-dimensional structures that can be formed. Furthermore, since the produced resin-containing member includes a soft portion, even if distortion occurs in the hard portion, the distortion is absorbed by the soft portion. This allows the resin-containing member to be easily deformed into a desired three-dimensional shape. Furthermore, by irradiating the deformed resin-containing member with light or applying heat, the resin-containing member can be completely cured. Therefore, the range of three-dimensional structures that can be formed as a resin-containing member is expanded and the handleability of the resin-containing member is improved. (13) A fifth embodiment of the present invention relates to a method for producing a sintered body, which includes the method for producing a resin-containing member described above, and further includes a step of sintering the resin-containing member cured by the method. The method for producing a sintered body allows for the production of sintered bodies having a variety of three-dimensional shapes. [Explanation of symbols]

[0083] 1... exposure device, 2... spray nozzle, 3... exposure device, 8... photocurable resin, 9... mold, 9S... outer peripheral surface, 10... fluid mixture, 10X... sheet-like member, 10h... through hole, 11a, 14a... semi-cured portion, 11b, 12b, 14b... uncured portion, 12a... fully cured portion, 13a... base portion, 13b... convex rib portion, SS... surface to be attached

Claims

1. The object has a three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and includes a soft portion made of the photocurable resin in at least one of a semi-cured state and an uncured state; A resin-containing member in which a bakeable powder material is added to the photocurable resin.

2. A resin-containing member having a three-dimensional structure that can be formed using a photopolymerization method in which photocured layers containing photocurable resin are stacked in an up-and-down direction, and including a soft portion made of photocurable resin in at least one of a semi-cured state and an uncured state, and having a plurality of through holes dispersed therein.

3. A three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and that includes a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state, The soft portion is a first soft portion made of a photocurable resin in a first semi-cured state; a second soft portion made of a photocurable resin in a second semi-cured state that is closer to an uncured state than the first semi-cured state, or in an uncured state.

4. The resin-containing member according to claim 3 , wherein the second soft portion is formed so as to exist inside the first soft portion.

5. A three-dimensional structure that can be formed using a stereolithography method in which photocurable layers containing a photocurable resin are stacked in the vertical direction, and that includes a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state, The resin-containing member, wherein the three-dimensional structure includes at least one selected from the group consisting of a lattice structure, a moth-eye structure, a gyroid structure, a mesh structure, an embossed structure, and a concave-convex structure.

6. The method includes a step of producing a resin-containing member by a stereolithography method in which photocured layers containing a photocurable resin are stacked in a vertical direction, The step of producing a resin-containing member includes: In the stereolithography method, the method includes forming a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state by adjusting at least one of the energy of light irradiated onto the photocurable resin and the irradiation position of the light, Forming the soft portion comprises: A method for manufacturing a resin-containing member, comprising: forming, in the optical molding method, a soft portion made of a photocurable resin in a first semi-cured state as a first soft portion; and forming, as a second soft portion, a soft portion made of a photocurable resin in a second semi-cured state or an uncured state that is closer to an uncured state than the first semi-cured state, so as to be present inside the first soft portion.

7. A method for manufacturing a resin-containing member, comprising: The method includes a step of producing a resin-containing member by a stereolithography method in which photocured layers containing a photocurable resin are stacked in a vertical direction, The step of producing a resin-containing member includes: In the stereolithography method, the method includes forming a soft portion made of a photocurable resin in at least one of a semi-cured state and an uncured state by adjusting at least one of the energy of light irradiated onto the photocurable resin and the irradiation position of the light, The method for producing the resin-containing member includes: The method further includes a step of curing the resin-containing member produced in the step of producing the resin-containing member, The step of curing the resin-containing member includes: deforming the resin-containing member; and curing the deformed resin-containing member by applying light energy or thermal energy to the deformed resin-containing member.

8. The step of curing the resin-containing member includes: The method for producing a resin-containing member according to claim 7 , further comprising: bonding the resin-containing member to a surface of another member that serves as a molding surface while deforming the soft portion.

9. A method for producing a fired body, comprising: The method for producing a resin-containing member according to claim 7 or 8, a bakeable powder material is added to the photocurable resin; The method for producing the sintered body includes: A method for producing a sintered body, further comprising the step of sintering the resin-containing member cured by the method for producing a resin-containing member.

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