WO2023166668A1

WO2023166668A1 - Shaping method and shaping device

Info

Publication number: WO2023166668A1
Application number: PCT/JP2022/009156
Authority: WO
Inventors: 良崇橋本; 亮二郎富永
Original assignee: 株式会社Fuji
Priority date: 2022-03-03
Filing date: 2022-03-03
Publication date: 2023-09-07
Also published as: JPWO2023166668A1

Abstract

The present invention provides a shaping method and a shaping device by which a locally thickened region formed on a semi-cured layer can be further flattened.　This shaping method includes: a first discharge step of discharging a first curable viscous fluid from above a stage; a first flattening step in which the first curable viscous fluid discharged in the first discharge step is flattened by means of a roller by moving the stage in the opposite direction to a rotating direction of the roller; a first curing step in which the first curable viscous fluid flattened in the first flattening step is cured; a flattened layer formation step in which a flattened layer is formed on the stage by repeating the above three steps; a second discharge step in which a second curable viscous fluid is discharged onto the flattened layer; a semi-curing step in which the second curable viscous fluid discharged in the second discharge step is semi-cured; a semi-cured layer formation step in which a semi-cured layer is formed on the flattened layer by repeating the above two steps; and a second flattening step in which the semi-cured layer is flattened by the roller by moving the stage in the same direction as the rotating direction of the roller.

Description

Modeling method and modeling apparatus

The present disclosure relates to a modeling method and modeling apparatus that performs modeling using a curable viscous fluid.

　Conventionally, technologies related to modeling methods have been developed that use curable viscous fluids such as ultraviolet curable resins to model objects. Specifically, in this modeling method, for example, a curable viscous fluid is ejected by an ejection device, the ejected curable viscous fluid is cured by irradiating it with ultraviolet rays, and a desired modeled object is created using the cured cured layer. do. In Japanese Unexamined Patent Application Publication No. 2002-100001, a first unit layer, which has been discharged with an ultraviolet curable resin, is semi-cured by being irradiated with ultraviolet rays, and the first unit layer is flattened by a flattening roller unit.

JP 2018-114657 A

In the process of semi-curing the UV curable resin described above, the surface tension of the UV curable resin may form a local enlarged portion. For example, the edge of a modeled object and the central part of a modeled object with a small width of several millimeters or less become higher than the target height in the design data due to surface tension. As a result, the shape of the upper layer and the shape of the finished product may be affected by the local enlarged portion.

The present disclosure has been made in view of such circumstances, and an object of the present disclosure is to provide a modeling method and a modeling apparatus capable of flattening the local enlarged portion formed in the semi-hardened layer.

In order to solve the above problems, the modeling method of the present disclosure includes a first discharging step of discharging a first curable viscous fluid from above a stage, and moving the stage in a direction opposite to the rotation direction of the roller. a first flattening step of flattening the first hardening viscous fluid discharged in the first flattening step with a roller; 1 curing step, said first discharging step, said first planarizing step, and said first curing step are repeatedly performed to form a planarized layer on said stage; said planarized layer forming step; a second discharging step of discharging a second curable viscous fluid onto the liquid, a semi-curing step of semi-curing the second curable viscous fluid discharged in the second discharging step, the second discharging step, the half a semi-cured layer forming step of repeatedly performing a curing step to form a semi-cured layer on the flattening layer; and a second planarization step of planarizing by

Further, the content of the present disclosure is not limited to being implemented as a modeling method, but is extremely effective when implemented as a modeling apparatus including a discharge device, rollers, a curing device, and a control device.

In the manufacturing method and manufacturing apparatus of the present disclosure, in the first flattening step, droplets of the first curable viscous fluid to be flattened are smaller than in the second flattening step. The intermolecular force between the members is weakened. Therefore, by moving the stage in a direction opposite to the rotation direction of the roller to flatten the surface, the first curable viscous fluid can be transferred to the roller while flattening can be performed quickly, and the modeling time can be shortened. On the other hand, in the semi-hard layer forming step, by repeatedly performing the second discharging step and the semi-hardening step, the second curable viscous fluid of the semi-hard layer has a large fluid film, and the fluid itself and the fluid and other members The intermolecular force between Therefore, in the second flattening step, flattening is performed by moving the stage in the same direction as the rotation direction of the roller. Accordingly, the second curable viscous fluid can be appropriately transferred to the roller by relatively lengthening the time for the second curable viscous fluid to move to the surface of the roller. As a result, compared to the case of flattening the second curable viscous fluid by moving the stage in the direction opposite to the direction of rotation of the roller, the locally increased portion of the semi-hardened layer can be flattened more.

The figure which shows the modeling apparatus of a present Example. The block diagram which shows a control apparatus. 4 is a flowchart showing the details of modeling processing. FIG. 4 is a schematic diagram showing a state in which an ultraviolet curable resin is ejected from an inkjet head; The schematic diagram which shows the state which is planarizing the ultraviolet curing resin by the planarization apparatus. FIG. 4 is a schematic diagram showing a state in which a first planarization layer is formed by curing a planarized ultraviolet curable resin in a curing section; FIG. 4 is a schematic diagram showing a first planarization layer with a planarized surface; The schematic diagram which shows the semi-hardened layer by which the surface was smoothed. The schematic diagram for demonstrating an enlarged part. Schematic diagram of a first planarization process. Schematic diagram of a second planarization process. FIG. 4 is a schematic diagram showing a state in which metal ink is ejected; FIG. 4 is a schematic diagram showing a state in which metal wiring is formed;

(1. Configuration of modeling apparatus 10)
An embodiment embodying the modeling method and modeling apparatus of the present disclosure will be described below. FIG. 1 shows a modeling apparatus 10 of this embodiment. As shown in FIG. 1, the modeling apparatus 10 includes a conveying device 20, a modeling unit 22, a mounting unit 23, an inspection unit 24, and a control device 26 (see FIG. 2). The conveying device 20 , the modeling unit 22 , the mounting unit 23 and the inspection unit 24 are arranged on the base 28 of the modeling device 10 . Base 28 is generally rectangular in shape. In the following description, the longitudinal direction of the base 28 is referred to as the X-axis direction, the lateral direction of the base 28 is referred to as the Y-axis direction, and the direction orthogonal to both the X-axis direction and the Y-axis direction is referred to as the Z-axis direction.

The transport device 20 has an X-axis slide mechanism 30 and a Y-axis slide mechanism 32 . The X-axis slide mechanism 30 has an X-axis slide rail 34 and an X-axis slider 36 . The X-axis slide rail 34 is arranged on the base 28 so as to extend in the X-axis direction. The X-axis slider 36 is held by an X-axis slide rail 34 so as to be slidable in the X-axis direction. Further, the X-axis slide mechanism 30 has an electromagnetic motor 38 (see FIG. 2), and by driving the electromagnetic motor 38, the X-axis slider 36 is moved to an arbitrary position in the X-axis direction.

Also, the Y-axis slide mechanism 32 has a Y-axis slide rail 50 and a stage 52 . The Y-axis slide rail 50 is arranged on the base 28 so as to extend in the Y-axis direction. One end of the Y-axis slide rail 50 in the Y-axis direction is connected to the X-axis slider 36 . As a result, the Y-axis slide rail 50 can move in the X-axis direction as the X-axis slider 36 slides. The stage 52 is held by a Y-axis slide rail 50 so as to be slidable in the Y-axis direction. Furthermore, the Y-axis slide mechanism 32 has an electromagnetic motor 56 (see FIG. 2), and by driving the electromagnetic motor 56, the stage 52 is moved to any position in the Y-axis direction. As a result, the stage 52 can be moved to any position in the X-axis direction and the Y-axis direction on the base 28 by driving the X-axis slide mechanism 30 and the Y-axis slide mechanism 32 .

The stage 52 has a base 60 , a holding device 62 and an elevating device 64 . The base 60 is formed in a flat plate shape, and a base member 70 (see FIG. 4) is mounted on the upper surface thereof. The base member 70 is, for example, a metal plate such as iron or stainless steel. The holding devices 62 are provided on both sides of the base 60 in the X-axis direction. The base member 70 is placed on the base 60 and is fixedly held with respect to the base 60 by sandwiching both edges in the X-axis direction with the holding device 62 . Further, the lifting device 64 is arranged below the base 60 and lifts and lowers the base 60 in the Z-axis direction.

The modeling unit 22 is a unit that models a structure on the base member 70 placed on the base 60 of the stage 52 , and has a printing section 72 and a curing section 74 . As shown in FIG. 4 , the printing unit 72 has an inkjet head 75 and ejects a thin film of fluid onto the base member 70 placed on the base 60 . As the fluid ejected by the inkjet head 75, an ultraviolet curable resin 76 (see FIG. 4) that is cured by ultraviolet rays can be used. The UV curable resin 76 is an example of first and second curable viscous fluids of the present disclosure. As the curable viscous fluid, other viscous fluids such as a thermosetting resin can be used in addition to the ultraviolet curable resin.

In addition, the inkjet head 75 can eject, for example, metal ink 77 (see FIG. 12) in addition to the ultraviolet curing resin 76 . Metal ink 77 is an example of a fluid containing metal particles of the present disclosure. The metal ink 77 is made by, for example, dispersing fine particles of nanometer-sized metal (such as silver) in a solvent, and is cured by being baked by heat. The surface of the metal fine particles is coated with, for example, a dispersant to suppress aggregation in the solvent.

When the inkjet head 75 ejects the ultraviolet curable resin 76, the ultraviolet curable resin 76 is ejected from a plurality of nozzles by, for example, a piezo method using piezoelectric elements. The inkjet head 75 may eject the ultraviolet curable resin 76 from a plurality of nozzles by a thermal method in which air bubbles are generated by heating the ultraviolet curable resin 76 and ejected from the nozzles. Moreover, when ejecting the metal ink 77, the inkjet head 75 ejects the metal ink 77 from a plurality of nozzles by, for example, a piezo method using piezoelectric elements. Note that the ejection device is not limited to the inkjet head 75 having a plurality of nozzles, and may be, for example, a dispenser having one nozzle. The inkjet head 75 may have separate nozzles for ejecting the metal ink 77 and nozzles for ejecting the ultraviolet curable resin 76, or may share a nozzle for ejecting two viscous fluids. In the following description, when collectively referring to the ultraviolet curing resin 76 and the metal ink 77, they may be referred to as a viscous fluid.

As shown in FIG. 2, the curing section 74 has a flattening device 78, an irradiation device 81, and a heater . The flattening device 78 is a device for flattening the upper surface of the ultraviolet curable resin 76 and the metal ink 77 ejected onto the base member 70 by the inkjet head 75 . The flattening device 78 has a roller 79 and a collection section 80 (see FIG. 5). The roller 79 has, for example, a cylindrical shape, and rotates in contact with the fluid viscous fluid (ultraviolet curable resin 76 or metal ink 77) under the control of the flattening device 78, and the surplus viscous fluid is transferred and flattened. The recovery unit 80 has, for example, a blade protruding toward the surface of the roller 79, scrapes the viscous fluid transferred to the roller 79 with the blade, and stores and discharges the viscous fluid scraped off with the blade. The recovery unit 80, for example, discharges the recovered viscous fluid to a waste liquid tank. The flattening device 78 flattens the surface of the viscous fluid by scraping off excess viscous fluid while flattening the surface of the viscous fluid. Note that the recovery unit 80 may return the recovered viscous fluid to the supply tank again. Further, the flattening by the flattening device 78 does not have to be performed every time the viscous fluid is discharged. For example, planarization may be performed only when forming a particular layer.

Also, the irradiation device 81 irradiates the ultraviolet curing resin 76 discharged onto the base member 70 with ultraviolet rays, for example. The UV curable resin 76 is cured by irradiation with UV rays to form a thin insulating layer (such as the first planarizing layer 86 in FIG. 6). A heater 82 is a device for heating the ejected metal ink 77 . The metal ink 77 is baked by applying heat from the heater 82 to form metal wiring. Firing of the metal ink 77 means, for example, applying energy to evaporate the solvent and decompose the protective film of the metal fine particles, that is, to decompose the dispersant. This is a phenomenon in which the electrical conductivity increases. Then, by baking the metal ink, metal wiring can be formed. The details of the modeling method will be described later. A device for heating the metal ink 77 is not limited to the heater 82 . For example, the modeling apparatus 10 heats the metal ink 77 by putting a laser irradiation device that irradiates the metal ink 77 with a laser beam, or putting the first planarization layer 86 onto which the metal ink 77 is ejected into a furnace to heat it. An atmosphere furnace may be provided.

The mounting unit 23 shown in FIG. 1 is, for example, a unit for mounting various electronic components connected to the metal wiring formed by the molding unit 22, and includes a mounting portion 83 and a supply portion 84. The mounting unit 83 has, for example, a suction nozzle (not shown) that suctions an electronic component, and mounts the electronic component held by the suction nozzle onto the metal wiring. The supply unit 84 has, for example, a plurality of tape feeders that feed taped electronic components one by one, and supplies the electronic components to the mounting unit 83 . Note that the supply unit 84 is not limited to a configuration including a tape feeder, and may be a tray-type supply device that picks up and supplies electronic components from a tray.

For example, when the base member 70 moves to a position below the mounting portion 83 as the stage 52 moves, the mounting unit 23 moves the mounting portion 83 to the component supply position of the supply portion 84 and supplies the components. The part 84 is driven to supply the necessary parts. The mounting section 83 sucks and holds the electronic component from the component supply position of the supply section 84 by means of the suction nozzle, and mounts it on the metal wiring or the like formed on the base member 70 .

The inspection unit 24 is a unit that inspects the structure manufactured by the modeling unit 22 and the mounting unit 23. The inspection unit 24 includes, for example, an imaging device such as a camera. Based on the image data captured by the inspection unit 24, the control device 26 can determine whether or not the electronic component is normally mounted. In addition, the modeling apparatus 10 may include a laser microscope or the like for inspecting the shape of the modeled object (unevenness of the smooth surface 93 to be described later, etc.).

As shown in FIG. 2, the control device 26 includes a controller 102, a plurality of drive circuits 104, and a storage device 106. A plurality of drive circuits 104 are connected to the

electromagnetic motors

38 and 56, the holding device 62, the lifting device 64, the inkjet head 75, the flattening device 78, the irradiation device 81, the heater 82, the mounting section 83, the supply section 84, and the inspection unit 24. It is connected. The controller 102 includes a CPU, ROM, RAM, etc., is mainly a computer, and is connected to a plurality of drive circuits 104 . The storage device 106 includes RAM, ROM, hard disk, etc., and stores a control program 107 for controlling the modeling apparatus 10 . The controller 102 can control the operations of the conveying device 20, the modeling unit 22, and the like by executing the control program 107 with the CPU.

The modeling apparatus 10 of the present embodiment has the configuration described above, by curing the ultraviolet curing resin 76 and the metal ink 77 as the viscous fluid, the first flattening layer 86 (see FIG. 6) having insulating properties, the smoothing layer 151 (see FIG. 12) and a conductive metal wiring 95 (see FIG. 13) are formed. By changing the shapes of the first planarization layer 86, the smooth layer 151, and the metal wiring 95, the modeling apparatus 10 can model a structure of any shape. Further, the modeling apparatus 10 may mount electronic components using the mounting unit 23 during the modeling process. For example, the control program 107 is set with three-dimensional data of each layer obtained by slicing the structure. Based on the data of the control program 107, the controller 102 discharges and hardens the viscous fluid to form a structure. The controller 102 also detects information such as the layer and position where the electronic component is to be placed based on the data of the control program 107, and mounts the electronic component based on the detected information.

(2. Operation of modeling apparatus 10)
Next, as an example of the operation of the modeling apparatus 10, modeling processing for modeling the metal wiring 95 on the smooth layer 151 will be described. FIG. 3 is a flow chart showing the details of the modeling process. For example, when receiving an instruction to start modeling, the control device 26 executes a predetermined program of the control program 107 to start the modeling process shown in FIG. Also, in the following description, the fact that the controller 102 executes the control program 107 to control each device may be simply referred to as "device name". For example, "the controller 102 moves the base 60" means "the controller 102 executes the control program 107, controls the operation of the carrier device 20 via the drive circuit 104, and controls the operation of the carrier device 20. It means "to move the base 60". 4 to 8, 12, and 13 schematically show each step of the modeling process. 4 to 8, 12, and 13 (such as the X-axis direction) are examples.

First, the base member 70 is set on the base 60 of the stage 52 . The setting of the base member 70 may be performed manually or automatically by the modeling apparatus 10 . The controller 102 controls the transport device 20 to move the stage 52 on which the base member 70 is set below the modeling unit 22 . In the first ejection process shown in S11 of FIG. 3, the controller 102 moves the stage 52 in the X-axis direction, for example, as shown in FIG. is discharged onto the base member 70 . The inkjet head 75 ejects the ultraviolet curable resin 76 onto the base member 70 in the form of a thin film. Note that the controller 102 may execute ejection by the inkjet head 75 in S11, for example, only one scan (one pass) along the X-axis direction, or may execute a plurality of scans.

Next, in the first flattening process of S13, the controller 102 rotates the rollers 79 of the flattening device 78 on the upper surface of the thin ultraviolet curable resin 76 to flatten it. The controller 102 moves the base member 70 (stage 52) in a movement direction 133 opposite to the rotation direction 131 of the roller 79, as indicated by the arrow in FIG. A roller 79 flattens the resin 76 . For example, the controller 102 rotates the roller 79 in a counterclockwise rotation direction 131 in FIG. 5 around a rotation axis parallel to the Y-axis direction. Further, the controller 102 moves the stage 52 in a movement direction 133 (a direction toward the back in FIG. 5) that is along the X-axis direction and opposite to the rotation direction 131 . The direction opposite to the rotation direction 131 here is, for example, parallel to the upper surface of the stage 52 , tangential to the roller 79 , and opposite to the rotation direction 131 . In this embodiment, the position of the roller 79 is fixed in the XYZ axis directions. The controller 102 raises the stage 52 by the lifting device 64 to a position where the roller 79 contacts the ultraviolet curable resin 76 discharged onto the base member 70 to perform flattening. Further, the controller 102 makes the rotation speed of the roller 79 in the rotation direction 131 larger (faster) than the moving speed of the stage 52 in the moving direction 133 .

The roller 79 contacts the UV curable resin 76 in a flowable state, transfers the UV curable resin 76 to the roller 79, scrapes it up, and recovers it by the recovery unit 80, while flattening the surface of the UV curable resin 76. It should be noted that the operating directions and the like of the base member 70 and the rollers 79 described above are examples. For example, the roller 79 is configured to be movable in the X-axis direction, and the controller 102 moves the roller 79 in a moving direction 133 or a direction opposite to the moving direction 133 and rotates it in a rotating direction 131 to perform flattening. can be

Next, in the first curing process of S15, the controller 102 causes the irradiation device 81 to irradiate the flattened ultraviolet curing resin 76 with ultraviolet rays. As shown in FIG. 6, the irradiation device 81 irradiates the ultraviolet curable resin 76 (see FIG. 5) spread in a thin film with ultraviolet rays to cure the ultraviolet curable resin 76, thereby forming a first flattening film having insulating properties. A layer 86 is formed. Thereby, a first planarization layer 86 having a planarized first planarization surface 86A on its surface is formed.

Next, the controller 102 determines whether or not the first planarization layer 86 with a predetermined thickness has been formed (S17). The controller 102, for example, makes a negative determination in S17 (S17: NO) until the thickness reaches a value designated by a setting value of the control program 107 or an operation input from the outside. The controller 102 can determine the thickness of the formed first planarization layer 86 based on, for example, the size of droplets of the ultraviolet curable resin 76 ejected from the inkjet head 75, the number of times S11 to S15 are repeatedly executed, and the like. . The controller 102 stacks insulating layers by repeatedly executing the processes of S11 to S15 to form the first planarizing layer 86 having a first planarizing surface 86A and a predetermined thickness. Note that the controller 102 does not have to execute the first flattening process of S13 each time S11 is executed. For example, the controller 102 may execute the first flattening process of S13 each time S11 and S15 are executed multiple times.

When the controller 102 determines in S17 that the first planarizing layer 86 having a predetermined thickness has been formed (S17: YES), the first planarizing surface 86A of the first planarizing layer 86 is removed in the second ejection process in S19. For smoothing, an ultraviolet curable resin 76 is discharged onto the first flattened surface 86A. Here, by repeatedly performing S11 to S15, a planarized first planarized surface 86A can be formed on the surface of the first planarized layer 86. Next, as shown in FIG. FIG. 7 schematically shows the first planarization layer 86 whose surface is planarized. As shown in FIG. 7, on the flattened first planarization surface 86A of the first planarization layer 86, for example, there is a difference in the amount of the ultraviolet curable resin 76 ejected from the nozzles of the inkjet head 75, and the amount of the ultraviolet curable resin 76 is Fine irregularities 91 are formed due to the size of the liquid droplets. The height of this unevenness 91 can be, for example, ±10 μm, which is extremely small compared to the size of the roller 79 . Therefore, even if the first planarizing surface 86A of the first planarizing layer 86 is planarized by the roller 79, it is difficult to planarize even the minute unevenness 91. FIG. In the present disclosure, the surface on which the fine unevenness 91 is formed is defined as a flattened surface. Further, a surface on which the fine irregularities 91 are reduced or the surface irregularities are ±1 μm or less (it can be hypothesized that the original irregularities 91 are eliminated) is defined as a smoothed surface.

Due to the unevenness 91 formed on the first flattened surface 86A, when metal wiring is formed on the first flattened surface 86A, the thickness of the formed metal wiring varies. Alternatively, the electrical conductivity of the metal wiring may be lowered because the metal wiring is not completely baked (the metal fine particles do not contact or fuse together) in the thick portion. As a result, the resistance value of the metal wiring becomes uniform, making it difficult to obtain desired high-frequency characteristics.

Therefore, the controller 102 discharges the ultraviolet curing resin 76 again onto the flattened first flattened surface 86A of the first flattened layer 86 to reduce or eliminate the unevenness 91 . The controller 102 ejects the ultraviolet curable resin 76 onto the first flattened surface 86A from the inkjet head 75 in the second ejection process of S19 of FIG. In the following description, when distinguishing between the UV curable resin 76 in the first ejection process of S11 and the UV curable resin 76 in the second ejection process of S19, the UV curable resin 76 of S19 will be referred to as the second UV curable resin 76A. . The controller 102 sets the discharge amount of the second ultraviolet curable resin 76A in S19 to an amount corresponding to the size of the unevenness 91 . For example, the controller 102 executes processing to increase the ejection amount of the inkjet head 75 when the height of the unevenness 91 to be formed is high (the groove is deep). Note that the controller 102 may discharge the second ultraviolet curable resin 76A at a constant discharge rate regardless of the size of the unevenness 91 .

Next, the controller 102 performs a semi-curing process on the second ultraviolet curing resin 76A discharged in S19 (S23). The controller 102 irradiates the second ultraviolet curing resin 76A with ultraviolet rays from the irradiation device 81 to semi-harden it (see FIG. 6). The term "semi-cured state" as used herein means a state in which the viscosity is lowered and the fluidity is improved, and the physical properties are not completely stable. The semi-cured state means, for example, when a new second ultraviolet curable resin 76A is discharged onto a layer of the semi-cured second ultraviolet curable resin 76A, the discharged second ultraviolet curable resin 76A does not mix with the layer. , is a state in which it is cured to the extent that it rides (stacks) on the semi-cured layer. The controller 102 controls, for example, the intensity (light intensity) of the ultraviolet rays irradiated to the second ultraviolet curing resin 76A, the scanning speed of the ultraviolet rays, the number of scanning times, The second ultraviolet curable resin 76A is semi-cured by reducing the irradiation time, the number of times of irradiation, and the like.

As in S17 described above, the controller 102 repeatedly executes the processes of S19 to S23 until a semi-cured layer having a predetermined thickness is formed (S25: NO), and the semi-cured second ultraviolet curable resin Laminate 76A. As shown in FIG. 8, on the first planarizing layer 86, a semi-cured layer 92 is formed by laminating a semi-cured second ultraviolet curable resin 76A. The semi-cured second ultraviolet curable resin 76A spreads over the fine irregularities 91 of the first flattened surface 86A due to the leveling effect and smoothes them to form a smooth surface 93. As shown in FIG. The leveling effect referred to here is a phenomenon in which the surface area of a liquid becomes as small as possible due to surface tension. Although it depends on the viscosity of the liquid, the thin film formed by the second ultraviolet curing resin 76A changes to a flat (more uniform) film thickness over time. The second ultraviolet curable resin 76A spreads by being discharged onto the first flattened surface 86A, and spreads so as to fill the irregularities 91. As shown in FIG.

After forming the semi-hardened layer 92 with a predetermined thickness (S25: YES), the controller 102 executes the second planarization process (S27). Here, during the formation of the semi-cured layer 92 in S19 to S25 described above, or during the subsequent curing, the surface tension of the second ultraviolet curable resin 76A forms a local increased portion. More specifically, FIG. 9 is a schematic diagram for explaining the enlargement part 135. As shown in FIG. As shown in FIG. 9, for example, when a small shaped object 139 with a width 137 in the X-axis direction of several millimeters or less is formed, the semi-cured layer 92 has a Z-axis due to the surface tension of the second ultraviolet curable resin 76A. An enlarged portion 135 that bulges upward in the axial direction is formed. Further, for example, when the modeled object 141 is formed with the width in the X-axis direction and the Y-axis direction expanded to a certain width (for example, 3 mm) or more, the ends of the modeled object 141 in the X-axis direction and the Y-axis direction have , an enlarged portion 135 bulging upward is formed. An enlarged portion 135 protruding from a predetermined height 143 is formed on each of the shaped

objects

139 and 141 . This predetermined height 143 is, for example, a target height defined by three-dimensional data of the control program 107 or the like, and is the height at which the smooth surface 93 is formed.

Further, when further modeling is continued on the semi-cured layer 92, for example, the ultraviolet curable resin discharged onto the enlarged portion 135 has a surface tension higher than that of the ultraviolet curable resin printed on a flat surface such as the smooth surface 93. , the force of adhering to the base (enlarged portion 135) is increased. For this reason, if the UV curable resin is discharged in the same amount onto the enlarged portion 135 and the smooth surface 93 and the flattening process is performed under the same conditions, the enlarged portion 135 will remain in the modeled object. As a result, the thickness and modeling accuracy of the completed modeled object deteriorate. In addition, there is a risk that the enlargement portion 135 and the roller 79 will come into contact with each other during the flattening process, and that a part of the modeled article will be damaged, and that the shavings of the modeled article will be collected by the collecting section 80 .

Therefore, the controller 102 executes the second flattening process of S27 to reduce the increase portion 135 (suppress the increase). The controller 102 moves the stage 52 to the position of the flattening device 78 so that the lower ends of the rollers 79 are positioned on the smooth surface 93, that is, at a predetermined height 143, as shown in FIG. Adjust the height of 52. As described above, in this embodiment, the positions of the rollers 79 in the X-axis direction and the Y-axis direction are fixed. Then, the position where the rotating roller 79 contacts the semi-hardened layer 92 while this position is fixed is aligned with the position of the upper surface (smooth surface 93) of the semi-hardened layer 92 in the design data, and flattening by the roller 79 is performed. Execute. As a result, the second ultraviolet curable resin 76A contained in the enlarged portion 135 projecting from the smooth surface 93 can be transferred to the roller 79 and collected, thereby reducing the size of the enlarged portion 135 and flattening it. The second flattening process may be performed while moving the roller 79 without fixing its position. Also, the position of the roller 79 may be slightly above or below the smooth surface 93 .

Also, the method of aligning the position of the roller 79 with the position of the upper surface of the semi-hardened layer 92 is not particularly limited. Based on the three-dimensional data of the control program 107 , the position of the lower end of the roller 79 may be aligned with the target height for forming the smooth surface 93 . Alternatively, the height of the upper surface of the semi-hardened layer 92 may be measured by forming a modeled object on a trial basis, and the position of the roller 79 may be aligned. Alternatively, the position of the roller 79 may be adjusted by measuring the height of the upper surface of the shaped semi-hardened layer 92 with a sensor or the like before executing S27 in the actual shaping process. Further, the position of the stage 52 may be fixed, the position of the roller 79 in the Z-axis direction may be adjusted, and the position of the roller 79 may be aligned with the position of the upper surface of the semi-hardened layer 92 . Moreover, both the stage 52 and the roller 79 may be moved in the Z-axis direction for adjustment.

Further, unlike the first flattening process of S13, the controller 102 moves the stage 52 in the moving direction 145, which is the same direction as the rotating direction 131 of the roller 79, as shown in FIG. is flattened by rollers 79 . The same direction as the rotation direction 131 here means, for example, parallel to the upper surface of the stage 52 , the tangential direction of the roller 79 , and the same direction as the rotation direction 131 . Since the position of the roller 79 is fixed as described above, the roller 79 rotates while the position in the movement direction 145 of the stage 52, for example, the X-axis direction is fixed. Here, FIG. 10 is a schematic diagram of the first planarization process. In the first flattening process of S13, for example, flattening is performed after one first ejection process (S11). For this reason, the ultraviolet curable resin 76 to be processed in the first planarization process is one by one, compared to the state in which many layers of the semi-cured second ultraviolet curable resin 76A are stacked as in the second planarization process. One droplet is small. The UV curable resin 76 has a weak intermolecular force between the droplet itself and the cured film (already cured portion of the first planarization layer 86) (see arrow in FIG. 10). In such a case, the rotation direction 131 and the movement direction 133 are reversed, and force is applied from the roller 79 to the ultraviolet curable resin 76 in the direction of the arrow 147 shown in FIG. , and can be planarized quickly and efficiently. As a result, the molding time can be shortened.

On the other hand, FIG. 11 is a schematic diagram of the second planarization process. In the second flattening process of S27, for example, the cycle of S19 to S23 is executed a plurality of times to fill the irregularities 91, and the semi-cured second ultraviolet curing resin 76A is laminated. For this reason, even if an attempt is made to quickly transfer and recover the droplets of the second ultraviolet curable resin 76A as in the first planarization process, the liquid film formed by the droplets of the second ultraviolet curing resin 76A is large. The intermolecular force between 86 is strong (see arrow in FIG. 11). Therefore, if the movement direction 133 and the rotation direction 131 are reversed to perform planarization as in the first planarization process, there is a possibility that the second ultraviolet curable resin 76A cannot be sufficiently collected (transferred). Therefore, by setting the rotating direction 131 of the roller 79 and the moving direction 145 of the stage 52 in the same direction, the time for the second ultraviolet curable resin 76A to move to the surface of the roller 79, that is, the transfer time can be lengthened. , the surplus second ultraviolet curable resin 76A can be more reliably transferred to the roller 79 and recovered to be flattened. The enlarged portion 135 can be made smaller more reliably.

Furthermore, as described above, the controller 102 increases (increases) the rotational speed of the rollers 79 in the rotational direction 131 compared to the movement speed of the stage 52 in the movement direction 133 in the first flattening process. For example, the controller 102 makes the rotational speed of the roller 79 several times the moving speed of the stage 52 . As a result, in the first flattening process, in which the intermolecular force is weaker than that in the second flattening process and droplets are easily transferred, the roller 79 is rotated at a high speed, and the transfer amount to the roller 79 per unit time is increased. It is possible to shorten the time required for the first planarization process. As a result, the molding time can be shortened.

In addition, the controller 102 makes the moving speed of the stage 52 in the moving direction 145 and the rotating speed of the roller 79 in the rotating direction 131 the same in the second flattening process. As a result, the difference in relative moving speed between the roller 79 and the second ultraviolet curable resin 76A on the stage 52 can be eliminated, as if the roller 79 holds down the second ultraviolet curable resin 76A from above. In the second flattening process, in which the intermolecular force is strong and droplet transfer is difficult compared to the first flattening process, by eliminating the relative movement between the roller 79 and the second ultraviolet curable resin 76A, the excess amount can be more reliably removed. The second ultraviolet curable resin 76A can be transferred to the roller 79. As shown in FIG.

After executing S27, the controller 102 executes a second curing process for curing the semi-cured layer 92 (S29). The controller 102 moves the stage 52 to the irradiation device 81 and irradiates the semi-cured layer 92 that has undergone the second planarization process with ultraviolet rays. The second ultraviolet curable resin 76A is cured so as to fill the irregularities 91 by being irradiated with ultraviolet rays and increasing in viscosity. A smoothing layer 151 obtained by curing the semi-cured layer 92 is formed on the first planarizing layer 86 (see FIG. 12). A smooth surface 93 formed on the upper surface of the smooth layer 151 is a surface with reduced or no unevenness 91 due to the above-described leveling effect. Further, the smooth surface 93 becomes a surface in which the enlarged portion 135 is reduced or eliminated by the second flattening process.

Next, the controller 102 forms metal wiring at predetermined locations on the smooth surface 93 based on the three-dimensional data of the control program 107 . More specifically, in the metal fluid ejection process of S31, the controller 102 controls the inkjet head 75 to eject the metal ink 77 in a thin film form onto the smooth surface 93 of the smooth layer 151 (see FIG. 12). In the conductor forming process of S33, the controller 102 heats and bakes the metal ink 77 ejected onto the smooth surface 93 by the heater 82 (see FIG. 13). The controller 102 determines in S35 whether or not the metal wiring 95 having the desired thickness and shape has been formed. For example, the controller 102 makes a negative determination in S35 up to a preset number of times (S35: NO), and repeats S31 and S33 to form the desired metal wiring 95 on the smooth surface 93 . The desired metal wiring 95 referred to here is the metal wiring 95 that satisfies the required thickness, shape, position, and electrical characteristics. After repeating S31 and S33 up to the preset number of times, the controller 102 makes an affirmative determination in S35 (S35: YES), and executes S37. As a result, the first planarization layer 86 (wiring substrate) having the metal wiring 95 formed on the smooth surface 93 can be formed.

Here, when the metal wiring 95 is formed by ejecting and curing the metal ink 77 on the first flattened surface 86A on which the unevenness 91 is formed, the thickness of the metal wiring 95 becomes uneven due to the unevenness 91 . Then, problems such as an increase in the resistance value of the metal wiring 95, disconnection, and deterioration of high-frequency characteristics may occur. On the other hand, in the modeling apparatus 10 of the present embodiment, the minute unevenness 91 and the enlarged portion 135 of the first flattened surface 86A are reduced, and the metal ink 77 is ejected onto the reduced smooth surface 93. A metal wiring 95 having a uniform thickness can be formed. As a result, the resistance value of metal wiring 95 can be reduced to a desired value, and the occurrence of disconnection can be suppressed.

Next, the controller 102 executes other processing in S37. For example, the controller 102 ejects the metal ink 77 from the inkjet head 75 onto the metal wiring 95, controls the mounting unit 23, and arranges the electronic component so that the ejected ink contacts the terminal of the electronic component. Also good. The controller 102 connects the electronic component with the metal wiring 95 (circuit) by baking the metal ink 77 with the heater 82 . Alternatively, the controller 102 may re-execute the process from S11 when further shaping of the first planarization layer 86 and the metal wiring 95 is required. The controller 102 may also control the inspection unit 24 to perform inspection of the completed structure (such as the first planarization layer 86 loaded with electronic components). After executing S37, the controller 102 ends the modeling process shown in FIG. Thereby, a desired structure can be modeled.

According to the above-described embodiment, the following effects are obtained.
The controller 102 of the modeling apparatus 10 moves the stage 52 in a direction opposite to the rotation direction 131 of the roller 79 in a first ejection process (S11) in which the ultraviolet curable resin 76 is ejected from above the stage 52, and ejects in S11. A first flattening process (S13) of flattening the ultraviolet curable resin 76 flattened by the roller 79 and a first hardening process (S15) of hardening the flattened ultraviolet curable resin 76 in S13 are performed. The controller 102 repeats S11, S13, and S15 to form the first planarization layer 86 until the predetermined thickness is reached (S17: NO). Further, the controller 102 performs a second ejection process (S19) for ejecting the second ultraviolet curable resin 76A onto the first planarizing layer 86, and a semi-curing process for semi-curing the second ultraviolet curable resin 76A ejected in S19. (S23) is executed. The controller 102 repeats S19 and S23 to form the semi-hardened layer 92 on the first planarization layer 86 until the predetermined thickness is reached (S25: NO). Then, the controller 102 moves the stage 52 in the same direction as the rotation direction 131 of the rollers 79 to flatten the semi-hardened layer 92 by the rollers 79 (S27).

According to this, in S13, by moving the stage 52 in the direction opposite to the rotation direction 131 of the roller 79 for flattening, the ultraviolet curable resin 76 can be transferred to the roller 79 and the flattening can be performed quickly. , the molding time can be shortened. Furthermore, in S23, by moving the stage 52 in the same direction as the rotation direction 131 of the roller 79 to perform flattening, the time required for the second ultraviolet curable resin 76A of the semi-cured layer 92 to move to the surface of the roller 79 is It can be relatively long and can perform adequate transfer. As a result, compared to the case where the stage 52 is moved in the direction opposite to the rotation direction 131 of the roller 79 to flatten the second ultraviolet curing resin 76A, the localized enlarged portion 135 of the semi-cured layer 92 is flattened more. can.

As shown in FIG. 2, the controller 102 of the control device 26 includes a first ejection section 110, a first planarization section 111, a first curing section 112, a planarization layer forming section 113, and a second ejection section. It has a portion 115 , a semi-hardened portion 116 , a semi-hardened layer forming portion 117 and a second flattened portion 118 . The first ejection unit 110 and the like are, for example, processing modules realized by executing the control program 107 in the CPU of the controller 102 . Note that the first ejection unit 110 and the like may be configured by hardware instead of software.

The first ejection part 110 is a functional part that ejects the ultraviolet curing resin 76 from the inkjet head 75 above the stage 52 . The first flattening section 111 is a functional section that flattens the ultraviolet curable resin 76 discharged by the first discharge section 110 by moving the stage 52 in a direction opposite to the rotation direction 131 of the roller 79 . The first curing section 112 is a functional section that causes the curing section 74 to cure the ultraviolet curable resin 76 flattened by the first flattening section 111 . The planarization layer forming unit 113 is a functional unit that repeatedly executes S11, S13, and S15 to form the first planarization layer 86 on the stage 52. FIG. The second ejection part 115 is a functional part that ejects the second ultraviolet curable resin 76A onto the first planarization layer 86 from the inkjet head 75 . The semi-curing section 116 is a functional section that semi-cures the second ultraviolet curable resin 76A discharged from the second discharge section 115 by the curing section 74 . The semi-hardened layer forming part 117 is a functional part that repeatedly executes S19 and S23 to form the semi-hardened layer 92 on the first planarization layer 86 . The second flattening section 118 is a functional section that flattens the semi-hardened layer 92 by the roller 79 by moving the stage 52 in the same direction as the rotation direction 131 of the roller 79 .

By the way, in the above embodiment, the curing section 74 is an example of a curing device. The inkjet head 75 is an example of an ejection device. The ultraviolet curable resin 76 is an example of the first curable viscous fluid. Metal ink 77 is an example of a fluid containing metal particles. The second ultraviolet curable resin 76A is an example of a second curable viscous fluid. The first planarization layer 86 is an example of a planarization layer. Metal wiring 95 is an example of a conductor. S11 is an example of the first discharge step and the planarizing layer forming step. S13 is an example of a first planarization step and a planarization layer formation step. S15 is an example of a first curing step and a flattening layer forming step. S19 is an example of a second ejection step, a semi-hardened layer forming step. S23 is an example of a semi-curing step and a semi-cured layer forming step. S27 is an example of a second planarization step. S29 is an example of a second curing step. S31 is an example of the metal fluid ejection step. S33 is an example of a conductor forming step.

(3. Others)
The present disclosure is not limited to the above-described embodiments, and can be implemented in various modes with various modifications and improvements based on the knowledge of those skilled in the art.
For example, the contents, order, etc. of each step of the manufacturing process shown in FIG. 3 are an example. For example, in the manufacturing process of FIG. 3, the first planarizing layer 86 is formed on the base member 70 of the stage 52 and the smooth layer 151 is formed on the first planarizing layer 86, but the present invention is not limited to this. For example, the smoothing layer 151 may be formed on the base member 70, the first planarizing layer 86 may be formed on the smoothing layer 151, and the smoothing layer 151 may be formed on the first planarizing layer 86. .
Also, the controller 102 does not need to form the metal wiring 95 .
Further, the controller 102 may set the rotational speed of the roller 79 to be the same as or lower than the moving speed of the stage 52 in S13.
Also, the controller 102 may make the moving speed of the stage 52 higher or lower than the rotational speed of the roller 79 in S27.
Although the position of the roller 79 is fixed in the modeling apparatus 10, the structure may be such that the position is not fixed. The modeling apparatus 10 may perform flattening by moving the roller 79 in each of the XYZ axial directions in each flattening step (processing).
Also, the controller 102 does not have to mount electronic components.

The first curable viscous fluid and the second curable viscous fluid of the present disclosure are not limited to the ultraviolet curable resin 76, and various curable viscous fluids that are cured by light, heat, or the like can be employed. Therefore, the method for curing the first curable viscous fluid and the second curable viscous fluid is not limited to ultraviolet rays.
The first curable viscous fluid and the second curable viscous fluid may be different types of curable viscous fluids.
The fluid containing metal particles of the present disclosure is not limited to the metal ink 77 containing silver, and fluids containing other metals can be employed.
In the above embodiment, the modeling apparatus 10 that manufactures wiring boards is employed as the modeling apparatus of the present disclosure, but the present invention is not limited to this. As the manufacturing apparatus of the present disclosure, various manufacturing apparatuses that perform modeling using the first curable viscous fluid and the second curable viscous fluid can be employed.

10 molding device, 26 control device, 52 stage, 74 curing unit (curing device), 75 inkjet head (ejection device), 76 ultraviolet curing resin (first curing viscous fluid), 76A second ultraviolet curing resin (second curing viscous fluid), 77 metal ink (fluid containing metal particles), 79 roller, 86 first flattening layer (flattening layer), 92 semi-hardened layer, 93 smooth surface, 95 metal wiring (conductor), 110 first Ejecting part 111 Flattening part 112 First hardening part 113 Flattening layer forming part 115 Second ejecting part 116 Semi-hardening part 117 Semi-hardening layer forming part 118 Second flattening part 131 Rotation direction 151 Smooth layer.

Claims

a first discharging step of discharging the first curable viscous fluid from above the stage;
a first flattening step of moving the stage in a direction opposite to the rotating direction of the roller to flatten the first curable viscous fluid discharged in the first discharging step by the roller;
a first curing step of curing the first curable viscous fluid flattened by the first flattening step;
a planarization layer forming step of repeatedly performing the first discharge step, the first planarization step, and the first curing step to form a planarization layer on the stage;
a second discharging step of discharging a second curable viscous fluid onto the planarizing layer;
a semi-curing step of semi-curing the second curable viscous fluid discharged in the second discharging step;
a semi-hardened layer forming step of repeatedly performing the second discharging step and the semi-hardening step to form a semi-hardened layer on the planarizing layer;
a second flattening step of flattening the semi-hardened layer with the roller by moving the stage in the same direction as the rotation direction of the roller;
A molding method, including
In the first planarization step,
2. The modeling method according to claim 1, wherein the rotational speed of said roller is increased compared to the moving speed of said stage.
In the second planarization step,
3. The modeling method according to claim 1, wherein the moving speed of the stage and the rotating speed of the roller are the same.
In the second planarization step,
The position of the roller in the moving direction of the stage is fixed, and the position where the roller contacts the semi-hardened layer is aligned with the position of the upper surface of the semi-hardened layer in the design data, and flattening is performed by the roller. The modeling method according to any one of claims 1 to 3, wherein:
a second curing step of curing the semi-cured layer flattened by the second flattening step to form a smooth layer having a smooth surface;
a metal fluid ejection step of ejecting a fluid containing metal particles onto the smooth surface;
a conductor forming step of curing the fluid containing the metal particles ejected by the metal fluid ejecting step to form a metallic conductor on the smooth surface;
The modeling method according to any one of claims 1 to 4, comprising:
a discharge device;
Laura and
a curing device;
a controller;
with
The control device is
a first ejection unit for ejecting the first curable viscous fluid from above the stage by the ejection device;
a first flattening section for flattening the first curable viscous fluid discharged by the first discharge section by moving the stage in a direction opposite to the rotation direction of the roller;
a first curing section for curing the first curable viscous fluid flattened by the first flattening section by the curing device;
a planarization layer forming unit that repeatedly executes the processes by the first ejection unit, the first planarization unit, and the first curing unit to form a planarization layer on the stage;
a second ejection unit for ejecting a second curable viscous fluid onto the surface of the planarizing layer by the ejection device;
a semi-curing section that semi-cures the second curable viscous fluid discharged by the second discharging section by the curing device;
a semi-hardened layer forming part that repeatedly executes the processes by the second ejection part and the semi-hardened part to form a semi-hardened layer on the planarizing layer;
a second flattening unit that flattens the semi-hardened layer with the roller by moving the stage in the same direction as the rotation direction of the roller;
A molding device.