Method for manufacturing material layer, method for manufacturing three-dimensional object, material-layer-forming apparatus, and additive manufacturing system

Patent metadata

Field	Value
Publication number	US-2020368818-A1
Application number	US-202016989717-A
Country	US
Kind code	A1
Filing date	Aug 10, 2020
Priority date	Feb 14, 2018
Publication date	Nov 26, 2020
Grant date	—

Abstract

A method for manufacturing a material layer includes a first step S101 of arranging first particles P1 in a pattern on a base material 11 and a second step S102 of arranging second particles in regions in which the first particles P1 are not arranged on the base material 11. The second step S102 includes a step of rubbing bearing materials S2 that carry the second particles P2 against the base material 11 on which the first particles P1 are arranged.

First claim

1 . A method for manufacturing a material layer, the method comprising:
a first step of arranging first particles in a pattern on a base material; and a second step of arranging second particles in regions in which the first particles are not arranged on the base material, wherein the second step includes a step of rubbing bearing materials that carry the second particles against the base material on which the first particles are arranged.

2 . The method for manufacturing a material layer according to claim 1 , wherein the bearing materials are any one of magnetic particles, brush fibers, and an elastic material.

3 . The method for manufacturing a material layer according to claim 1 , wherein
the base material is provided with an uneven pattern by the first particles, a median diameter of the second particles is smaller than an opening diameter of a recessed portion of the uneven pattern, and an average particle diameter of the bearing materials is larger than the opening diameter of the recessed portion of the uneven pattern.

4 . The method for manufacturing a material layer according to claim 1 , wherein in the regions in which the first particles are not arranged on the base material, the second particles are enabled to be in contact with the base material, and the bearing materials are not enabled to be in contact with the base material.

5 . The method for manufacturing a material layer according to claim 1 , wherein the base material has an adhesive layer on a surface.

6 . The method for manufacturing a material layer according to claim 1 , wherein
the first step includes a step of arranging the first particles in a pattern on a transfer base material different from the base material, and a step of transferring the first particles from the transfer base material to the base material.

7 . The method for manufacturing a material layer according to claim 6 , wherein
a transfer uneven pattern is formed on a surface of the transfer base material, and the step of arranging the first particles in a pattern on the transfer base material includes a step of rubbing second bearing materials that carry the first particles against the transfer uneven pattern.

8 . The method for manufacturing a material layer according to claim 7 , wherein the second bearing materials are any one of magnetic particles, brush fibers, and an elastic material.

9 . The method for manufacturing a material layer according to claim 7 , wherein
a median diameter of the first particles is smaller than an opening diameter of a recessed portion of the transfer uneven pattern, and an average particle diameter of the second bearing materials is larger than an opening diameter of the recessed portion of the transfer uneven pattern.

10 . The method for manufacturing a material layer according to claim 7 , wherein
the first particles are enabled to be in contact with a bottom portion of a recessed portion of the transfer uneven pattern, and the second bearing materials are not enabled to be in contact with the bottom portion of the transfer uneven pattern.

11 . The method for manufacturing a material layer according to claim 1 , wherein
the first step includes a step of arranging a liquid in a pattern on the base material, and a step of applying the first particles to the base material on which the liquid is arranged in the pattern so that the first particles adhere to the liquid.

12 . The method for manufacturing a material layer according to claim 11 , wherein the step of arranging a liquid in a pattern on the base material is a step of coating the base material with the liquid by using an ink jet method.

13 . The method for manufacturing a material layer according to claim 11 , further comprising a step of removing the first particles not adhering to the liquid, after the step of applying the first particles.

14 . A method for manufacturing a three-dimensional object, the method comprising:
a material-layer-forming step of forming a material layer on a base material; a stacking step of forming a multilayer body by stacking a plurality of base materials each of which is provided with the material layer; and a removing step of removing the plurality of base materials from the multilayer body, wherein the material-layer-forming step includes a first step of arranging first particles in a pattern on the base material and a second step of arranging second particles in regions in which the first particles are not arranged on the base material, and the second step includes a step of rubbing bearing materials that carry the second particles against the base material on which the first particles are arranged.

15 . The method for manufacturing a three-dimensional object according to claim 14 , wherein the base material is removed by heating in the removing step.

16 . The method for manufacturing a three-dimensional object according to claim 14 , wherein
at least one of the first particles and the second particles are a solid electrolyte material, and the three-dimensional object is a solid electrolyte sheet.

17 . The method for manufacturing a three-dimensional object according to claim 14 , wherein
at least one of the first particles and the second particles are a material for forming an electrode, and the three-dimensional object is an electrode sheet.

18 . The method for manufacturing a three-dimensional object according to claim 14 , wherein
the material-layer-forming step includes a step of forming a material layer containing a solid electrolyte material and a step of forming a material layer containing a positive electrode material or a negative electrode material, and the three-dimensional object is an all-solid-state battery.

19 . A material-layer-forming apparatus comprising:
a first arranging device configured to arrange first particles in a pattern on a base material; and a second arranging device configured to arrange second particles in regions in which the first particles are not arranged on the base material, wherein the second arranging device is configured to rub bearing materials that carry the second particles against the base material on which the first particles are arranged.

20 . An additive manufacturing system comprising:
a material-layer-forming unit configured to form a material layer on a base material; a stacking unit configured to form a multilayer body by stacking a plurality of base materials each of which has the material layer formed thereon; and a removing unit configured to remove the plurality of base materials from the multilayer body, wherein the material-layer-forming unit includes a first arranging device configured to arrange first particles in a pattern on the base materials and a second arranging device configured to arrange second particles in regions in which the first particles are not arranged on the base materials, and the second arranging device is configured to rub bearing materials that carry the second particles against the base materials on which the first particles are arranged.

21 . A material layer comprising a pattern layer and a base material provided with the pattern layer, wherein the pattern layer includes first regions in which a plurality of first particles that contain a first inorganic material and that are before subjected to sintering treatment are arranged and second regions in which a plurality of second particles that contain a second inorganic material and that are before subjected to s

Assignees

• Canon Kk

Inventors

• Kubo Kenta
• Taniuchi Hiroshi

Classifications

• B22F10/43

  characterised by material · CPC title

• B22F12/57

  Metering means · CPC title

• B22F12/86

  Serial processing with multiple devices grouped · CPC title

• B22F12/63

  Rollers · CPC title

• B22F12/55

  Two or more means for feeding material · CPC title