Thermo-fusion additive fabrication method, production method for thermo-fusion additive fabrication object, and structure partially including thermo-fusion additive fabrication object

Patent metadata

Field	Value
Publication number	US-11084227-B2
Application number	US-201916368789-A
Country	US
Kind code	B2
Filing date	Mar 28, 2019
Priority date	Mar 29, 2018
Publication date	Aug 10, 2021
Grant date	Aug 10, 2021

Abstract

A method for performing thermo-fusion additive fabrication so as to allow the fusion with a member shaped by an arbitrary method, a method allowing a thermo-fusion additive fabrication object to be surely fused with another member, and a structure at least partially including the thermo-fusion additive fabrication object are provided. A method for performing thermo-fusion additive fabrication such that fusion can be performed on a shaped member even afterward includes: a step of providing a near infrared ray absorption material on the member by the thermo-fusion additive fabrication, the near infrared ray absorption material containing a near infrared ray absorption agent that absorbs a near infrared ray and a resin in which the near infrared ray absorption agent is dispersed; and a step of providing a thermoplastic resin material on the near infrared ray absorption material by the thermo-fusion additive fabrication.

First claim

What is claimed is:

1. A production method of producing a structure at least partially including a thermo-fusion additive fabrication object, the production method being a method of producing a structure including the thermo-fusion additive fabrication object and a member that are joined to each other by fusion, the production method comprising:
a step of performing a first thermo-fusion additive fabrication to provide a near infrared ray absorption part on the member, wherein
a near infrared ray absorption material is laminated in a plurality of layers on the member to form the near infrared ray absorption part, the near infrared ray absorption material containing a near infrared ray absorption agent absorbing a near infrared ray and a thermoplastic matrix resin in which the near infrared ray absorption agent is dispersed, and
in the first thermo-fusion additive fabrication, the thermoplastic matrix resin of the near infrared ray absorption material in a melted state is applied to laminate the near infrared ray absorption material on the member;

a step of performing a second thermo-fusion additive fabrication to provide a fabrication body part to the member at the near infrared ray absorption part, wherein
the fabrication body part is formed from a thermoplastic resin material, and
the fabrication body part and the near infrared ray absorption part form the thermo-fusion additive fabrication object, and

after the step of performing the second thermo-fusion additive fabrication, a step of irradiating the near infrared ray absorption part with the near infrared ray through the fabrication body part or the member to fuse the thermo-fusion additive fabrication object and the member to form the structure.

2. The production method of producing the structure at least partially including the thermo-fusion additive fabrication object according to claim 1 , wherein
the structure is included in an aircraft.

3. The production method according to claim 1 , wherein the near infrared ray has a wavelength range between 700 nm and 2500 nm.

4. The production method according to claim 1 , wherein the near infrared ray absorption agent of the near infrared ray absorption material includes metal powders composed of stainless steel, brass, aluminum, or copper.

5. The production method according to claim 1 , wherein the thermoplastic matrix resin of the near infrared ray absorption material includes a material same as that of the thermoplastic resin material.

6. A production method of producing a structure at least partially including a thermo-fusion additive fabrication object, the production method being a method of producing a structure including the thermo-fusion additive fabrication object and a member that are joined to each other by fusion, the production method comprising:
a step of performing a second thermo-fusion additive fabrication to provide a near infrared ray absorption part on a fabrication body part using a near infrared ray absorption material, following a step of fabricating the fabrication body part by a first thermo-fusion additive fabrication using a thermoplastic resin material, the near infrared ray absorption material containing a near infrared ray absorption agent that absorbs a near infrared ray and a thermoplastic matrix resin in which the near infrared ray absorption agent is dispersed, wherein
the near infrared ray absorption material is laminated in a plurality of layers on the fabrication body part to form the near infrared ray absorption part, and
in the second thermo-fusion additive fabrication, the thermoplastic matrix resin of the near infrared ray absorption material in a melted state is applied to laminate the near infrared ray absorption material on the fabrication body part;

a step of disposing the member on a near infrared ray absorption part side of the thermo-fusion additive fabrication object including the fabrication body part and the near infrared ray absorption part; and
a step of irradiating the near infrared ray absorption part with the near infrared ray through the fabrication body part or the member to fuse the thermo-fusion additive fabrication object and the member.

7. The production method of producing the structure at least partially including the thermo-fusion additive fabrication object according to claim 6 , wherein
the structure is included in an aircraft.

8. A production method of producing a structure at least partially including a thermo-fusion additive fabrication object, the production method being a method of producing a structure including the thermo-fusion additive fabrication object and a member that are joined to each other by fusion, the production method comprising:
a step of providing a near infrared ray absorption part on one of the thermo-fusion additive fabrication object and the member, the near infrared ray absorption part formed from a near infrared ray absorption material containing a near infrared ray absorption agent that absorbs a near infrared ray and a thermoplastic matrix resin in which the near infrared ray absorption agent is dispersed, wherein
the near infrared ray absorption material is laminated in a plurality of layers on the one of the thermo-fusion additive fabrication object and the member to form the near infrared ray absorption part, and
in providing the near infrared ray absorption part, the thermoplastic matrix resin of the near infrared ray absorption material in a melted state is applied to laminate the near infrared ray absorption material on the one of the thermo-fusion additive fabrication object and the member;

a step of performing a thermo-fusion additive fabrication to fabricate the other of the thermo-fusion additive fabrication object and the member on the near infrared ray absorption part provided on the one of the thermo-fusion additive fabrication object and the member; and
after the step of performing the thermo-fusion additive fabrication, a step of irradiating the near infrared ray absorption part with the near infrared ray through the thermo-fusion additive fabrication object or the member to fuse the thermo-fusion additive fabrication object and the member.

9. The production method of producing the structure at least partially including the thermo-fusion additive fabrication object according to claim 8 , wherein
the production method is a method for obtaining a structure at least partially including an overhang shape as a whole of the thermo-fusion additive fabrication object and the member.

10. The production method of producing the structure at least partially including the thermo-fusion additive fabrication object according to claim 8 , wherein
the structure is included in an aircraft.

Assignees

• Mitsubishi Heavy Ind Ltd

Inventors

• Yui Yuichi

Classifications

• B29C65/1416 Primary

  Near-infrared radiation [NIR] · CPC title

• B29C64/106 Primary

  using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material · CPC title

• B22F10/385

  Overhang structures · CPC title

• B22F10/18

  by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] · CPC title

• B22F12/41

  characterised by the type, e.g. laser or electron beam · CPC title