Apparatus and method of laminate molding using releaser

• US 5,833,914 A
• Filed: 08/24/1995
• Issued: 11/10/1998
• Est. Priority Date: 12/24/1993
• Status: Expired due to Fees

• Current Assignee: K-Tec Systems, Inc.
• Original Assignee: K-Tec Systems, Inc.
• Inventors: Kawaguchi, Noboru
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): Eashoo, Mark
• Application Number:
  US08/507,234
• Time in Patent Office: 1,174 Days
• Field of Search: 264/308, 264/246, 264/401, 264/400, 264/40.1, 264/496, 264/219, 264/317, 264/130, 264/163, 264/221, 425/87, 425/90, 425/150, 425/175, 425/176, 425/375, 156/275.5, 156/353, 156/257, 156/264, 156/517, 156/522, 164/98, 164/456, 164/100
• US Class Current: 264/400
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 67/06 Coagulating
• CPC Class Codes: Y10T 156/1064 Partial cutting [e.g., grooving or incising]
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina

Abstract

A laminate molding method of fabricating a desired shape consisting of laminate layers having a first type layer in a completely solidified state, the method includes a first step of forming a second type layer on the first type layer, the first type layer having a viscosity larger than the second type layer, a second step of forming a slot groove in the second layer, the second type layer having first and second regions, a third step of printing a releaser on a predetermined region of the second type layer, a fourth step of forming a third type layer on the second type layer or on the first type layer, the second type having a viscosity larger than the third type layer, a fifth step of solidifying the third type layer to form the first type layer, and a sixth step of repeating the first, second, third, fourth, and fifth steps as desired.

Claims

1. A laminate molding method of fabricating a desired shape consisting of laminate layers having a first layer in a completely solidified state, the method comprising:

providing a solidified first layer;

a first step of forming a second layer on the first layer;

the first layer having a viscosity higher than the second layer;

a second step of forming a slot groove in the second layer thereby forming first and second regions, the slot groove dividing the first and second regions at least one of the regions comprising a necessary region for the desired shaped;

a third step of printing a releaser on the second layer;

a fourth step of forming a third layer on the second or on the first layer, the second layer having a viscosity higher than the third layer;

a fifth step of solidifying the third layer; and

a sixth step of repeating the first, second, third, fourth, and fifth steps using a solidified third layer as the first layer until the laminate having the desired shape is completed.

2. The laminate molding method according to claim 1, wherein the third layer is applied to a surface of the second layer having a predetermined thickness in a non-solidified state.

3. The laminate molding method according to claim 1 or 2, wherein the first layer comprises polyvinyl alcohol and a co-compound added to urea.

4. The laminate molding method according to claim 1, wherein the releaser in the third step includes a photo-hardening resin.

5. The laminate molding method according to claim 4, wherein the photo-hardening resin is hardened by an ultraviolet source or a visible light source.

6. The laminate molding method according to claim 1, wherein the first layer is formed by placing a first layer sheet on the second layer, and the first layer sheet is melted to be in a non-solidified state.

7. The laminate molding method according to claim 1, wherein the first layer is formed by cutting out a first layer sheet into a predetermined size thereby forming a cut-out first layer sheet, and the cut-out first layer sheet is melted to be in a non-solidified state.

8. The laminate molding method according to claim 1, wherein the releaser in the third step is printed on the second type layer corresponding to regions of exclusive logic sums for the first and second regions on the second layer.

9. The laminate molding method according to claim 1, wherein the second layer, in a non-solidified state, is pressed against a temperature regulating plate having a high releasing characteristic film on a surface thereof.

10. The laminate molding method according to claim 1, wherein the slot groove in the second step is formed by a laser beam.

11. The laminate molding method according to claim 1, wherein the slot groove in the second step is formed to have an inclined angle with respect to a vertical plane of the second type layer.

12. The laminate molding method according to claim 1, wherein the releaser in the third step includes a plurality of colors to form a desired color in a desired region.

13. The laminate molding method according to claim 1, wherein the first region in the second step constitutes the desired shape.

14. The laminate molding method according to claim 1, wherein the third layer solidifies with changes from a high temperature to a low temperature.

15. The laminate molding method according to claim 1, wherein the releaser in the third step includes a ceramic in a slurry state.

16. The laminate molding method according to claim 15, wherein the ceramic has a thickness of 20 to 100 μ

m.

17. The laminate molding method according to claim 1, wherein the fourth step includes applying a molten metal using a metal flame-sprayer to form the third layer.

18. The laminate molding method according to claim 17, wherein the molten metal has a thickness of 30 to 200 μ

m.

19. A laminate molding apparatus for fabricating a desired shape consisting of laminate layers having a first layer in a completely solidified state, the apparatus comprising:

a slot groove forming means for forming a slot groove in a second layer on the first layer, the first layer having a viscosity larger than the second layer;

a releaser printing means for printing a releaser on predetermined regions of the second layer or a third layer, the second layer having a viscosity larger than the third layer;

a third layer forming means for forming the third layer on the second layer on which the releaser is printed or on the first layer; and

a solidifying means for solidifying the third layer.

20. The laminate molding apparatus according to claim 19, wherein a material for the third layer is applied to have a predetermined thickness on a surface of the second layer being in a non-solidified state.

21. The laminate molding apparatus according to claim 19, wherein the third layer forming means includes a spray applicator for spraying a material for the third layer which is applied in a predetermined thickness on a surface of the laminate layers on which the second layer is laminated and formed.

22. The laminate molding apparatus according to claim 19, wherein the third layer forming means comprises a first layer sheet placement means for placing the first layer sheet on the second layer, and a first layer melting means for melting the first layer sheet to thereby form the first layer into a non-solidified state.

23. The laminate molding apparatus according to claim 19, wherein the third layer forming means comprises a first layer sheet placement means for placing the first layer sheet on the second layer;

a first layer sheet cut-out means for cutting out the first layer sheet into a predetermined size; and

first layer melting means for melting the first layer sheet to thereby form the first layer into a non-solidified state.

24. The laminate molding apparatus according to claim 19, wherein the slot groove forming means includes a laser.

25. The laminate molding apparatus according to claim 19, wherein the slot groove forming means includes a mechanical cutter.

26. The laminate molding apparatus according to claim 19, wherein the releaser printing means includes an ink jet printer.

27. The laminate molding apparatus according to claim 19, wherein the releaser printing means includes an electrostatic transfer printer.

28. The laminate molding apparatus according to claim 19, wherein the third layer forming means includes a metal flame-sprayer.

29. The laminate molding apparatus according to claim 19, wherein the solidifying means includes a cooling fan.

30. The laminate molding apparatus according to claim 19, wherein the third layer solidifies with changes from a high temperature to a low temperature.