Method for manufacturing three-dimensional structure

Patent metadata

Field	Value
Publication number	US-11235513-B2
Application number	US-201716071346-A
Country	US
Kind code	B2
Filing date	Jan 16, 2017
Priority date	Jan 22, 2016
Publication date	Feb 1, 2022
Grant date	Feb 1, 2022

Abstract

Provided is a method for manufacturing a three-dimensional structure, capable of yielding a three dimensional structure that excels in buildability. The method for manufacturing a three-dimensional structure, comprises melting a filament that contains a thermoplastic resin by using a 3D printer, and depositing it onto a base, and comprising bonding the filament at one end of the filament to a surface of the base so as to achieve a bond strength to the base of 15 N or larger, and discharging the filament through a nozzle of the 3D printer onto a surface of the base so as to deposit thereon, while moving at least one of the base or the nozzle.

First claim

What is claimed is:

1. A method for manufacturing a three-dimensional structure, the method comprising melting a filament that contains a thermoplastic resin by using a 3D printer, and depositing it onto a base, and
comprising setting the filament in a 3D printer, drawing out a part of the filament through a nozzle of the 3D printer, bonding the filament at one end of the filament to a surface of the base so as to achieve a bond strength to the base of 20 to 50 N, after one end of the filament is bonded to the surface of the base, driving the 3D printer to discharge the filament, at a discharge temperature of 15 to 60° C. higher than the melting point of the thermoplastic resin, through the nozzle of the 3D printer onto a surface of the base so as to deposit thereon, while moving at least one of the base or the nozzle,
where, the bond strength is measured by cutting the base into a 40 mm-long×60 mm-wide rectangular piece; bonding a 60 mm-long filament to the cut base over a 20 mm-range in parallel with the lateral side of the cut base, so that the filament originates from a point on the cut base laterally 40 mm-away and longitudinally 20 mm-away from one apex of the cut base; bringing a point on the cut base laterally 20 mm-away and longitudinally 20 mm-away from the apex of the cut base, and a point on the filament longitudinally 40 mm-away from the originating point thereof, apart from each other in the direction parallel to the cut base plane at a tensile speed of 5 mm/second; then finding the force necessary for detaching the filament,
wherein the filament comprises a commingled yarn that contains a continuous reinforcing fiber and a continuous thermoplastic resin fiber,
the continuous reinforcing fiber being dispersed in the continuous thermoplastic resin fiber such that at least a portion of the continuous thermoplastic resin fiber remains in the fiber form, and is not impregnated into the continuous reinforcing fiber,
the continuous thermoplastic resin fiber has a number-average fiber length of 1 m or longer, and the continuous reinforcing fiber has a number-average fiber length of 1 m or longer, and
the ratio of the continuous reinforcing fiber in the commingled yarn is 40% by weight or more, and the ratio of the continuous thermoplastic resin fiber in the commingled yarn is 35% by weight or more,
a total number of fibers used for manufacturing a single commingled yarn, which is a sum of a total number of fibers of continuous thermoplastic resin fiber and a total number of fibers of continuous reinforcing fiber, is 1,000 to 100,000 f; and
the continuous reinforcing fiber in the commingled yarn fiber has a dispersity of 60 to 100%.

2. The method for manufacturing a three-dimensional structure of claim 1 , wherein the thermoplastic resin is a polyamide resin.

3. The method for manufacturing a three-dimensional structure of claim 1 , wherein the thermoplastic resin contains a structural unit derived from diamine and a structural unit derived from dicarboxylic acid, and 50 mol % or more of the structural unit derived from diamine is derived from xylylenediamine.

4. The method for manufacturing a three-dimensional structure of claim 1 , wherein the base is a thermoplastic resin base.

5. The method for manufacturing a three-dimensional structure of claim 4 , wherein the thermoplastic resin contained in the filament and the thermoplastic resin contained in the thermoplastic resin base belong to the same category.

6. The method for manufacturing a three-dimensional structure of claim 4 , wherein both of the thermoplastic resin contained in the filament and the thermoplastic resin contained in the thermoplastic resin base are polyamide resins.

7. The method for manufacturing a three-dimensional structure of claim 4 , wherein the filament is bonded to the base by heat sealing.

8. The method for manufacturing a three-dimensional structure of claim 4 ,
wherein the thermoplastic resin contained in the filament and the thermoplastic resin contained in the thermoplastic resin base belong to the same category; and
the thermoplastic resin contains a structural unit derived from diamine and a structural unit derived from dicarboxylic acid, and 50 mol % or more of the structural unit derived from diamine is derived from xylylenediamine.

9. The method for manufacturing a three-dimensional structure of claim 1 , wherein a discharge speed is set to 1 to 100 mm/second.

10. The method for manufacturing a three-dimensional structure of claim 1 , wherein a distance between a tip of the nozzle and the base is 3 mm or less.

11. The method for manufacturing a three-dimensional structure of claim 1 , wherein the filament is deposited on the base with the base having a temperature of 50 to 100° C.

12. The method for manufacturing a three-dimensional structure of claim 1 , wherein the reinforcing fiber is a carbon fiber and/or a glass fiber.

13. The method for manufacturing a three-dimensional structure of claim 1 , wherein the reinforcing fiber is a carbon fiber and/or a glass fiber, and the thermoplastic resin fiber is a polyamide resin fiber.

Assignees

• Mitsubishi Gas Chemical Co

Inventors

• Nakai Asami
• Ohtani Akio
• Ito Hiroto
• Hirano Fumiya
• Hirooka Nobuki
• Matsumoto Nobuhiko

Classifications

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B29C64/118 Primary

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• B29K2077/00

  Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material · CPC title

• D02G3/402

  the adhesive being one component of the yarn, i.e. thermoplastic yarn · CPC title

• B29K2309/08

  Glass · CPC title