Shaping System with Patterned Thermal Conversion Layer

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Solution Overview

Problem

Existing shaping systems struggle to manufacture shaped objects with fine unevenness due to unwanted expansion of thermally expandable microspheres in the vicinity of the image portion.

Innovation Solution

A shaping system and manufacturing method that utilize a molding sheet with a thermal expansion layer and a thermal conversion layer, where the thermal conversion layer is patterned to control the expansion of thermally expandable microspheres, allowing for the formation of both large and fine unevennesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the image-molding material is used to form the image by heating, then the image can be formed on the thermally expandable sheet, but the thermally expandable microspheres in the vicinity of the image portion are also heated and expand unintentionally

Engineering Contradiction:

Improveimage formation precisionVSAvoidunwanted expansion of microspheres

Core Design Contradiction:

Manufacturing precisionVSObject-generated harmful factors

Solution Approach 1:

The patent divides the heating function into two separate components: the image-molding material that absorbs light and generates heat, and the thermally expandable microspheres that expand when heated. By segmenting the heating source from the expansion target, the system can control which areas expand by precisely controlling the light absorption pattern of the image-molding material.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The image-molding material is applied selectively only to specific regions where image formation is desired, creating local variations in heat absorption. This local quality approach ensures that heat is generated only in the intended image areas, preventing unwanted expansion of microspheres in non-image regions while maintaining high manufacturing precision.

Inventive Principle:

Principle #3Local quality

2Manufacturing precision

If the thermally expandable microspheres are heated to form the image, then the image portion expands as intended, but the surrounding microspheres also expand due to heat diffusion

Engineering Contradiction:

Improveunevenness formation precisionVSAvoidheat diffusion to surrounding areas

Core Design Contradiction:

Manufacturing precisionVSTemperature

Solution Approach 1:

The image-molding material acts as an intermediary between the light source and the thermally expandable microspheres. It absorbs the incident light and converts it to heat locally, serving as a mediator that prevents direct heat diffusion from the light source to the surrounding microspheres. This intermediary layer enables precise thermal control for forming unevenness with fine detail.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If conventional foam molding is used to create three-dimensional shapes, then large unevenness can be formed, but fine unevennesses cannot be manufactured due to uncontrollable foaming

Engineering Contradiction:

Improvefine unevenness manufacturing capabilityVSAvoidfoaming control difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the conventional mechanical foam molding process with a photothermal system. Instead of using mechanical pressure and chemical foaming agents that are difficult to control locally, the system uses light absorption by the image-molding material to generate heat precisely where needed, triggering controlled expansion of thermally expandable microspheres. This substitution enables fine unevenness manufacturing while maintaining ease of operation through non-contact light-based processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The system effectively manufactures shaped objects with both tall and fine unevennesses, enhancing the precision and detail of the shaped objects compared to traditional methods.

Implementation Method 1

an image-molding material having excellent light absorption characteristics

Methodology Applied

Scientific EffectLight absorption: Absorption (EM radiation)

Implementation Method 2

thermally expandable microspheres... by selecting heating an image portion by irradiating with light

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3663064B1Shaping system and manufacturing method of shaped object

Publication Date: 2025.06.11 CASIO COMPUTER CO LTD

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AI summary

An expansion apparatus (300) includes: a first expander (310) for irradiating with electromagnetic waves emitted from a lamp (312) a thermal conversion layer (80) for conversion of the electromagnetic waves to heat, to cause at least a portion of a thermal expansion layer (20) to expand, the thermal conversion layer (80) being laminated to a molding sheet including a base and the thermal expansion layer (20) laminated to a first main surface (12a) of the base; and a second expander (320) for causing expansion of a region (C) of the thermal expansion layer (20) that is smaller in size than a region (B) of the thermal expansion layer (20) expanded by the first expander (310).