Apparatus and method for forming three-dimensional object

• US 6,506,477 B1
• Filed: 12/15/1999
• Issued: 01/14/2003
• Est. Priority Date: 12/17/1998
• Status: Expired due to Fees

• Current Assignee: Minolta Co., Ltd. (Konica Minolta Inc.)
• Original Assignee: Minolta Co., Ltd. (Konica Minolta Inc.)
• Inventors: Ueda, Masahide, Kamisaki, Akiyoshi, Kubo, Naoki, Yagi, Fumiya
• Primary Examiner(s): DIXON, MERRICK L
• Application Number:
  US09/461,034
• Time in Patent Office: 1,126 Days
• Field of Search: 425/210, 425/215, 425/131.1, 425/130, 425/218, 425/190, 264/113, 264/109, 264/308, 264/64, 264/510, 264/517, 264/555, 264/103, 264/129, 264/136, 264/280, 264/299, 264/297.4, 156/62.2, 156/285, 156/148, 156/242, 156/244.11, 428/546, 428/190
• US Class Current: 428/195.1
• 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: B32B 7/04 Interconnection of layers
• CPC Class Codes: B41J 2/0057 where an intermediate transfer member receives the ink before transferring it on the printing material
• CPC Class Codes: B41J 2/01 Ink jet
• CPC Class Codes: G03G 15/224 Machines for forming tactile or three dimensional images by electrographic means, e.g. braille, 3d printing
• CPC Class Codes: G03G 2215/00835 Toner binding
• CPC Class Codes: G03G 2215/0177 Rotating set of developing units
• CPC Class Codes: H04N 1/60 Colour correction or control H04N1/54 takes precedence
• CPC Class Codes: Y10T 428/12014 having metal particles
• CPC Class Codes: Y10T 428/2476 Fabric, cloth or textile component
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

Data defining an outline shape of a section, color-region image data and adhesion-region image data are generated, color toners are transferred onto a color region and an adhesion region on a sheet in accordance with the respective image data, the sheet is aligned on processed sheets and laminated thereon. Next, a laminated body of the sheets is bonded by heating and pressurizing, and the laminated and bonded sheets are cut along the sectional outline shape. Further, sectional shape data of a solid model are generated and a transparent toner is transferred as an adhesive onto the adhesion region of the sheet. Then, after aligning and laminating the sheet on the processed sheets, the transparent toner is melted to bond the sheets. Color toners are transferred onto the color region of the sheet and the sheet is cut along the outline shape. Furthermore, the color region is defined on a transparent sheet in accordance with the sectional shape of the solid model. After entirely covering the color region with a white toner layer, a three-primary-color toner layer in which the three primary color toners are spatially tone-distributed is applied to the color region, to form a colored layer of double-layered structure. Alternatively, a colored layer is formed of one-layered structure in which the white toner fills clearances of dots of the three primary color toners.

Claims

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

a processor for generating outline-shape data including a sectional outline shape of a solid and color-region data including a region to be colored on each of said sheet-like members on the basis of data representing a shape of said solid and data representing a color of a surface of said solid; and

a unit for coloring each of said sheet-like members on the basis of said color-region data, cutting each of said sheet-like members on the basis of said outline-shape data and laminating each of said sheet-like members.

2. The apparatus according to claim 1, wherein

said unit colors each of said sheet-like members before laminating.

3. The apparatus according to claim 1, wherein

said unit colors each of said sheet-like members after laminating.

4. The apparatus according to claim 1, wherein

said region to be colored is a predetermined region including a sectional contour line of said solid on each of said sheet-like members.

5. The apparatus according to claim 1, wherein

said unit colors said sheet-like members with a toner.

6. The apparatus according to claim 1, wherein

said unit colors said sheet-like members with an ink.

7. The apparatus according to claim 1, wherein

said unit includes a mechanism for supplying a plurality of kinds of sheet-like members having different thicknesses.

8. The apparatus according to claim 7, wherein

said processor slices said solid at different intervals on the basis of said data representing said shape of said solid to generate said outline-shape data and makes a selection from said plurality of kinds of sheet-like members in accordance with said intervals.

9. The apparatus according to claim 1, wherein

said sheet-like members are obtained by cutting a continuous sheet, and

said unit colors said continuous sheet with a plurality of image forming units arranged in series correspondingly to a plurality of different colors.

10. The apparatus according to claim 1, wherein

said unit includes

a mounting pedestal on which said sheet-like members are laminated;

and

a detector for detecting the height of said sheet-like members laminated on said mounting pedestal.

11. The apparatus according to claim 1, wherein

said processor further generates adhesion-region data including a region to be coated with an adhesive on each of said sheet-like members, and

said unit coats each of said sheet-like members with said adhesive on the basis of said adhesion-region data.

12. The apparatus according to claim 11, wherein

said adhesive is a toner.

13. The apparatus according to claim 12, wherein

said toner is transparent.

14. The apparatus according to claim 12, wherein

said toner is white.

15. The apparatus according to claim 1, wherein

said unit colors each of said sheet-like members with a predetermined base color as well as an inherent color corresponding to a color of a surface of said solid.

16. The apparatus according to claim 15, wherein

said base color is white.

17. The apparatus according to claim 15, wherein

said sheet-like members are transparent.

18. The apparatus according to claim 15, wherein

said unit colors each of said sheet-like members by layering a first layer entirely made of said base color and a second layer in which color components corresponding to said inherent color are distributed, and

said first layer is formed below said second layer when each of said sheet-like members to be colored corresponds to an overhung portion of said three-dimensional object and formed above said second layer when each of said sheet-like members to be colored corresponds to a step-up portion of said three-dimensional object.

19. The apparatus according to claim 15, wherein

said unit colors each of said sheet-like members by distributing said color components corresponding to said inherent color and said base color with substantially no clearance.

20. The apparatus according to claim 1, wherein

said unit includes a mechanism for reversing each of said sheet-like members before laminating.

21. A method for forming a three-dimensional object by laminating foundation members, comprising the steps of:

(a) generating outline-shape data including a sectional outline shape of a solid and color-region data including a region to be colored on each of said foundation members on the basis of data representing a shape of said solid and data representing a color of a surface of said solid; and

(b) coloring each of said foundation members on the basis of said color-region data, molding the sectional outline shape on each of said foundation members on the basis of said outline-shape data and laminating each of said foundation members.

22. The method according to claim 21, wherein

each of said foundation members is colored before laminating in said step (b).

23. The method according to claim 21, wherein

each of said foundation members is colored after laminating in said step (b).

24. The method according to claim 21, wherein

said region to be colored is a predetermined region including a sectional contour line of said solid on each of said foundation members.

25. The method according to claim 21, wherein

said foundation members are colored with a toner in said step (b).

26. The method according to claim 21, wherein

said foundation members are colored with an ink in said step (b).

27. The method according to claim 21, further comprising the step of:

supplying a plurality of kinds of foundation members having different thicknesses.

28. The method according to claim 27, wherein

said step (a) includes the step of:

slicing said solid at different intervals on the basis of said data representing said shape of said solid to generate said outline-shape data,

said method further comprising the step of;

making a selection from said plurality of kinds of foundation members in accordance with said intervals.

29. The method according to claim 21, wherein

said foundation members are obtained by cutting a continuous sheet, and

said continuous sheet is colored with a plurality of image forming units arranged in series correspondingly to a plurality of different colors in said step (b).

30. The method according to claim 21, wherein

said step (b) includes the step of:

laminating each of said foundation members on a mounting pedestal,

said method further comprising the step of;

detecting the height of said foundation members laminated on said mounting pedestal.

31. The method according to claim 21, further comprising the steps of:

generating adhesion-region data including a region to be coated with an adhesive on each of said foundation members; and

coating each of said foundation members with said adhesive on the basis of said adhesion-region data.

32. The method according to claim 31, wherein

said adhesive is a toner.

33. The method according to claim 32, wherein

said toner is transparent.

34. The method according to claim 32, wherein

said toner is white.

35. The method according to claim 21, wherein

each of said foundation members is colored with a predetermined base color as well as an inherent color corresponding to a color of a surface of said solid in said step (b).

36. The method according to claim 35, wherein

said base color is white.

37. The method according to claim 35, wherein

said foundation members are transparent.

38. The method according to claim 35, wherein

said step (b) includes the step of:

layering a first layer entirely made of said base color and a second layer in which color components corresponding to said inherent color are distributed, to color each of said foundation members,

and wherein said first layer is formed below said second layer when each of said foundation members to be colored corresponds to an overhung portion of said three-dimensional object and formed above said second layer when each of said foundation members to be colored corresponds to a step-up portion of said three-dimensional object.

39. The method according to claim 35, wherein

each of said foundation members is colored by distributing said color components corresponding to said inherent color and said base color with substantially no clearance in said step (b).

40. The method according to claim 21, wherein

said step (b) includes the step of:

reversing each of said foundation members before laminating.

41. A method for forming a three-dimensional object by forming a layered body consisting of a plurality df colored layers representing each of sections of a solid model on the basis of data on said solid model, comprising the steps of:

(a) sequentially layering a plurality of powder-type or paste-type formed layers including inherent colors corresponding to appearance colors on each of sectional positions of said three-dimensional object; and

(b) coagulating a portion of each of said formed layers corresponding to a sectional shape of said solid model every time when a new formed layer is layered, said step (a) comprises the steps of;

(a-1) defining a portion contributing to an appearance of said three-dimensional object as a color region in a region where each of said formed layers is to be formed on the basis of a shape of said solid model; and

(a-2) providing a colored layer on said color region, said colored layer including a first layer entirely made of a predetermined base color and a second layer which is layered below or above said first layer, in which color components corresponding to said inherent colors are distributed.

42. An apparatus for forming a three-dimensional object by forming a layered body consisting of a plurality of colored layers representing each of sections of a solid model on the basis of data on said solid model, comprising:

a plurality of coloring material supply sources each consisting of a first material supply source for supplying a white coloring material and a second material supply source for supplying coloring materials other than white;

a formed-layer forming device for selectively driving said plurality of coloring material supply sources in accordance with appearance colors on each of sectional positions of said solid model to sequentially layer a plurality of powder-type or paste-type formed layers in which a predetermined color region is provided with a spatial distribution of a plurality of coloring materials; and

a device for providing a colored layer on said color region, said colored layer including a first layer entirely made of a predetermined base color and a second layer which is layered below or above said first layer, in which color components corresponding to said appearance colors are distributed.

43. A three-dimensional object, comprising:

laminated sheet-like members; and

a colored layer formed in a region including a peripheral portion of each of said sheet-like members.

44. The three-dimensional object according to claim 43, wherein

said sheet-like members are transparent.

45. A three-dimensional object formed as a layered body, wherein

said layered body made of a plurality of coloring-material coagulated layers which are obtained by coagulating powder-type or paste-type formed layers including coloring materials, and

a colored layer including a first layer entirely made of a predetermined base color and a second layer which is layered below or above said first layer, in which color components corresponding to appearance colors of said three-dimensional object are distributed is formed in a portion which appears on an appearance of said three-dimensional object in each of coloring material coagulated layers.

46. A method for forming a three-dimensional object by laminating foundation members, comprising:

(a) receiving outline-shape data including a sectional outline shape of a solid and color-region data including a region to be colored on each of said foundation members on the basis of data representing a shape of said solid and data representing a color of a surface of said solid; and

(b) coloring each of said foundation members on the basis of said color region data, molding the sectional outline shape on each of said foundation members on the basis of said outline-shape data and laminating each of said foundation members.

47. A method of forming a three-dimensional object having a colored surface by laminating a layer corresponding to a sectional shape in a position upon another, comprising the steps of:

(a) preparing a layer of a basic shape;

(b) upon preparation of said layer of said basic shape, coloring an outline of said sectional shape and the outside and the inside of said outline of said sectional shape with a color corresponding to that of said layer of said basic shape on said surface of said three-dimensional object; and

(c) upon preparation of said layer of said basic shape, molding said sectional shape in said layer of said basic shape.

48. The method according to claim 47, wherein

said basic shape is rectangle.

49. The method according to claim 47, wherein

said layer is a sheet-like member, and

said sectional shape is molded by cutting said sheet-like member in a form of said sectional shape in said step (c).

50. A method of generating data necessary for and to be used in an apparatus for forming a three-dimensional object having a colored surface by laminating a layer corresponding to a sectional shape in a position upon another, comprising the steps of:

(a) generating data, on each layer of said three-dimensional object, for coloring an outline of said sectional shape in each layer and the outside and the inside of said outline of said sectional shape with a color corresponding to that of each layer on said surface of said three-dimensional object; and

(b) generating data, on each layer of said three-dimensional object, for molding said sectional shape in each layer.

51. A computer-readable medium containing a program that executes the following steps:

(a) generating outline-shape data including a sectional outline shape of a solid and color-region data including a region to be colored on each of a plurality of foundation members on the basis of data representing a shape of said solid and data representing a color of a surface of said solid; and

(b) controlling the coloring of each of said foundation members on the basis of said color-region data, cutting each of said foundation members on the basis of said outline-shape data and laminating each of said foundation members.

52. The computer-readable medium of claim 51, wherein

said step (b) includes the step of:

layering a first layer entirely made of a predetermined base color and a second layer in which color components corresponding to an inherent color corresponding to a color of a surface of said solid are distributed, to color each of said foundation members,

wherein said first layer is formed below said second layer when each of said foundation members to be colored corresponds to an overhung portion of said three-dimensional object and formed above said second layer when each of said foundation members to be colored corresponds to a step-up portion of said three-dimensional object.

53. A computer-readable medium containing a program for controlling a process for forming a layered body consisting of a plurality of colored layers representing each of the sections of a solid model on the basis of data on said solid model, comprising the steps of:

(a) sequentially layering a plurality of powder-type or paste-type formed layers including inherent colors corresponding to appearance colors on each sectional position of said three-dimensional object; and

(b) coagulating a portion of each of said formed layers corresponding to a sectional shape of said solid model every time a new formed layer is layered, said step (a) comprising the steps of;

(a-1) defining a portion contributing to an appearance of said three-dimensional object as a color region in a region where each of said formed layers is to be formed on the basis of a shape of said solid model; and

(a-2) providing a colored layer on said color region, said colored layer including a first layer entirely made of a predetermined base color and a second layer which is layered below or above said first layer, in which color components corresponding to said inherent colors are distributed.