Thermally Expansive Layer Edge Definition via Selective Heating

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Solution Overview

Problem

Existing methods for producing three-dimensional images using thermally expandable sheets result in dulled edge portions due to heat conduction from image-forming material, leading to reduced convexity in the three-dimensional image.

Innovation Solution

A method involving a formation sheet with a base and a thermally expansive layer, where a thermal conversion layer is laminated on one surface to selectively heat and expand the thermally expansive layer using specific electromagnetic waves, while cross-linking the binder to control expansion and prevent edge dulling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the image portion is heated by irradiating with light to expand thermally expandable microspheres, then a three-dimensional image is formed, but heat conduction to surrounding areas causes edge portions to become dulled (hemming)

Engineering Contradiction:

Improveedge definition of three-dimensional imageVSAvoidheat conduction to surrounding areas

Core Design Contradiction:

Manufacturing precisionVSTemperature

Solution Approach 1:

A heat-insulating layer is introduced as an intermediary between the image-forming material and the thermally expandable microspheres in the coating layer. This layer prevents heat conduction from the image portion to the surrounding areas, thereby avoiding edge dulling while maintaining the three-dimensional image formation effect

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The coating layer is divided into multiple functional layers: an image-forming material layer, a heat-insulating layer, and a thermally expandable microsphere layer. This segmentation allows each layer to perform its specific function independently, with the heat-insulating layer preventing unwanted heat transfer to preserve edge definition

Inventive Principle:

Principle #1Segmentation

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 approach effectively suppresses edge portion dulling, enhancing the clarity and definition of the three-dimensional image by selectively heating and cross-linking the thermally expansive layer, resulting in a more precise and aesthetically appealing pseudo-three-dimensional object.

Implementation Method 1

a thermal conversion layer for converting first electromagnetic waves into heat

Methodology Applied

Scientific EffectElectromagnetic wave conversion to heat: Photoacoustic Effect

Implementation Method 2

a thermally expansive layer that is laminated on a first main surface of the base, the thermally expansive layer containing a binder and a thermal expansion material

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 3

second electromagnetic waves that cause the binder to become cross-linked

Methodology Applied

Scientific EffectCross-linking: Photopolymerisation

Data Source

PatentUS11511533B2Shaped object production method and expansion device

Publication Date: 2022.11.29 CASIO COMPUTER CO LTD

AI summary

A method of producing a shaped object includes preparing a formation sheet that includes a base and a thermally expansive layer that is laminated on a first main surface of the base, the thermally expansive layer containing a binder and a thermal expansion material; laminating, onto a second main surface on a side opposite to the first main surface of the base or onto the thermally expansive layer, a thermal conversion layer in predetermined pattern, the thermal conversion layer converting first electromagnetic waves into heat; and causing the thermally expansive layer to expand in a pattern that corresponds to the predetermined pattern by irradiating the formation sheet on which the thermal conversion layer is laminated with the first electromagnetic waves and second electromagnetic waves that cause the binder to become cross-linked.