JP2002347128A - Stereolithography and manufacturing method - Google Patents

Abstract

(57) [Summary] [Problem] Even if a target article has a hollow portion through which a fluid passes and the pressure difference between the inside and outside is large during use, the original pressure of the article using a resin model by stereolithography To provide a stereolithography product that enables a characteristic test and a real machine test under conditions. SOLUTION: In a stereolithography product in which each layer when a design model is sliced in parallel into a number of layers is formed as a cured layer of a photocurable resin, an outer surface of the stereolithography product 1 is a cloth 2 impregnated with a synthetic resin. Coated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an optical molded product obtained by laminating layers obtained by parallel slicing a three-dimensional model as a cured layer of a photocurable resin by optical molding, and particularly to a hollow part to which pressure is applied. The present invention relates to a stereolithographic product and a method of manufacturing the same.

[0002]

2. Description of the Related Art In recent years, automobiles, aircraft, buildings, home appliances,
2. Description of the Related Art Techniques for designing and designing products and parts in various industrial fields such as toys and daily necessities on computers such as CAD, CAM, and CAE are widely used. As the latest means for producing a real model which embodies a three-dimensional model designed on such a computer, for example, a design model M ₀ on a computer C as shown in FIG. create data for each cross-section patterns when parallel sliced into many layers P ₁ to PN having a thickness of several tens to several hundreds μm units as (b), stereolithography obtain a three-dimensional resin model directly from the data Has appeared.

In this stereolithography method, as shown in FIG. 4C, an elevating pedestal 32 is provided in a molding tank 31 containing a solution 30 of a photocurable resin such as an ultraviolet-curable resin. An optical shaping apparatus in which a laser head 33 with an XY scanner is arranged on 31 is used. And the laser head 33
First, the position of the upper surface of the lifting pedestal 32 is set from the liquid level 30a of the solution 30 to a depth corresponding to the thickness of the sliced layer, and the liquid level is set in the controller (not shown). 30a to apply the laser beam L to the lowermost layer P
By irradiating along _one of the cross pattern, to form a cured resin layer P ₁ of the cross section pattern shape, then the elevating pedestal 32 is lowered by the thickness of the one layer Rikota (not shown) in the layer P ₁ The solution 30 is spread over the substrate, and similarly, the cured resin layer P ₂ is irradiated with the laser beam L to form the layer P _2.
Is formed on the _1, by irradiating a laser beam L lowers the elevating pedestal 32 sequentially one by one minute in the same manner since, ultimately FIG cured resin layer P ₁ ~, as shown in (d)
A resin model M in which P _n is laminated and integrated is produced.

However, such a resin model is used not only for confirming the form of a design model but also for conducting various characteristic tests as a prototype or as a part for a real machine test by incorporating it into a mechanical device. Is done. Above all,
In the design of articles that allow fluid to pass through, the actual state of flow and the hydrodynamic properties of the fluid that are actually passed through the optically molded resin model can be examined to evaluate the practicality of the designed product and to improve the finished product. There is an advantage that the suggestion of can be obtained.

[0005]

However, while an article in which the internal pressure during use is extremely high is generally made of metal, the optically molded resin model has poor pressure-resistant strength, and the resin model is subjected to actual machine tests. , Because it is difficult to set the same pressure conditions as when using the actual article,
There was a problem that sufficient test data could not be obtained. In particular, relatively large cavities such as gas mixing chambers, distribution chambers, and decompression chambers are more vulnerable to internal and external pressure differences than pipe-shaped tubular passages, even in the same fluid path, and are damaged. There was also a danger that the pieces that had fallen apart would fly around.

In view of the above circumstances, the present invention utilizes a resin model by stereolithography even if the target article has a hollow portion through which a fluid passes and the pressure difference between the inside and the outside during use is large. It is another object of the present invention to provide a stereolithographic product capable of performing a characteristic test and an actual machine test under the original pressure condition of the article, and a method of manufacturing the same.

[0007]

In order to achieve the above object, a stereolithographic product according to a first aspect of the present invention is provided by attaching a reference numeral in the drawing and slicing a design model into multiple layers in parallel. In this case, the outer surface of the stereolithographic object 1 is covered with a cloth 2 impregnated with a synthetic resin, in which the respective layers are laminated and formed as a cured layer of a photocurable resin. That is, in the stereolithography product having such a configuration,
Since the outer surface of the optical molded article 1 is reinforced by the covering of the cloth 2 impregnated with the synthetic resin and the pressure resistance is improved, the original pressure condition of the target article can be set when subjected to a characteristic test or an actual machine test. Further, even if the test piece deteriorates or breaks due to exceeding the critical pressure due to repeated tests, only a crack is generated and no fragments are scattered. Further, the impact resistance and durability of the optically shaped article are also improved by the coating layer 3.

According to a second aspect of the present invention, in the optical molded article according to the first aspect, the synthetic resin is a cured product of a photocurable resin. In this case, the resin component impregnated in the cloth 2 is the same resin component as the stereolithographic object 1, and the entire coating layer 3 of the cloth 2 is firmly integrated with the stereolithographic object 1. No, the reinforcement effect is greater.

According to the third aspect of the present invention, the first or second aspect is provided.
In the stereolithography, the cloth 2 is a glass cloth or a carbon cloth. In this case, the cloth 2 has high strength and good resin impregnation, and a sufficient reinforcing effect can be achieved even with a thin cloth. It is possible to stick it neatly. In addition, due to the material of the cloth 2, the chemical resistance and the corrosion resistance of the optically formed product are improved.

A fourth aspect of the present invention is the optically shaped article according to any one of the first to third aspects, wherein the cloth 2 is a plain weave cloth. In this case, since the flatness of the cloth 2 is good, the smoothness of the surface of the coating layer 3 is improved, and the fiber density of the coating layer 3 is increased, so that a large reinforcing effect can be obtained.

According to a fifth aspect of the present invention, in the optical molded article according to any one of the first to fourth aspects, the optical molded article 1 constitutes at least a part of a hollow portion whose inside becomes an emergency pressure during use. The configuration is a resin model of the article. Since this stereolithographic product has a high pressure-resistant strength due to the reinforcing effect of the cloth 2 impregnated with the synthetic resin, the use condition of the original emergency pressure (positive pressure or negative pressure with respect to the atmospheric pressure) having the hollow part is used. Can perform characteristic tests and actual machine tests.

According to a sixth aspect of the present invention, there is provided a method of manufacturing an optically molded article, wherein each layer obtained when a design model is sliced in parallel into a plurality of layers is laminated by photolithography as a cured layer of a photocurable resin. A cloth 2 impregnated with a synthetic resin solution is adhered to the outer surface of 1 and the impregnated synthetic resin is cured. According to this method, the above claims 1 to
4 can easily be manufactured.

According to a seventh aspect of the present invention, in the method for manufacturing an optically molded article according to the sixth aspect, a photocurable resin solution is used as a synthetic resin solution for impregnating the cloth 2, and the cloth 2 is adhered thereto. The outer surface of the object is irradiated with light to cure the photocurable resin. In this method, cross 2
The synthetic resin impregnated in the resin can be easily cured by light irradiation, and the cured resin component can be hardened by the light molding 1
Since the resin component is the same as that described above, the coating layer 3 is firmly integrated with the stereolithographic object 1.

[0014]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a stereolithography product of the present invention and a method of manufacturing the same.

The stereolithographic object 1 which is the main body of the optical molded article shown in FIGS. 1 (a) and 1 (b) is a resin model of the surge tank cover 10 of the intake manifold for an automobile engine shown in FIG. 4 (a) to (d), a three-dimensional model designed on a computer is sliced in parallel into a large number of layers to create cross-sectional pattern data, and this data is used as an optical shaping apparatus. Input to the controller and automatically irradiate the UV curable resin solution surface with a laser beam in the UV wavelength range along the cross-sectional pattern of each layer on the solution surface of the UV curable resin, and the formed cured resin layers are laminated one by one from the bottom layer one by one. The resin model is integrated and finally a concrete model of the design model.

As shown in FIG. 3, the optical molding 1 has a joint peripheral portion 1b having a flat lower surface integrally formed around a wall portion 1a bulging outward. 1b
Are provided with bolt insertion holes 4 at a plurality of locations. On the other hand, the manifold body 11 of the intake manifold has a surge tank 12 in which a plurality of (four in the figure) distribution pipes 13 having a curved pipe and an intake pipe 14 are integrally connected to each other.
The surge tank 12 has screw holes 15 in the opening peripheral portion 12a for bolting the surge tank cover 10.

As shown in FIGS. 1 (a) and 1 (b), the entire surface of the optically formed article 1 extending from the wall 1a to the joining peripheral portion 1b is covered with the coating layer 3. As shown in FIG. 2, a plurality of cloths 2 impregnated with a solution of a synthetic resin are successively adhered to the coating layer 3 in a laminated state along the curved shape of the outer surface of the optically formed object 1, as shown in FIG. Is cut off and the impregnated synthetic resin is cured. At the positions of the bolt insertion holes 4 at the joining peripheral portion 1b of the optically formed object 1, holes are formed in the coating layer 3 after the hardening of the synthetic resin, so that each bolt insertion hole 4 is vertically penetrated. .

In such a stereolithographic article, the outer surface of the stereolithographic article 1 is covered and reinforced by the covering layer 3 with the cloth 2 impregnated with a synthetic resin, and therefore, compared to the original stereolithographic article 1, The compressive strength is remarkably improved. Therefore, this stereolithographic product is connected to the surge tank 1 of the manifold body 11 shown in FIG.
2 is bolted to the peripheral edge 12a of the opening 2 and is used as a prototype model of the intake manifold for a characteristic test or an actual machine test. Tank cover 1
0 is unlikely to be damaged, so that it is possible to obtain various useful data that are actually used.

Further, even if the optical molded article is degraded due to the repetition of the test or damaged by exceeding the limit pressure, the coating layer 3
Since the cloth 2 has a fastening action, the fragments are not scattered just by generating cracks, thereby ensuring safety during the test. Furthermore, the impact resistance and durability of the optically shaped article are also improved by the coating layer 3, so that the article is not easily broken even if an impact or an external force is applied during handling during transportation, display, storage, or the like.

The synthetic resin to be impregnated with the cloth 2 is not particularly limited, and various reaction-curable resins and thermoplastic resins can be used, but a light-curable resin such as an ultraviolet-curable resin or a two-part epoxy resin is used. It is suitable, and in particular, a photocurable resin is most preferable. That is, when the same photocurable resin component as that of the stereolithographic object 1 is used as the synthetic resin, the two resin components are fused and integrated, and the entire coating layer 3 of the cloth 2 is firmly adhered to the stereolithographic object 1. Therefore, there is no fear of causing interface delamination, the reinforcing effect is further increased, and there is an advantage that curing can be easily performed by light irradiation (ultraviolet irradiation) in a short time, thereby improving workability. on the other hand,
In the case of the two-pack type epoxy resin, since the photocurable resin component of the optical molding 1 as the base is generally an epoxy-based resin, the affinity between the resin component of the cloth 2 and the base is good. It is firmly adhered and integrated on the surface of the optical molding 1.

On the other hand, the cloth 2 can be made of various natural fibers and synthetic fibers, but glass cloth and carbon cloth are particularly preferable. That is, since the cloth made of glass fiber or carbon fiber has high strength and good impregnation with the resin, even a thin cloth can achieve a sufficient reinforcing effect. Therefore, if these thin glass cloths or carbon cloths are used, they can be stuck neatly along the undulations of the surface of the optical molded article 1 in a state of being impregnated with the solution of the synthetic resin, and have a good appearance. Stereolithography is obtained. Further, since the glass cloth and the carbon cloth cloth are excellent in chemical resistance and corrosion resistance, the chemical resistance and corrosion resistance of the optically formed product are also improved.

The weaving structure of the cloth 2 is not particularly limited, but a plain weave cloth is preferably used. This is because, in a plain weave structure, the cloth 2 has good flatness, so that the surface of the coating layer 3 is easily finished to be smooth, and in a punched structure, the fiber density of the coating layer 3 is high, so that a large reinforcing effect is obtained. by.

Although the stereolithographic product of the above embodiment has a coating layer 3 in which a plurality of cloths 2 impregnated with a synthetic resin are laminated, in the present invention, the coating layer 3 is formed by using only one cloth 2. It may be formed.

[Pressure strength test] An optically molded article A optically molded using an ultraviolet curable resin, and a glass cloth impregnated with a solution of the ultraviolet curable resin used for the optical molding on the entire outer surface of the optically molded article A. A compression strength test was performed on the optically molded products B and C of the present invention, which were adhered to form a coating layer. The results are shown in Table 1 below. The details of the test product and the test method are as follows. The UV-curable resin of the coating layer in the optically molded products B and C was cured by irradiating ultraviolet rays for 1 hour in a processing chamber provided with 16 UV lamps of 40 W.

<Test Product> Stereolithography A: Stereolithography 1 (width 160 mm, length 320 mm, wall surface 1 a thickness 3 mm) of the surge tank cover 10 shown in FIGS. 2 and 3. Stereolithography B: Glass cloth impregnated with the resin solution (a plain weave glass cloth manufactured by Epoch Corporation; thickness: 0.1 mm).
One having a thickness of 13 mm and a weight of 104 g / m ² ) was adhered to form a coating layer having a thickness of about 0.15 mm. Stereolithographic product C: A coating layer having a thickness of about 0.7 mm formed by attaching five pieces of the same glass cloth.

<Test Method> A sealant is applied to the lower surface of the joint peripheral portion 1b of the optically molded article, sealed with a test jig, fixed with bolts and nuts in each bolt insertion hole 4, and manually pressed. A pressure was applied to the inner space of the optically shaped article by a pump, and a break pressure load was measured.

[0027]

[Table 1]

As can be seen from the results in the above table, the optically molded article of the present invention has a coating layer formed by sticking a cloth impregnated with a synthetic resin on the outer surface. It is evident that the strength is remarkably improved, and that the test can be safely performed under the actual pressure conditions without shards being scattered even if the pressure limit is reached and breakage occurs.

In the above embodiment, the surging tank cover of the intake manifold is shown as an optically molded product. However, if the manifold body 11 shown in FIG. 3 is an optically molded resin model, the surge tank 12 is similarly synthesized. A coating layer of a cloth impregnated with a resin may be formed. Thus, the present invention is not limited to the related parts of the manifold for an automobile engine exemplified above, but also includes an optically shaped article having various shapes and structures, particularly an article which constitutes at least a part of a hollow portion in which the inside becomes an emergency pressure during use. It is a resin model and can be widely applied to stereolithography to be used for various characteristic tests and actual machine tests under the emergency pressure. The emergency pressure means both a case where the pressure is positive with respect to the atmospheric pressure and a case where the pressure is negative with respect to the atmospheric pressure.

[0030]

According to the first aspect of the present invention, as the optical molded article, since the outer surface of the optical molded article is a resin model excellent in pressure resistance by being reinforced by the covering of the cloth impregnated with the synthetic resin, Even if the article has a hollow part through which fluid passes and the pressure difference between inside and outside during use is large, it is possible to perform a characteristic test and an actual machine test under the original pressure condition of the article, and A product that can ensure safety and has good impact resistance is provided.

According to the second aspect of the present invention, as the stereolithography product, the synthetic resin impregnated in the cloth is a cured product of the same photocurable resin as the stereolithography product, and the coating layer is firmly attached to the stereolithography product. And a stereolithography product which exhibits a more excellent reinforcing effect.

According to the third aspect of the present invention, as the above-mentioned stereolithographic product, since the cloth is a glass cloth or a carbon cloth, even a thin cloth can achieve a sufficient reinforcing effect. Good appearance,
Also provided is one having excellent chemical resistance and corrosion resistance.

According to the fourth aspect of the present invention, there is provided, as the above-mentioned stereolithography product, the cross is a plain weave cloth, the surface of the coating layer is smooth, and a greater reinforcing effect is exhibited. You.

According to the fifth aspect of the present invention, the above-mentioned stereolithography product is a resin model of an article constituting at least a part of a hollow portion in which the inside becomes an emergency pressure during use. What can perform a characteristic test and an actual machine test under the use condition of the article's original emergency pressure is provided.

According to the method of manufacturing an optically shaped article according to the sixth aspect, there is an advantage that the optically shaped article excellent in the pressure resistance can be easily manufactured.

According to the seventh aspect of the present invention, in the above-described method for manufacturing an optically molded article, since a solution of a photocurable resin is used as a synthetic resin solution to be impregnated into the cloth, the impregnated resin is easily cured by light irradiation. In addition to this, the obtained optically shaped article has an advantage that the coating layer is firmly integrated with the optically shaped article and exhibits an excellent reinforcing effect.

[Brief description of the drawings]

FIG. 1 shows an optical molded product according to an embodiment of the present invention,
(A) is a perspective view, and (B) is a longitudinal side view.

FIG. 2 is a perspective view showing a method for manufacturing the optically shaped article.

FIG. 3 is an exploded perspective view of a manifold for an automobile engine which is a target object of the stereolithography product.

4A and 4B illustrate the basic principle of stereolithography, wherein FIG. 4A is a front view of a computer displaying an image of a designed three-dimensional model, and FIG. Schematic diagram showing the state of slicing parallel to the layer, (c)
The figure is a schematic vertical sectional side view showing an initial stage of the optical shaping by the optical shaping apparatus, and the figure (d) is a schematic vertical side view showing the final stage of the optical shaping.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Stereolithography 1a Wall part 1b Joining peripheral part 2 Cross 3 Coating layer 4 Bolt insertion hole 10 Surge tank cover 11 Manifold body 12 Surge tank

Claims (7)

[Claims] 1. A stereolithography product in which each layer when a design model is sliced in parallel into a plurality of layers is formed as a cured layer of a photocurable resin, and the outer surface of the stereolithography product is a cloth impregnated with a synthetic resin. A stereolithographic product characterized by being coated. 2. An optically molded article according to claim 1, wherein said synthetic resin is a cured product of a photocurable resin. 3. The optically shaped article according to claim 1, wherein the cloth is a glass cloth or a carbon cloth. 4. The optically shaped article according to claim 1, wherein the cloth is a plain weave cloth. 5. The stereolithography article according to claim 1, wherein the stereolithography article is a resin model of an article constituting at least a part of a hollow portion in which the inside becomes an emergency pressure during use. 6. A cloth in which each layer obtained when a design model is sliced in parallel into a plurality of layers is formed as a hardened layer of a photocurable resin by stereolithography, and an outer surface of the obtained stereolithographic product is impregnated with a synthetic resin solution. And curing the impregnated synthetic resin. 7. A photo-curable resin solution is used as a synthetic resin solution for impregnating the cloth, and the photo-curable resin is cured by irradiating light to the outer surface of the photolithographic object to which the cloth is adhered. The manufacturing method of the stereolithography described in the above.