Method and apparatus for manufacturing a solid object through sheet laminating

• US 5,578,155 A
• Filed: 06/27/1994
• Issued: 11/26/1996
• Est. Priority Date: 10/28/1992
• Status: Expired due to Fees

• Current Assignee: Sanyo Machine Works Ltd. (Panasonic Holdings Corporation)
• Original Assignee: Sanyo Machine Works Ltd. (Panasonic Holdings Corporation)
• Inventors: Kawaguchi, Noboru
• Primary Examiner(s): SELLS, JAMES D
• Application Number:
  US08/256,107
• Time in Patent Office: 883 Days
• Field of Search: 156/272.2, 156/273.3, 156/273.5, 156/273.7, 156/275.5, 156/275.7, 156/290, 156/267, 156/269, 156/379.6, 156/379.8, 156/380.9, 156/510, 156/516 , 156/522, 156/58, 156/59, 156/63, 156/85, 264/22, 264/308, 264/DIG. 59, 264/401, 264/405, 425/174.4
• US Class Current: 156/267
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B29C 64/147 using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal
• CPC Class Codes: Y10T 156/1317 Means feeding plural workpieces to be joined
• CPC Class Codes: Y10T 156/1343 Cutting indefinite length web after assembly with discrete article

Abstract

A first plastic film 90 is prepared which is cut into an effective area V1 constituting a three-dimensional object and a non-required area U1 not constituting the three-dimensional object, and a second plastic film 94 is fed above the first plastic film 90. Meanwhile, a photo-setting adhesive 96 is applied on a lower surface of the second plastic film 94, and a portion 96a corresponding to a sum of the non-required area U1 of the first plastic film and a non-required area U2 of the second plastic film is solidified whereas a residual portion 96b remains non-solid. The non-solid portion 96b is irradiated with a light beam and solidified to attach the first and the second plastic films with each other. The second plastic film 94 is then cut into an effective area V2 and the non-required area U2. The three-dimensional object is formed by successively laminating plastic films through repetition of the above steps.

Claims

1. A method of forming a three-dimensional object by laminating sheet members within a solid model forming apparatus that includes a data processing unit, said method comprising the steps of:

(A) preparing a first sheet member, which is cut into a first usable area constituting said three-dimensional object and a first excess area not constituting said three-dimensional object;

(B) feeding a second sheet member above said first sheet member while selectively interposing a powdery adhesive layer between said first and second sheet members using a xerography unit that receives cross-sectional data of said three-dimensional object from said, data processing unit, said powdery adhesive layer being formed in at least part of an area which is included in both of said first usable area of said first sheet member and a second usable area of said second sheet member;

(C) attaching said first and second sheet members with each other by said powdery adhesive layer;

(D) cutting said second sheet member into said second usable area and a second excess area; and

(E) successively laminating sheet members through repetition of said steps (B) through (D) to form said three-dimensional object.

2. A method in accordance with claim 1, wherein said step (B) comprises a step of depositing said powdery adhesive onto at least one of opposed surfaces of said first and second sheet members.

3. A method in accordance with claim 2, wherein

said step (C) comprises a step of heating and pressing down said first and second sheet members by heating-pressing means to melt said powdery adhesive, thereby attaching said first and second sheet members with each other by said powdery adhesive.

4. Art apparatus for forming a three-dimensional object by laminating sheet members, comprising:

a vertically movable table for holding a laminated object formed by laminating sheet members, each sheet member being cut into a usable area constituting said three-dimensional object and an excess area not constituting said three-dimensional object;

a xerography unit for selectively depositing a powdery adhesive onto at least one of an upper surface of a first sheet member positioned uppermost on said laminated object and a lower surface of a second sheet member to be laminated on said first sheet member, said powdery adhesive being deposited in at least part of an area included in both of a first usable area of said first sheet member and a second usable area of said second sheet member;

sheet feeding means for feeding and placing said second sheet member of a predetermined length onto said first sheet member;

attaching means for attaching said first and second sheet members with each other by said powdery adhesive at least by applying a pressure onto said second sheet member; and

cutting means for cutting said second sheet member into said second usable area and a second excess area.

5. An apparatus in accordance with claim 4, wherein

said first and second sheet members am paper sheets which are cut in advance into said predetermined length.

6. An apparatus in accordance with claim 5, wherein

said attaching means comprises means for melting said powdery adhesive by applying heat and pressure onto said first and second sheet members, to thereby attach said fast and second sheet members with each other via said powdery adhesive.

7. An apparatus for forming a three-dimensional object by laminating sheet members, comprising:

a vertically movable table for holding a laminated object formed by laminating sheet members, each sheet member being cut into a usable area constituting said three-dimensional object and an excess area not constituting said three-dimensional object;

sheet feeding means for feeding said sheet members of a predetermined length towards said table;

application means for applying a photo-setting adhesive on a lower surface of a first sheet member supplied from said sheet feeding means;

a xerography unit for selectively transferring a masking agent directly onto said photo-setting adhesive thus forming a mask; and

a light source for irradiating said member such that a part of said photo-setting adhesive corresponding to said mask is not solidified and

a part of said photo-setting adhesive corresponding to at least one of a second excess area of a second sheet member positioned uppermost on said laminated object and a first excess area of said first sheet member is solidified;

attaching means for pressing said first sheet member towards said second sheet member and irradiating a non-solid portion of said photo-setting adhesive with a predetermined light beam, to thereby solidify said non-solid portion to attach said first and second sheet members with each other by said photo-setting adhesive; and

cutting means for cutting said first sheet member and said solid photo-setting adhesive into a first usable area and said first excess area.

8. An apparatus for forming a three-dimensional object by laminating sheet members, said apparatus comprising:

a vertically movable table for holding a laminated object formed by laminating sheet members, each sheet member being cut into a usable area constituting said three-dimensional object and an excess area not constituting said three-dimensional object;

sheet feeding means for feeding a three-layered sheet member of a predetermined length towards said table, said three-layered sheet member comprising a first sheet member, a cover sheet, and an adhesive layer interposed between said first sheet member and said cover sheet, said cover sheet being a heat shrinkable film;

means for selectively shrinking and rupturing a portion of said cover sheet in order to form an opening in said cover sheet thus exposing a portion of said adhesive layer;

a light source for irradiating said three-layered sheet member in order to solidify a part of said adhesive layer corresponding to at least one of a second excess area of a second sheet member positioned uppermost on said laminate and a first excess area of said first sheet member;

removal means for removing said cover sheet from said three-layered sheet member;

attaching means for pressing said first sheet member of said layered sheet member without said cover sheet towards said second sheet member and solidifying a non-solid portion of said adhesive layer, to thereby attach said first and second sheet members with each other by said adhesive layer; and

cutting means for cutting said first sheet member and said solid adhesive layer into a first usable area and said first excess area.

9. An apparatus for forming a three-dimensional object by laminating sheet members, comprising:

a vertically movable table for holding a laminated object formed by laminating sheet members, each sheet member being cut into a usable area constituting said three-dimensional object and an excess area not constituting said three-dimensional object;

sheet feeding means for feeding said sheet members of a predetermined length towards said table;

a depositing unit for depositing micro-capsules containing a photo-setting adhesive over an area of said predetermined length on a lower surface of a first sheet member supplied from said sheet feeding means;

irradiation means for selectively irradiating said micro-capsules deposited on said first sheet member with a predetermined light beam to solidify a first part of said micro-capsules corresponding to either a second excess area of a second sheet member positioned uppermost on said laminated object or to a first excess area of said first sheet member;

rupturing means for rupturing a non-solid part of said micro-capsules corresponding to at least part of an area which is included in both of a first usable area of said first sheet member and a second usable area of said second sheet member;

attaching means for pressing said first sheet member towards said second sheet member and for attaching said first and second sheet members with each other by said photo-setting adhesive; and

cutting means for cutting said first sheet member and said solid photo-setting adhesive into a first usable area and said first excess area.

10. An apparatus for forming a three-dimensional object by laminating sheet members, comprising:

a vertically movable table for holding a laminated object formed by laminating sheet members, each sheet member being cut into a usable area constituting said three-dimensional object and an excess area not constituting said three-dimensional object;

sheet feeding means for feeding said sheet members of a predetermined length towards said table;

application means for applying a photo-setting adhesive on a lower surface of a first sheet member supplied from said sheet feeding means;

a xerography unit for selectively transferring a solidification accelerator directly onto said photo-setting adhesive, thus forming a solidification region of said photo-setting adhesive that contains said solidification accelerator; and

a light source for irradiating said first sheet member such that a part of said photo-setting adhesive not corresponding to said solidification region is not solidified and a part of said photo-setting adhesive corresponding to at least one of a second excess area of a second sheet member positioned uppermost on said laminated object and a first excess area of said first sheet member is solidified;

attaching means for pressing said first sheet member towards said second sheet member and irradiating a non-solid portion of said photo-setting adhesive with a predetermined light beam, to thereby solidify said non-solid portion to attach said first and second sheet members with each other by said photo-setting adhesive; and

cutting means for cutting said first sheet member and said solid photo-setting adhesive into a first usable area and said first excess area.