3D Shaping Device Thermal Layer Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing three-dimensional shaped objects using stacked layers face challenges in achieving high adhesion strength between layers without the use of solvents, which are costly and require additional infrastructure.
Innovation Solution
A method involving a three-dimensional shaping device that discharges and presses shaping material against a tip end surface, with a heating step to raise the first layer to a temperature below the glass transition point, followed by a second layer formation with increased pressing, enhancing adhesion without solvents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solvent is used to increase adhesion strength between layers, then adhesion strength is improved, but device complexity and cost increase due to solvent supply mechanism and storage space requirements
Solution Approach 1:
The invention extracts and eliminates the solvent from the three-dimensional shaping system. Instead of using solvent to dissolve and bond layers, the patent uses a heating unit to thermally activate the resin material directly, allowing layers to adhere through controlled thermal softening and pressing without any solvent medium.
Solution Approach 2:
The heating unit serves as a thermal intermediary that activates the resin material. By heating the previously formed layer to a temperature below the glass transition temperature, the resin becomes sufficiently soft to bond with the next layer when pressed, replacing the chemical mediation role previously played by solvents.
2Strength
If solvent is used to increase adhesion strength between layers, then adhesion strength is improved, but manufacturing cost increases due to solvent purchase and infrastructure requirements
Solution Approach 1:
The invention extracts and eliminates the solvent from the three-dimensional shaping system. Instead of using solvent to dissolve and bond layers, the patent uses a heating unit to thermally activate the resin material directly, allowing layers to adhere through controlled thermal softening and pressing without any solvent medium.
Solution Approach 2:
The resin material itself provides the bonding function through its thermal response. When heated below its glass transition temperature, the resin naturally softens and becomes adhesive, eliminating the need for external solvent chemicals. The material serves its own bonding purpose through controlled thermal activation.
3Strength
If heating temperature is increased to improve adhesion, then adhesion strength is improved, but material degradation may occur if temperature exceeds glass transition temperature
Solution Approach 1:
The invention precisely controls the heating temperature parameter to be below the glass transition temperature of the resin material. This parameter optimization allows the resin to soften sufficiently for bonding while remaining below the threshold that would cause degradation or loss of structural integrity.
Solution Approach 2:
The heating unit is controlled to maintain temperature below the glass transition temperature, creating a feedback-controlled process where the thermal activation is precisely regulated to achieve bonding without exceeding material safety thresholds.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively increases adhesion strength between layers, improving the structural integrity of the three-dimensional shaped object in the stacking direction without the need for solvents, thereby enhancing the manufacturing process's efficiency and cost-effectiveness.
Implementation Method 1
heating the first portion to a temperature less than a glass transition temperature of the resin
Implementation Method 2
heating the first portion to a temperature less than a glass transition temperature of the resin
Data Source
AI summary
A method for manufacturing a three-dimensional shaped object includes: a first step of forming a first portion of the three-dimensional shaped object by discharging a shaping material containing a resin from a discharge portion toward a stage or a previously formed layer and pressing the discharged shaping material against a tip end surface of the discharge portion; a heating step of heating the first portion to a temperature less than a glass transition temperature of the resin; and a second step of forming a second portion of the three-dimensional shaped object by discharging the shaping material from the discharge portion toward the first portion heated in the heating step and pressing the discharged shaping material against the tip end surface.