TWI821428B - 3d立體列印熱膨脹結構的製造方法 - Google Patents
3d立體列印熱膨脹結構的製造方法 Download PDFInfo
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Abstract
一種3D立體列印熱膨脹結構包括一熱可塑材料及一熱膨脹材料,其中該熱可塑材料占該3D立體列印熱膨脹結構重量的50wt%~90wt%;該熱膨脹材料占該3D立體列印熱膨脹結構重量的10wt%~50wt%;其中,該熱可塑材料及該熱膨脹材料混合成一混合材料,該混合材料係利用一3D立體列印設備形成一立體物,以及將該立體物加熱膨脹成該3D立體列印熱膨脹結構。本發明提供的3D立體列印熱膨脹結構可快速製造成型,且無須開模塑型,以大幅降低生產成本及工時。一種3D立體列印熱膨脹結構的製造方法亦在此提供。
Description
本發明係與3D立體列印結構有關;特別是指一種3D立體列印熱膨脹結構及其製造方法。
隨著科技的進步,3D列印技術能應用的範圍也越來越廣泛;舉例來說,玩具、生活用品、各類手工具、車用物品、甚至大型建築都可以使用3D列印技術製成。
然而,3D列印技術雖然有無需開模即可製作複雜結構的優點,但利用3D列印技術受限於其固化時間,使得3D列印技術的生產效率緩慢,而無法廣泛應用於大量生產。因此,若需要短時間大量製造相同產品,依現有技術來說,仍需以傳統模製方式大量生產。如此一來,需大量製造的產品將無法有效地降低生產成本,也無法製作結構相對複雜的產品。
綜上可知,目前亟需一種能應用3D列印技術大量製造的結構及其製造方法,進而有效地提升3D列印技術的生產效率及用以製造結構相對複雜的產品。
有鑑於此,本發明之目的在於提供一種3D立體列印熱膨脹結構,其包括由熱可塑材料及熱膨脹材料混合的混合材料,且利用3D立體列印設備及加熱步驟,將混合材料製成3D立體列印熱膨脹結構。如此,便可利用3D立體列印設備製作結構較為複雜的產品,再配合加熱步驟,使3D立體列印形成的立體物等比例膨脹成3D立體列印熱膨脹結構,以縮短3D立體列印熱膨脹結構的整體製造時間。
緣以達成上述目的,本發明提供的一種3D立體列印熱膨脹結構包括有一熱可塑材料及一熱膨脹材料,其中該熱可塑材料占該3D立體列印熱膨脹結構重量的50wt%~90wt%;該熱膨脹材料占該3D立體列印熱膨脹結構重量的10wt%~50wt%;其中,該熱可塑材料及該熱膨脹材料混合成一混合材料,該混合材料係利用一3D立體列印設備形成一立體物,以及將該立體物加熱膨脹成該3D立體列印熱膨脹結構。
本發明的另一目的在於提供一種3D立體列印熱膨脹結構的製造方法,其至少包括以下步驟:提供一混合材料;利用一3D立體列印設備將該混合材料形成一立體物;以及加熱該立體物,使該立體物膨脹成該3D立體列印熱膨脹結構;其中,該3D立體列印熱膨脹結構與該立體物具有相同的構型。
本發明的再一目的在於提供一種利用上述3D立體列印熱膨脹結構的製造方法製成的3D立體列印熱膨脹結構。
本發明之效果在於,利用3D立體列印設備將由熱可塑材料及熱膨脹材料混合的混合材料形成立體物,再透過加熱步驟,將立體物製成3D立體列印熱膨脹結構。如此,便可利用3D立體列印設備製作結構較為複雜的產品,再配合加熱步驟,使立體物等比例膨脹成3D立體
列印熱膨脹結構。透過本發明所提供的方法,可保留3D立體列印可製作結構較為複雜的產品的優勢,又可大幅縮短3D立體列印製作大量產品的製造時間。
1:3D立體列印設備
2:加熱設備
10:立體物
12:熱可塑材料
14:熱膨脹材料
20:3D立體列印熱膨脹結構
24:熱膨脹材料
S02、S04、S06:步驟
圖1為本發明一較佳實施例之3D立體列印熱膨脹結構的製造方法流程圖;圖2為本發明一較佳實施例之利用3D立體列印設備製作立體物的示意圖;圖3為本發明一較佳實施例之利用加熱設備加熱立體物的示意圖;圖4為本發明一較佳實施例之利用加熱設備使立體物膨脹成3D立體列印熱膨脹結構的示意圖;圖5為本發明一較佳實施例之立體物的立體示意圖;圖6為本發明一較佳實施例之3D立體列印熱膨脹結構的立體示意圖;圖7為圖5之7-7方向剖視圖;圖8為圖6之8-8方向剖視圖。
為能更清楚地說明本發明,茲舉一較佳實施例並配合圖式詳細說明如後。
請參考圖1,為本發明一較佳實施例之3D立體列印熱膨脹結構20的製造方法流程圖;請一併參圖2、圖5及圖7所示,圖2為
本發明一較佳實施例之利用3D立體列印設備1製作立體物10的示意圖,圖5為本發明一較佳實施例之立體物的立體示意圖,圖7為圖5之7-7方向剖視圖。
圖1的3D立體列印熱膨脹結構20的製造方法包括至少以下步驟:步驟S02,提供混合材料;步驟S04,利用3D立體列印設備1將混合材料形成立體物10;步驟S06,加熱立體物10,使立體物10膨脹成3D立體列印熱膨脹結構20;其中,3D立體列印熱膨脹結構20與立體物10具有相同的構型。
在本發明實施例中,3D立體列印設備1所運用到的3D列印技術可為光固化成型(SLA;stereolithography apparatus)、選擇性雷射燒結(SLS;selective laser sintering)、粉床噴墨列印(3DP;powder bed and inkjet head 3D printing)或熔融沉積成型(FDM;fused deposition modeling),但不以此為限制。
在圖2中,立體物10包括熱可塑材料12及熱膨脹材料14。其中,熱可塑材料12及熱膨脹材料14混合成混合材料,混合材料係利用3D立體列印設備1形成立體物10。在本發明實施例中,熱可塑材料12占立體物10重量的50wt%~90wt%;熱膨脹材料14占立體物10重量的10wt%~50wt%。
在本發明實施例中,熱可塑材料12包括光固化材料或可燒結材料,例如可為環氧樹脂(epoxy)、丙烯酸(acrylic acid)、熱塑性聚氨酯(TPU)、聚醯胺(PA)、聚丙烯(PP)、聚碳酸酯(PC)或丙烯腈-丁二烯-苯乙烯共聚物(ABS),但不以此為限制。在本發明實施例中,熱可塑材料12為液態或粉體,且當熱可塑材料12為粉體時,熱可塑材料12係
與接著劑(binder)預混合,再與熱膨脹材料14混合。在本發明實施例中,若熱可塑材料12及熱膨脹材料14均為液態,則可將熱可塑材料12及熱膨脹材料14直接混合均勻;若熱可塑材料12及熱膨脹材料14均為粉體,則熱可塑材料12係與接著劑(binder)預混合,再與熱膨脹材料14混合,以使熱可塑材料12及熱膨脹材料14混合均勻。如3D立體列印的效果不佳時,可將熱可塑材料12及熱膨脹材料14預先密煉,得到一混合材料,再將該混合材料研磨成適合3D立體列印設備使用的粉體狀;抑或是,將液態的熱可塑材料12及熱膨脹材料14利用預先噴塗的方式,乾燥製成適合3D立體列印設備使用的粉體狀。
在本發明實施例中,熱膨脹材料14包括閉孔發泡材料(closed-cell foam),其中閉孔發泡材料包括複數個微囊發泡球體,例如松本油脂製藥株式會社所生產的FN-78D微囊發泡球。在本發明實施例中,一發泡原材係經過預發泡過程,預先發泡成熱膨脹材料14。在本發明實施例中,熱膨脹材料14的體積為發泡原材的體積的10~40倍。
接著請參考圖3、圖4、圖6及圖8,圖3為本發明一較佳實施例之利用加熱設備2加熱立體物10的示意圖;圖4為本發明一較佳實施例之利用加熱設備2使立體物10膨脹成3D立體列印熱膨脹結構20的示意圖;圖6為本發明一較佳實施例之3D立體列印熱膨脹結構20的立體示意圖;圖8為圖6之8-8方向剖視圖。
在圖3中,將立體物10設置於一加熱設備2中。在本發明實施例中,加熱設備2例如可為蒸箱、烤箱、微波爐或烘箱,但不以此為限制,只要能對立體物10提升溫度的設備均適用。在本發明實施例中,立體物10中的熱膨脹材料14受熱膨脹成3D立體列印熱膨脹結構20中的熱膨脹材料24。在膨脹過程中,需要控制加熱設備2的加熱溫度、能量功
率及加熱時間,其中,加熱設備2的加熱溫度需高於熱膨脹材料24的初始發泡溫度,以使熱膨脹材料24能順利發泡膨脹。若是加熱設備2的加熱溫度及/或加熱時間控制不當,則容易導致熱膨脹材料24無法順利發泡或產生破泡等缺陷。
在圖4中,加熱設備2將立體物10加熱膨脹成3D立體列印熱膨脹結構20,且3D立體列印熱膨脹結構20與立體物10具有相同的構型。在本發明實施例中,熱可塑材料12占3D立體列印熱膨脹結構20重量的50wt%~90wt%;熱膨脹材料14占3D立體列印熱膨脹結構20重量的10wt%~50wt%。在本發明實施例中,3D立體列印熱膨脹結構20係立體物10等比例放大。在圖7及圖8中,3D立體列印熱膨脹結構20的體積係立體物10的體積的1.2倍至2.5倍;若小於1.2倍,則因為3D立體列印熱膨脹結構20的體積係立體物10的體積的差異太小,致使3D立體列印熱膨脹結構20的製造效率不佳;若大於2.5倍,則因為3D立體列印熱膨脹結構20的結構鬆散,以致3D立體列印熱膨脹結構20的機械性質(物性)不符合使用需求。在本發明實施例中,3D立體列印熱膨脹結構20中熱膨脹材料24的體積係立體物10中熱膨脹材料14的體積的1.2倍至2.5倍。
在立體物10加熱膨脹成3D立體列印熱膨脹結構20之後,熱膨脹結構20可依需要進行後續加工處理,例如研磨、切削、清洗、上色、包膜等後續加工步驟,亦可再依需要與其他物體進行接合或膠合。
透過本發明的設計,本發明實施例利用3D立體列印設備將由熱可塑材料及熱膨脹材料混合的混合材料形成立體物,再透過加熱步驟,將立體物製成3D立體列印熱膨脹結構。如此,便可利用3D立體列印設備製作結構較為複雜的產品,再配合加熱步驟,使立體物等比例膨脹成3D立體列印熱膨脹結構,以縮短3D立體列印熱膨脹結構的整體製造時間。透過本發明所提供的方法可保留3D立體列印可製作結構較為複雜的產品的優勢,又可大幅縮短3D立體列印製作大量產品的製造時間。
以上所述僅為本發明較佳可行實施例而已,舉凡應用本發明說明書及申請專利範圍所為之等效變化,理應包含在本發明之專利範圍內。
S02、S04、S06:步驟
Claims (7)
- 一種3D立體列印熱膨脹結構的製造方法,包括:提供一混合材料,該混合材料包括一熱可塑材料及一熱膨脹材料,且該熱膨脹材料分布該熱可塑材料之中,其中該熱可塑材料係為液態的光固化材料,該熱膨脹材料包括一閉孔發泡材料,該閉孔發泡材料包括複數個微囊發泡球體;利用一3D立體列印設備係使用光固化成型列印技術將該混合材料印製成一立體物;以及加熱該立體物,使該立體物膨脹成該3D立體列印熱膨脹結構,其中該立體物置放在一加熱設備中進行加熱,該熱可塑材料的熱變形溫度(HDT)係小於該熱膨脹材料的熱膨脹溫度,該加熱設備的加熱溫度高於該立體物中的所述熱膨脹材料的熱膨脹溫度,使得該立體物中的所述熱膨脹材料受熱發泡膨脹,且該立體物經加熱以等比例放大形成該3D立體列印熱膨脹結構,藉以該3D立體列印熱膨脹結構與該立體物具有相同的構型;形成該立體物及形成該3D立體列印熱膨脹結構的過程無需開模,且該3D立體列印熱膨脹結構的體積係該立體物的體積的1.2倍至2.5倍。
- 如請求項1所述之3D立體列印熱膨脹結構的製造方法,其中該熱可塑材料占該混合材料的50wt%~90wt%,而該熱膨脹材料占該混合材料的10wt%~50wt%。
- 如請求項1述之3D立體列印熱膨脹結構的製造方法,其中經過一預發泡過程,將一發泡原材預發泡成該熱膨脹材料。
- 如請求項3所述之3D立體列印熱膨脹結構的製造方法,其中該熱膨脹材料的體積為該發泡原材的體積的10~40倍。
- 一種3D立體列印熱膨脹結構的製造方法,能夠提升3D列印技術的生產效率,包括:提供一混合材料,其中該混合材料包括一熱可塑材料及一熱膨脹材料,該熱可塑材料占該混合材料的50wt%~90wt%,而該熱膨脹材料占該混合材料的10wt%~50wt%,且該熱膨脹材料分布該熱可塑材料之中,其中該熱可塑材料係為液態的光固化材料,該熱膨脹材料包括一閉孔發泡材料,該閉孔發泡材料包括複數個微囊發泡球體;利用一3D立體列印設備係使用光固化成型列印技術將該混合材料印製成一立體物;以及加熱該立體物,使該立體物膨脹成該3D立體列印熱膨脹結構,其中該立體物置放在一加熱設備中進行加熱,該熱可塑材料的熱變形溫度(HDT)係小於該熱膨脹材料的熱膨脹溫度,該加熱設備的加熱溫度高於該立體物中的所述熱膨脹材料的熱膨脹溫度,使得該立體物中的所述熱膨脹材料受熱發泡膨脹,且該立體物經加熱以等比例放大形成該3D立體列印熱膨脹結構,藉以該3D立體列印熱膨脹結構與該立體物具有相同的構型;形成該立體物及形成該3D立體列印熱膨脹結構的過程無需開模,直接以3D立體列印方式及加熱方式即可獲得該3D立體列印熱膨脹結構,且該3D立體列印熱膨脹結構的體積係該立體物的體積的1.2倍至2.5倍。
- 如請求項5述之3D立體列印熱膨脹結構的製造方法,其中經過一預發泡過程,將一發泡原材預發泡成該熱膨脹材料。
- 如請求項6所述之3D立體列印熱膨脹結構的製造方法,其中該熱膨脹材料的體積為該發泡原材的體積的10~40倍。
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US16/780,351 US20210101331A1 (en) | 2019-10-04 | 2020-02-03 | Three-dimensional printed thermal expansion structure and manufacturing method of the same |
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TW201138946A (en) * | 2010-03-26 | 2011-11-16 | Sekisui Chemical Co Ltd | Thermally expandable microcapsule |
CN105218939A (zh) * | 2015-11-05 | 2016-01-06 | 中国科学院福建物质结构研究所 | 一种可发泡的3d打印材料及其制备方法 |
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