U.S. patent application number 17/406110 was filed with the patent office on 2021-12-09 for shaped article.
This patent application is currently assigned to MIMAKI ENGINEERING CO., LTD.. The applicant listed for this patent is MIMAKI ENGINEERING CO., LTD.. Invention is credited to Kunio Hakkaku, Hirofumi HARA.
Application Number | 20210379816 17/406110 |
Document ID | / |
Family ID | 1000005787194 |
Filed Date | 2021-12-09 |
United States Patent
Application |
20210379816 |
Kind Code |
A1 |
Hakkaku; Kunio ; et
al. |
December 9, 2021 |
SHAPED ARTICLE
Abstract
A shaped article is provided. The shaped article includes a
light reflective layer, a decorative layer, and a first transparent
layer. The light reflective layer is being provided from an ink
having light reflectiveness. The first transparent layer is being
provided from a transparent ink. The decorative layer is disposed
on an outer side of the light reflective layer. The first
transparent layer is disposed on an outer side of the decorative
layer.
Inventors: |
Hakkaku; Kunio; (NAGANO,
JP) ; HARA; Hirofumi; (NAGANO, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MIMAKI ENGINEERING CO., LTD. |
Nagano |
|
JP |
|
|
Assignee: |
MIMAKI ENGINEERING CO.,
LTD.
Nagano
JP
|
Family ID: |
1000005787194 |
Appl. No.: |
17/406110 |
Filed: |
August 19, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16659578 |
Oct 22, 2019 |
11135762 |
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17406110 |
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16005718 |
Jun 12, 2018 |
10500787 |
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16659578 |
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15116513 |
Aug 4, 2016 |
10647052 |
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PCT/JP2015/053039 |
Feb 4, 2015 |
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16005718 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B 2307/416 20130101;
B29K 2105/0032 20130101; B33Y 10/00 20141201; B32B 1/00 20130101;
B29C 64/40 20170801; B29K 2505/00 20130101; B33Y 80/00 20141201;
B32B 2307/402 20130101; B29C 64/129 20170801; B29K 2105/16
20130101; B32B 2307/412 20130101; B29C 64/112 20170801; B29K
2105/0058 20130101 |
International
Class: |
B29C 64/112 20060101
B29C064/112; B32B 1/00 20060101 B32B001/00; B33Y 10/00 20060101
B33Y010/00; B29C 64/129 20060101 B29C064/129; B29C 64/40 20060101
B29C064/40; B33Y 80/00 20060101 B33Y080/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 5, 2014 |
JP |
2014-020776 |
Feb 5, 2014 |
JP |
2014-020784 |
Feb 5, 2014 |
JP |
2014-020786 |
Claims
1. A shaped article, comprising: a light reflective layer, being
provided from an ink having light reflectiveness; a decorative
layer; and a first transparent layer, being provided from a
transparent ink, wherein the decorative layer is disposed on an
outer side of the light reflective layer, and the first transparent
layer is disposed on an outer side of the decorative layer.
2. The shaped article according to claim 1, further comprising: a
second transparent layer, being provided between the light
reflective layer and the decorative layer.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of and claims
the priority benefit of U.S. patent application Ser. No.
16/659,578, filed on Oct. 22, 2019, now allowable. U.S. patent
application Ser. No. 16/659,578 is a divisional application of U.S.
patent application Ser. No. 16/005,718, filed on Jun. 12, 2018, now
allowed, which is a divisional application of U.S. patent
application Ser. No. 15/116,513 filed on Aug. 4, 2016, now allowed.
U.S. patent application Ser. No. 15/116,513 is a 371 application of
an international PCT application serial no. PCT/JP2015/053039,
filed on Feb. 4, 2015, which claims the priority benefit of Japan
application no. JP 2014-020776, filed on Feb. 5, 2014, Japan
application no. JP 2014-020786, filed on Feb. 5, 2014, and Japan
application no. JP 2014-020784, filed on Feb. 5, 2014. The entirety
of each of the above-mentioned patent applications is hereby
incorporated by reference herein and made a part of this
specification.
TECHNICAL FIELD
[0002] This disclosure relates to a shaped article.
BACKGROUND ART
[0003] Examples of known techniques that may be employed to mold
three-dimensional objects include the sheet lamination method as
described in Patent Literature 1, as well as fuse deposition
molding (FDM), inkjet method, inkjet binder method,
stereolithography (SL), and selective laser sintering (SLS).
[0004] Among the known techniques is often employed a technique,
pattern lamination, wherein ultraviolet-curable resins are
discharged from 3D printers to form multilayered objects. To
produce a three-dimensional object, this method generates data of
exterior and interior designs and structures of a final product
using a three-dimensional CAD, and slices the data using a computer
to generate a multilayer laminate pattern data. Then, an
ultraviolet-curable resin is discharged from a head according to
the pattern data and stacked in layers.
[0005] Conventionally, three-dimensional objects thus molded may be
decorated (with patterns and/or colors).
CITATION LIST
Patent Literature
[0006] Patent Literature 1: JP 2003-71530 A (disclosed on Mar. 11,
2003)
SUMMARY
Technical Problems
[0007] The inventors of this application found a problem with the
known inkjet 3D molding, which occurred when a molding ink and
decorative inks (coloring inks of, for example, yellow, magenta,
cyan, and black) were discharged by inkjet printing technique. The
problem is, once the molding ink and the decorative inks blend into
one another at their interfaces, a shaped article may no longer be
decorated as desired (failure to record characters and images in
colors by way of subtractive color mixture).
[0008] Such intermixing of inks may be more apparent, particularly,
in parts to be decorated on a mold surface extending in a direction
perpendicular to the in-plane direction of layers. This is because
relative movements of an inkjet head and a shaped article along the
in-plane direction of layers may be prone to lower the positional
accuracy in the in-plane direction of inks discharged from the
inkjet head, consequently causing the molding ink and the
decorative inks to be intermixed.
[0009] In view of the issue, this disclosure is directed to
providing a shaped article that may be decorated as desired, and a
manufacturing method for such a shaped article.
Solutions to the Problems
[0010] To address the issue, a shaped article disclosed herein
includes: a light reflective layer formed from an ink having light
reflectiveness; a decorative layer; and a first transparent layer
formed from a transparent ink, wherein the decorative layer, the
first transparent layer, and the light reflective layer are formed
in this order from an outer-layer side toward an inner side of the
shaped article.
[0011] This shaped article has the first transparent layer between
the decorative layer and the light reflective layer, preventing the
light reflective ink forming the light reflective layer from
blending into an ink forming the decorative layer. Supposing that
the decorative layer is a colored layer formed from a
colorant-containing ink, the colorant-containing ink, if mixed with
the light reflective ink forming the light reflective layer, may
lose its original colors, thereby failing to produce an intended
color tone. In this shaped article, however, even if the ink of the
decorative layer is mixed into the transparent ink of the first
transparent layer, this does not deprive the decorative layer ink
of its original colors, producing no adverse impact on decorative
effects of the shaped article. The shaped article, therefore, may
be successfully decorated as desired.
[0012] The shaped article disclosed herein according to an aspect
is further characterized in that the light reflective layer is
formed from an ink containing a white pigment.
[0013] In the shaped article thus further characterized, the light
reflective layer formed from the white pigment-containing ink may
adequately reflect light entering through the decorative layer from
the outer-layer side of the shaped article. As a result, the shaped
article may be favorably decorated with colors by the subtractive
color mixture.
[0014] In another aspect of this disclosure, the shaped article
further includes a second transparent layer formed from a
transparent ink on the outer-layer side of the decorative
layer.
[0015] The second transparent layer may serve to protect the
decorative layer to prevent decolorization under friction and color
fading by exposure to ultraviolet. The second transparent layer may
also contribute to elaborateness and high accuracy of the shaped
article.
[0016] The shaped article disclosed herein according to yet another
aspect is further characterized in that the decorative layer formed
has its ink density filled by a transparent supplementary ink in a
part of the decorative layer in which decorative inks alone are
insufficient to meet a predetermined ink density.
[0017] Using the decorative inks alone to form the decorative layer
may lead to abundant ink supply in its parts to be decorated at
higher concentrations, while supplying less inks in its parts to be
decorated at lower concentrations. Such variability of the ink
density in different parts of the decorative layer may generate
irregularities and/or voids in the decorative layer. The
irregularities and/or voids may provoke optical diffuse reflection
and/or deflection, resulting in unattractive appearance of the
decorative layer, or may incur failure to obtain any desired shape
of the shaped article in the manufacturing process. On the other
hand, the shaped article characterized as described may eliminate
the risk of such irregularities and/or voids because the ink
density of the decorative layer is filled by the transparent
supplementary ink. The shaped article, therefore, may be
successfully decorated as desired and also shaped as desired.
[0018] The shaped article disclosed herein according to yet another
aspect is further characterized in that the shaped article includes
a plurality of layers stacked on one another, wherein two or more
of the plurality of layers each include a part of the decorative
layer, a part of the first transparent layer, and a part of the
light reflective layer that are formed in this order from an end
side toward a center side of each one of the layers.
[0019] In yet another aspect of this disclosure, the shaped article
further includes a second transparent layer formed from a
transparent ink on the outer-layer side of the decorative layer,
wherein the two or more of the plurality of layers each include a
part of the decorative layer between a part of the first
transparent layer and a part of the second transparent layer.
[0020] The shaped article disclosed herein according to yet another
aspect is further characterized in having a region in which the
layers are stacked on one another, the layers each including a part
of the decorative layer between a part of the first transparent
layer and a part of the second transparent layer. In this shaped
article, in a portion of the region with no overlap between a part
of the decorative layer in one of the layers and a part of the
decorative layer in another one of the layers on or below the one
of the layers, there is an overlap between a part of the decorative
layer in one of the layers and a part of the first transparent
layer or a part of the second transparent layer in another one of
the layers on or below the one of the layers.
[0021] Such an overlap in the vertical direction between the
decorative layer and the transparent layer may suppress the
possibility that the light reflective layer is present on and below
the decorative layer (layer overlap ratio). By overlapping the
decorative layer with the transparent layer in the vertical
direction, intermixing, if any, may occur between the decorative
layer and the transparent ink. Hence, the shaped article may be
successfully decorated as desired.
[0022] A shaped article manufacturing method disclosed herein is a
manufacturing method for a shaped article including a decorative
layer, a first transparent layer, and a light reflective layer
formed from an ink having light reflectiveness, wherein the
decorative layer, the first transparent layer, and the light
reflective layer are formed in this order from an outer-layer side
toward an inner side of the shaped article. This method employs the
multilayer lamination technique to form layers and includes a layer
forming process including forming a part of the decorative layer, a
part of the first transparent layer, and a part of the light
reflective layer in this order from an end side toward a center
side of each one of the layers.
[0023] In the presence of the first transparent layer between the
decorative layer and the light reflective layer, the ink of the
decorative layer, though possibly mixed with the transparent ink of
the first transparent layer during the manufacturing process, may
be prevented from blending into the light reflective ink of the
light reflective layer. Supposing that the decorative layer is a
colored layer formed from a colorant-containing ink, the
colorant-containing ink, if mixed with the light reflective ink
forming the light reflective layer, may lose its original colors,
thereby failing to produce an intended color tone. In this shaped
article, however, even if the ink of the decorative layer is mixed
into the transparent ink of the first transparent layer, this does
not deprive the decorative layer ink of its original colors,
producing no adverse impact on decorative effects of the shaped
article. The shaped article, therefore, may be successfully
decorated as desired.
[0024] The shaped article manufacturing method is further
characterized in that the layer forming process includes forming a
second transparent layer using a transparent ink on the outer-layer
side of the decorative layer by forming a part of the second
transparent layer at a position nearer to the end side than a part
of the decorative layer in each of the layers.
[0025] The second transparent layer may serve to protect the
decorative layer to prevent decolorization under friction and color
fading by exposure to ultraviolet. The second transparent layer may
also contribute to elaborateness and high accuracy of the shaped
article.
[0026] Specifically, a part of the second transparent layer is
formed before a part of the decorative layer is formed in each of
the layers. This may allow the formed part of the second
transparent layer to serve as the outer moat for a part of the
decorative layer to be later formed, preventing part of the
decorative layer from spreading unintendedly.
[0027] At the time of forming the upper decorative layer of two
layers vertically formed, the second transparent layer already
formed as its underlayer may allow a larger formation area to be
secured for the decorative layer. Such an increase of the
decorative layer formation area may prevent the risk that the ink
applied to form the upper decorative layer runs off an edge of its
underlayer and drops downward. Hence, the shaped article may be
successfully manufactured as desired.
[0028] The shaped article manufacturing method disclosed herein is
further characterized in that the layer forming process includes
steps of: forming a part of the decorative layer; forming a part of
the first transparent layer using a transparent ink; forming a part
of the light reflective layer using an ink having light
reflectivity; and forming a part of the second transparent layer
using a transparent ink, wherein the step of forming a part of the
decorative layer is performed subsequent to the step of forming a
part of the first transparent layer and the step of forming a part
of the second transparent layer to form a part of the decorative
layer between the parts of the first transparent layer and the
second transparent layer.
[0029] Thus, a part of the first transparent layer and a part of
the second transparent layer are formed before a part of the
decorative layer is formed as described earlier. This may allow the
parts of the first and second transparent layers to serve as the
outer moat for a part of the decorative layer to be later formed,
preventing the part of the decorative layer from spreading
unintendedly. The shaped article, therefore, may be successfully
manufactured as desired.
[0030] The shaped article manufacturing method disclosed herein
further includes providing, in a portion of the region with no
overlap between a part of the decorative layer in one of the layers
and a part of the decorative layer in another one of the layers on
or below the one of the layers, an overlap between a part of the
decorative layer in one of the layers and a part of the first
transparent layer or a part of the second transparent layer in
another one of the layers on or below the one of the layers.
[0031] The decorative layer may be interposed between the
transparent layers in the layer-stacked direction as well. This may
avoid an overlap between the parts of the decorative layer in the
upper and lower layers. The shaped article thus formed may not
exhibit undesirable variability in color tone when viewed in a
certain direction or when viewed in another direction inclined from
the direction.
[0032] The shaped article manufacturing method disclosed herein is
further characterized in forming a part of the decorative layer by
filling the ink density of the decorative layer using a transparent
supplementary ink in a part of the decorative layer in which
decorative inks alone are insufficient to meet a predetermined ink
density.
[0033] By having the ink density of the decorative layer partly
filled by the supplementary ink, it may be avoided that the
decorative layer partly has undesirable irregularities and/or
voids. Using the decorative inks alone to form the decorative layer
may lead to abundant ink supply in its parts to be decorated at
higher concentrations, while supplying less inks in its parts to be
decorated at lower concentrations. Such variability of the ink
density in different parts of the decorative layer may generate
irregularities and/or voids in the decorative layer. The
irregularities and/or voids may provoke optical diffuse reflection
and/or deflection, resulting in unattractive appearance of the
decorative layer, or may incur failure to obtain any desired shape
of the shaped article in the manufacturing process. On the other
hand, the shaped article manufacturing method characterized as
described may eliminate the risk of such irregularities and/or
voids because the ink density of the decorative layer is filled by
the transparent supplementary ink. The shaped article, therefore,
may be successfully decorated as desired and also shaped as
desired.
Effect of the Disclosure
[0034] This disclosure may provide a shaped article exhibiting a
desired color tone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] FIG. 1 is a perspective view of an outer shape of a shaped
article disclosed herein according to an embodiment.
[0036] FIG. 2 is a cross-sectional view of the shaped article of
FIG. 1 taken along a cutting-plane line A-A'.
[0037] FIG. 3 is a schematic drawing of inkjet heads used in
manufacturing of the shaped article of FIG. 1, illustrating a
surface where nozzle holes are located.
[0038] FIG. 4 shows drawings of manufacturing steps for the shaped
article of FIG. 1.
[0039] FIG. 5 is an upper view of the shaped article of FIG. 1
currently being manufactured.
[0040] FIG. 6 is a partial cross-sectional view of the shaped
article of FIG. 1 illustrated to describe its advantages.
[0041] FIG. 7 is a partial cross-sectional view of a shaped article
for comparison.
[0042] FIG. 8 shows perspective views each illustrating a shaped
article disclosed herein according to a modified example.
[0043] FIG. 9 is a cross-sectional view of a shaped article
disclosed herein according to another embodiment.
[0044] FIG. 10 is a schematic drawing of inkjet heads used in
manufacturing of the shaped article of FIG. 9, illustrating a
surface where nozzle holes are located.
[0045] FIG. 11 shows drawings of manufacturing steps for the shaped
article of FIG. 9.
[0046] FIG. 12 is a schematic drawing of another example of inkjet
heads used in manufacturing of the shaped article disclosed
herein.
[0047] FIG. 13 is a schematic drawing of yet another example of
inkjet heads used in manufacturing of the shaped article disclosed
herein.
[0048] FIG. 14 is a schematic drawing of yet another example of
inkjet heads used in manufacturing of the shaped article disclosed
herein.
DESCRIPTION OF EMBODIMENTS
First Embodiment
[0049] An embodiment of a shaped article and a shaped article
manufacturing method disclosed herein is hereinafter described
referring to FIG. 1 to FIG. 8. The shaped article disclosed herein
has a three-dimensional structure constructed of a laminate of
layers (formed by multilayer lamination technique). In the
embodiment hereinafter described, inkjet printing technique is
employed to manufacture the shaped article. This is, however, just
an option presented in this disclosure. This disclosure may be
applicable to any kinds of manufacturing methods that can obtain a
shaped article by leveraging the multilayer lamination technique
and decorate its surface (recording of characters and images in
colors).
[0050] [1] Structure of Shaped Article
[0051] FIG. 1 is a perspective view of an outer shape of a shaped
article 50 according to an embodiment. The shaped article 50
according to this embodiment has a substantially cylindrical shape
with a curved side surface bulging outward. The shaped article
disclosed herein and the shaped article manufactured by the
manufacturing method disclosed herein may not be limited to the
shape illustrated in FIG. 1. There are many other examples of the
shape, including a hexahedral shape described later, a spherical
shape, a hollow structure, a ring-like shape, and a horseshoe-like
shape.
[0052] The shaped article 50 according to this embodiment includes
a second transparent layer, a colored layer (decorative layer)
formed from colorant-containing inks (decorative ink), a first
transparent layer formed from a transparent ink, and a light
reflective layer formed from an ink having light reflectiveness,
wherein these layers are formed in the mentioned order from an
outer-layer side (outer peripheral side) toward an inner side
(center) of the shaped article 50. This is a distinctive technical
feature of this disclosure. FIG. 1 is a drawing of the shaped
article 50. In this drawing, a second transparent layer 4 formed
from a transparent ink, which is the outermost layer, can be seen
on the curved side surface of the shaped article 50.
[0053] FIG. 2 is a cross-sectional view of the illustration of FIG.
1 taken along a cutting-plane line A-A'. The cross-sectional view
of the shaped article 50 illustrated in FIG. 2 is taken at a
central position of the shaped article 50 along the X-Z plane of
the XYZ coordinate system illustrated in FIG. 1.
[0054] The embodiment of FIG. 2 presents an example of the shaped
article 50 having a three-dimensional structure formed by stacking
21 layers 50a on one another in the Z direction. It should be
understood that the shaped article 50 may include less than or more
than 21 layers.
[0055] [2] Structures of Layers
[0056] FIG. 5 is a drawing of the X-Y plane of a layer 50a in the
vicinity of a mid-stage of the shaped article 50. The layers 50a
each include a part 54 of the second transparent layer, a part 53
of the colored layer, a part 52 of the first transparent layer, and
a part 51 of the light reflective layer. These layers are formed in
the mentioned order from an outer peripheral side toward a center
side of the shaped article. If the shaped article 50 according to
this embodiment is stated another way, the light reflective layer
1, which is the body of the shaped article, is coated with the
first transparent layer 2, colored layer 3, and second transparent
layer 4 in the mentioned order toward the outer-layer side (outer
peripheral side). Each one of the layers 50a has a thickness in the
Z direction (vertical direction in the drawing) between 5 .mu.m and
50 .mu.m. This is an adequate range of thickness values for
multicolor formation of the colored layer 3 using the subtractive
color mixture. For example, a preferable range of thickness values
is 10 .mu.m to 25 .mu.m when layers are formed from inks of
ultraviolet curing type by inkjet printing technique.
[0057] In this embodiment, the light reflective layer 1 is the body
of the shaped article; however, the light reflective layer may or
may not constitute the body of the shaped article. Specifically,
the shaped article may have, at its center, a body or a cavity
apart from the light reflective layer, wherein the light reflective
layer, first transparent layer, colored layer, and second
transparent layer are formed in the mentioned order from the body
(may or may not have light reflectiveness) toward the outer-layer
side (outer peripheral side). Alternatively, a core (may or may not
have light reflectiveness) and the light reflective layer 1 formed
on a surface of the core may be collectively regarded as the body
of the shaped article.
[0058] By stacking the layers 50a in the Z direction as illustrated
in FIG. 2, the parts 54 of the second transparent layer in the
respective layers 50a are substantially continuous in a direction
along the outermost surface of the shaped article 50, forming the
second transparent layer 4. The parts 53 of the colored layer in
the respective layers 50a are substantially continuous in the
direction along the outermost surface of the shaped article 50,
forming the colored layer 3. The parts 52 of the first transparent
layer in the respective layers 50a are substantially continuous in
the direction along the outermost surface of the shaped article 50,
forming the first transparent layer 2. The parts 51 of the light
reflective layer in the respective layers 50a are substantially
continuous in the direction along the outermost surface of the
shaped article 50, forming the light reflective layer 1.
[0059] Looking at, in any of the X, Y, and Z directions, the outer
surface of the shaped article 50 including the second transparent
layer, colored layer, first transparent layer, and light reflective
layer arranged in the mentioned order, a color tone produced by the
subtractive color mixture may be visually recognized.
[0060] The parts 52 of the first transparent layer may preferably
have a dimension in the direction of X-Y plane slightly greater
than the part 53 of the colored layer vertically in contact with
the parts 52. This may more reliably prevent intermixing of the
inks forming the colored layer 3 and the light reflective layer
1.
[0061] The parts 54 of the second transparent layer may preferably
have a dimension in the direction of X-Y plane slightly greater
than the parts 53 of the colored layer vertically in contact with
the parts 54 of the second transparent layer. This may provide for
better protection of the colored layer 3.
[0062] The width of the shaped article 50 along the Z direction
(hereinafter may be referred to as thickness or height in the Z
direction) is not particularly limited. The thickness (height) of
the layer 50a in the Z direction may be optionally decided
depending on the number of layers. As described later, this
embodiment constructs the multilayered structure using the inkjet
printing technique. Therefore, any feasible values in the technique
should be contemplated for the thickness of the layer 50a in the Z
direction. When inks of ultraviolet curing type are applied by
inkjet printing technique to form the layers (described later), the
layer 50a may have a thickness ranging from 5 .mu.m to 20 .mu.m
depending on the sizes of ink droplets. As for a large-sized shaped
article for which a high resolution is not particularly required,
plural layers may be formed based on the same data simply by
increasing the sizes of ink droplets. In such a case, a smaller
data volume and a higher molding rate may be anticipated.
[0063] [3] Structure of Light Reflective Layer 1 (Parts 51 of Light
Reflective Layer)
[0064] The light reflective layer 1 (parts 51 of the light
reflective layer) is a layer formed from a light reflective ink.
This layer, therefore, has light reflectiveness that allows rays of
light in the whole visible light region to be reflected on at least
the surface of the light reflective layer 1 in contact with the
colored layer.
[0065] Specific examples of ink of the light reflective layer 1
(parts 51 of the light reflective layer) may include metallic
powder-containing inks and white pigment-containing inks. The light
reflective layer 1 may preferably be formed from a white ink. The
light reflective layer 1 formed from a white ink may adequately
reflect rays of light entering from the outer-layer side of the
shaped article, allowing the shaped article to be colored by the
subtractive color mixture.
[0066] In this embodiment, the light reflective layer 1 constitutes
the body of the shaped article. In case the light reflective layer
1 is formed on the surface of the body of any shaped article for
which light reflectiveness is not required, the thickness of the
light reflective layer 1, i.e., the width of the part 51 of the
light reflective layer from the outer peripheral side to the center
side, as illustrated in FIG. 2, may be between 5 .mu.m and 20 .mu.m
at the least. The width in this disclosure may include but is not
limited to the range of values.
[0067] [4] Structure of First Transparent Layer 2 (Parts 52 of
First Transparent Layer)
[0068] The first transparent layer 2 (parts 52 of the first
transparent layer) is formed from a transparent ink.
[0069] The transparent ink may refer to an ink capable of forming a
transparent layer having light transmittance greater than or equal
to 50% per unit thickness. The light transmittance less than 50%
per unit thickness of the transparent layer may unintendedly block
the transmission of light. This may be a drawback that fails to
exhibit a desired color tone of the shaped article by way of the
subtractive color mixture. Preferably is used an ink having light
transmittance greater than or equal to 80% per unit thickness of
the transparent layer. Further, an ink having light transmittance
greater than or equal to 90% per unit thickness of the transparent
layer is particularly preferable.
[0070] By interposing the first transparent layer 2 (part 52 of the
first transparent layer) between the light reflective layer 1 (part
51 of the light reflective layer) and the colored layer 3 (part 53
of the colored layer), intermixing of the coloring inks of the
colored layer 3 and the ink of the light reflective layer 1 may be
avoidable. Even if the coloring inks applied to form the colored
layer are mixed with the transparent ink of the first transparent
layer, intermixing of these inks may not adversely affect colors of
the colored layer or cause any undesirable change to the color
tone. Therefore, the resulting shaped article exhibits a desired
color tone (decorated as desired) expressed by the colored layer
3.
[0071] The width of the part 52 of the first transparent layer from
the outer peripheral side to the center side (hereinafter, referred
to as the thickness of the first transparent layer) is between 5
.mu.m and 20 .mu.m at the least in a decorated portion on a surface
perpendicular to the layer-stacked direction. The width in this
disclosure may include but is not limited to the range of
values.
[0072] [5] Structure of Colored Layer 3 (Part 53 of Colored
Layer)
[0073] The colored layer 3 (part 53 of the colored layer) is formed
from a colorant-containing coloring ink.
[0074] Examples of the colorant-containing inks (hereinafter may be
referred to as coloring ink) may include but are not limited to
yellow (Y), magenta (M), cyan (C), black (K), and pale color inks.
Further, red (R), green (G), blue (B), and orange (Or) color inks
may be additionally used. Other usable inks may include metallic,
pearl, and phosphor inks. One or more than one of these coloring
inks may preferably be used to express a desired color tone.
[0075] The amounts of the coloring inks to form the colored layer 3
(parts 53 of the colored layer) may be variable depending on a
desired (desirably expressed) color tone. In case the coloring inks
alone are used to express a bright color tone at a relatively low
concentration, the ink density of the colored layer 3 may fail to
meet a predetermined ink density. This may generate irregularities
in the Z direction and/or ink-less dented parts at positions along
the X-Y direction. In any case, the shaped article formed by the
multilayer lamination technique, as described in this embodiment,
may consequently have an irregular, unattractive shape, which is
desirably avoided. In case one cross-sectional surface of the
colored layer 3 has the ink density of two lateral and two vertical
ink droplets; four ink droplets in total, formed by the error
diffusion method on a vertical mold surface near the mid position
of the multilayered structure illustrated in FIG. 2, the coloring
inks each form four ink droplets at the most (largest
concentration) and no ink droplet at the least (zero concentration,
meaning colorless). The number of ink droplets being zero may leave
an unfilled space as large as four ink droplets, significantly
degrading the shaped article in view of its shape and color
tone.
[0076] This embodiment, therefore, fills the ink density of the
colored layer 3 (part 53 of the colored layer) using a
supplementary ink in parts of the colored layer 3 (part 53 of the
colored layer) in which the coloring inks alone are insufficient to
meet a predetermined ink density. Specifically, the colored layer 3
(parts 53 of the colored layer) is formed at a constant total
density (number of ink droplets) of the coloring inks and the
supplementary ink. This may successfully prevent the formation of
dented parts, allowing the shaped article 50 to be elaborately
shaped.
[0077] The amounts of the coloring inks to be discharged and their
landing positions are known beforehand, based on which the amount
and position (landing position) of the supplementary ink to be
additionally discharged may be suitably determined. The amount and
position may be decided by an inkjet head device 10 or by a
controller not illustrated in the drawings.
[0078] Having the ink density filled by the supplementary ink may
allow a surface formed by the colored layer 3 to be flattened,
imparting glossiness to the surface.
[0079] The supplementary ink may be any ink unless it adversely
affects the color tone to be expressed by the colored layer 3
(parts 53 of the colored layer). An example of the supplementary
ink may be the transparent ink used to form the first transparent
layer 2 (parts 52 of the first transparent layer) and the second
transparent layer 4 (parts 54 of the first transparent layer).
[0080] The thickness of the colored layer 3, i.e., the width of the
part 53 of the colored layer from the outer peripheral side to the
center side illustrated in FIG. 2 (hereinafter, referred to as the
thickness of the colored layer 3) may be between 5 .mu.m and 20
.mu.m.
[0081] The colored layer 3 described in this embodiment is just an
option and may be any decorative layer.
[0082] [6] Structure of Second Transparent Layer 4 (Parts 54 of
Second Transparent Layer)
[0083] The second transparent layer 4 (parts 54 of the second
transparent layer) is formed from the same transparent ink as that
of the first transparent layer 2 (parts 52 of the first transparent
layer). The same transparent ink or different transparent inks may
be used to form the second transparent layer 4 and the first
transparent layer 2.
[0084] The thickness of the second transparent layer 4, i.e., the
width of the part 54 of the second transparent layer from the outer
peripheral side to the center side illustrated in FIG. 2
(hereinafter, referred to as the thickness of the second
transparent layer 4) may be between 10 .mu.m and 100 .mu.m.
[0085] The second transparent layer 4 functions as a protective
layer for the colored layer 3. In this disclosure that employs the
multilayer lamination technique (this embodiment), the second
transparent layer 4 may also advantageously contribute to
elaborateness of the shaped article.
[0086] Supposing that the colored layer 3 is the outermost layer of
the shaped article 50, i.e., the parts 53 of the colored layer are
located at the farthest ends of the respective layers 50a
illustrated in FIG. 2, the colored layer 3 (parts 53 of the colored
layer) formed may not be as accurate as expected. On the other
hand, the shaped article 50 whose outermost layer is the second
transparent layer 4 (parts 54 of the second transparent layer), as
described in this embodiment, may ensure the accuracy of the
colored layer 3 (parts 53 of the colored layer). Thus, the second
transparent layer 4 (parts 54 of the second transparent layer) may
greatly contribute to a desired color tone.
[0087] Another disadvantage in case the colored layer 3 is the
outermost layer of the shaped article 50 is that the exposed
colored layer 3 may be prone to decolorization under friction and
color fading by exposure to ultraviolet. However, as described in
this embodiment, the shaped article 50 whose outermost layer is the
second transparent layer 4 (parts 54 of the second transparent
layer) may prevent such unfavorable events as decolorization and
color fading.
[0088] [7] Manufacturing Method for Shaped article
[0089] A manufacturing method for the shaped article 50 according
to this embodiment is hereinafter described. FIG. 3 is a drawing of
the lower surface of the inkjet head device 10 used in the
manufacturing method. FIG. 4 shows schematic drawings of ongoing
steps of manufacturing the shaped article 50 according to this
embodiment.
[0090] The inkjet head device 10 has, on its lower surface, roughly
three inkjet heads 11H to 13H. As illustrated in FIG. 3, the first
inkjet head 11H, second inkjet head 12H, and third inkjet head 13H
are displaced from one another in the X direction. As illustrated
in FIG. 3, the first inkjet head 11H, second inkjet head 12H, and
third inkjet head 13H are also displaced from one another in the Y
direction. Thus, the inkjet heads 11H to 13H are positioned in,
generally called, staggered arrangement.
[0091] The first inkjet head 11H has a cyan ink nozzle 10 (C) for
discharging a cyan ink, a magenta ink nozzle 10 (M) for discharging
a magenta ink, a yellow ink nozzle 10 (Y) for discharging a yellow
ink, and a black ink nozzle 10 (K) for discharging a black ink. The
number and the order of arrangement of the nozzles 10 (C), 10 (M),
10 (Y), and 10 (K) are not limited to the example illustrated in
FIG. 3. All of the inks discharged through these nozzles are
coloring inks used to form the colored layer 3 (parts 53 of the
colored layer) illustrated in FIG. 2.
[0092] The second inkjet head 12H has a white ink nozzle 10 (W) for
discharging a white ink (W). The white ink (W) is an ink used to
form the light reflective layer 1 (parts 51 of the light reflective
layer) illustrated in FIG. 2.
[0093] The third inkjet head 13H has a transparent ink nozzle 10
(CL) for discharging a transparent ink (CL). The transparent ink
(CL) is an ink used to form the first transparent layer 2 (parts 52
of the first transparent layer) and the second transparent layer 4
(parts 54 of the second transparent layer) illustrated in FIG.
2.
[0094] The inkjet head device 10 is located so as to have its lower
surface illustrated in FIG. 3 face the layer 50a currently being
formed. The inkjet head device 10 is configured to reciprocate in
the X direction and discharge the inks while moving in the
direction. The inkjet head device 10 is moved in a predetermined
direction in an XYZ coordinate system, or a table with the layers
50a placed thereon (FIG. 4 shows a layer formation surface B of the
table) is moved in a predetermined direction in the XYZ coordinate
system to change relative positions of the inkjet head device 10
and the layer 50a currently being formed. Which one of them should
be moved may be optionally decided.
[0095] Each of the inks is an ink of ultraviolet curing type that
needs to be irradiated with ultraviolet light after being
discharged. An ultraviolet irradiator may be mounted in the inkjet
head device 10 or may be installed as a separate device. The inks
are cured by being irradiated with ultraviolet light to form the
layers 50a illustrated in FIG. 2.
[0096] The manufacturing process for the shaped article 50 using
the inkjet head device 10 is hereinafter described referring to
FIG. 4.
[0097] To start with, a first one of the layers 50a (first layer
50a (1)) is formed on the layer formation surface B of the
table.
[0098] In the step of forming (manufacturing) the first layer 50a
(1), by using the inkjet printing technique, the respective inks
are discharged from the inkjet head device 10 at predetermined
timings to form a part of the second transparent layer, a part of
the colored layer, a part of the first transparent layer, and a
part of the light reflective layer in the mentioned order from the
end side toward the center side of the first layer 50a.
[0099] The steps of forming (manufacturing) the first layer 50a (1)
are described in further detail referring to (a).about.(c) of FIG.
4.
[0100] In step Si illustrated in (a) of FIG. 4, the part 54 of the
second transparent layer is formed from the transparent ink, and
the part 52 of the first transparent layer is formed from the
transparent ink. In this step, the inkjet head device 10 is moved
in a positive direction along the X axis, and the transparent ink
is discharged at a predetermined timing through the transparent ink
nozzle 10 (CL) illustrated in FIG. 3. The discharged ink lands on a
position at which the part 54 of the second transparent layer
should be formed and a position at which the part 52 of the first
transparent layer should be formed. Then, the discharged ink pooled
at the respective positions is irradiated with ultraviolet light to
be cured. As a result, the part 52 of the first transparent layer
and the part 54 of the second transparent layer are formed as
illustrated in (a) of FIG. 4.
[0101] In step S2 illustrated in (b) of FIG. 4, the inkjet head
device 10 is moved in a negative direction along the X axis, and
the white ink (W), which is the light reflective ink, is discharged
at a predetermined timing through the white ink nozzle 10 (W).
Then, the discharged ink pooled there is irradiated with
ultraviolet light to be cured. As a result, the part 51 of the
light reflective layer is formed as illustrated in (b) of FIG.
4.
[0102] In step S3 illustrated in (c) of FIG. 4, the inkjet head
device 10 is moved in the positive direction along the X axis, and
the colored layer forming inks including the coloring inks and the
supplementary ink are discharged at a predetermined timing so that
the total amount of these inks discharged is constant, and then
irradiated with ultraviolet light. The predetermined timing refers
to a timing at which the nozzles of the first inkjet head 11H are
located at positions at which the colored layer forming inks are
dischargeable in a region between the part 52 of the first
transparent layer and the part 54 of the second transparent layer
formed in step S1. The ink droplets in a predetermined amount are
discharged by inkjet printing technique at this timing to form a
pool of ink. Then, the pooled ink is irradiated with ultraviolet
light to be cured. This forms the part 53 of the colored layer
exhibiting a desired color tone between the part 52 of the first
transparent layer and the part 54 of the second transparent layer
as illustrated in FIG. 4.
[0103] As a result of steps Si to S3, the formation of the first
layer 50a (1) is completed. The first layer 50a (1) has the same
structure as illustrated in the upper view of the layer 50a in FIG.
5. Optionally, step 1 and step 2 may be performed in the reversed
order. Likewise, step S2 and step S3 may be performed in the
reversed order.
[0104] After the first layer 50a (1) is formed, a new layer 50a
(second layer 50a (2)) is formed on the first layer 50a (1)
(laminate of layers).
[0105] In the shaped article 50 according to this embodiment, the
layers 50a stacked on one another are progressively increased in
size (area) from the bottom toward the mid stage of the
multilayered body as illustrated in FIG. 2. In the shaped article
50 manufactured in such a shape that increases in size along the
layer-stacked direction when viewed in cross section, the end of
one layer 50a is sticking out sideways further than the end of
another layer 50a already formed below the one layer 50a. To form
the layers 50a thus characterized, support material layers may
preferably be formed.
[0106] In FIG. 4, (d) is a drawing of the step of forming the
second layer 50a (2). Referring to this drawing, a part 53 (2) of
the colored layer in the second layer 50a (2) is formed so as to
overlap a part 54 (1) of the second transparent layer in the first
layer 50a (1). Since the second layer 50a (2) is greater in size
(area) along the X-Y plane than the first layer 50a (1), the part
54 (2) of the second transparent layer forming the end of the
second layer 50a (2) is sticking out sideways further than the part
54 (1) of the second transparent layer forming the end of the first
layer 50a (1). Because of this structure, the ink to be deposited
on a part of the layer 50a (2) where the stick-out part should be
formed possibly runs off this part and drops downward. To avoid
that, a support material 60 is formed on the outer side (on the
lateral side) than the part 54 (1) of the second transparent layer
in the first layer 50a (1).
[0107] The support material 60 may preferably be formed from any
ink that can be discharged by inkjet printing technique. The
support material 60 should preferably have enough strength not to
collapse under the weight of another layer formed thereon. The
support material 60 per se will not be left in the finalized shaped
article 50. The ink forming the support material 60, therefore,
should preferably be selected from inks that can be stripped off
afterwards. The ink of the support material 60 may preferably be
curable by ultraviolet light (to a degree of cure at which the ink
is stripped off in subsequent steps), or may be a water-soluble ink
that can be dissolved in water and removed in subsequent steps.
[0108] The steps of forming the layers 50a are repeatedly performed
in the X and Y directions as many times as required to form one
layer, and then repeatedly performed again in the Z direction. As a
result, the shaped article 50 illustrated in FIG. 2 is finally
obtained. During the steps of forming one layer, the known
interlace scan conventionally employed to form two-dimensional
images may preferably be performed to obtain a shaped article with
less unevenness in shape and favorably decorated.
[0109] The shaped article manufacturing method according to this
embodiment is further characterized in that the layer forming
process includes steps of: forming the part 54 of the second
transparent layer using the transparent ink; forming the part 53 of
the colored layer using the coloring inks; forming the part 52 of
the first transparent layer using the transparent ink; and forming
the part 51 of the light reflective layer using the light
reflective ink, wherein the step of forming the part 53 of the
colored layer is performed subsequent to the step of forming the
part 52 of the first transparent layer and the step of forming the
part 54 of the second transparent layer to form the part 53 of the
colored layer between the part 52 of the first transparent layer
and the part 54 of the second transparent layer. When the part 53
of the colored layer is formed, the part 54 of the second
transparent layer may serve as the outer moat of the pooled inks to
form the colored layer. This may prevent the ink of the colored
layer from spreading unintendedly, ensuring a high accuracy of the
part 53 of the colored layer.
[0110] Further benefits delivered by forming the part 54 of the
second transparent layer are described referring to FIG. 6 and FIG.
7. FIG. 6 is a drawing of a part of the shaped article 50 according
to this embodiment, which is the part of (d) of FIG. 4 from which
the support material has been removed. FIG. 7 is a cross-sectional
view of a shaped article for comparison. The shaped article for
comparison is formed by the multilayer lamination technique
similarly to the shaped article 50 according to this embodiment.
Unlike the shaped article 50, however, this shaped article lacks
parts corresponding to the part 52 of the first transparent layer
and the part 54 of the second transparent layer. In this shaped
article for comparison, therefore, the light reflective layer is
directly coated with the colored layer. Provided that the upper
layer is larger in size (area) along the X-Y plane than the lower
layer in the shaped article for comparison, problems with this
shaped article are described.
[0111] In the shaped article for comparison illustrated in FIG. 7,
the end of the upper layer includes a colored layer 152 (2). The
colored layer 152 (2) is sticking out further than a colored layer
152 (1) formed on the end of the lower layer. This shaped article,
therefore, involves the risk that the inks for the colored layer
discharged to form the stick-out part run off a coloring position
and drop downward.
[0112] The colored layer is the deciding factor for the color tone
of the shaped article. Therefore, thus losing the inks of the
colored layer may cause an intended color tone of the shaped
article to change.
[0113] On the other hand, the shaped article 50 according to this
embodiment illustrated in FIG. 6 has the parts 54 of the second
transparent layer at the ends of the layers 50a. The ink applied to
form the parts 54 of the second transparent layer, even if it falls
downward in FIG. 6, may not adversely affect a color tone desirably
expressed because the colored layer is the deciding factor for the
color tone. This embodiment may thus successfully manufacture the
shaped article 50 that excels in reliability and exhibits a desired
color tone.
[0114] There are other benefits as well. One of them is, forming
the part 54 of the second transparent layer in the first layer 50a
(1) allow a larger formation area (formation allowable region) to
be secured for the colored layer of the second layer 50a (2). This
may help to mitigate a demanded degree of manufacturing accuracy to
some extent, conducing to an improved manufacturing efficiency.
[0115] The ability to secure a larger formation area is
advantageously effective even if the part 54 of the second
transparent layer is formed subsequent to the part 53 of the
colored layer. This disclosure, therefore, further includes forming
the part 54 of the second transparent layer subsequent to the part
53 of the colored layer.
[0116] In the shaped article 50 according to this embodiment, the
surface of the colored layer 3 is coated with the second
transparent layer 4. The second transparent layer 4 thus serves as
the protective layer of the colored layer 3.
[0117] FIG. 4 illustrates an example in which the upper layer is
greater in size (area) along the X-Y plane than the lower layer.
This example refers to the lower half of the shaped article 50 of
FIG. 1 split in two halves.
[0118] The manufacturing method described so far is basically
applicable to the upper-half structure of the shaped article 50 of
FIG. 1 split in two halves. As for the upper half of the shaped
article 50, as illustrated in FIG. 2, the upper colored layer is
nearer to the center side of the layer 50a than the lower colored
layer, and the parts 53 of the upper colored layer overlap the
parts 52 of the lower first transparent layer. Further, the parts
54 of the upper second transparent layer overlap the parts 53 of
the lower colored layer.
[0119] In the upper half of the shaped article 50, as illustrated
in FIG. 2, the lower layers are greater in size (area) along the
X-Y plane than the upper layers formed thereon. In this upper-half
structure, the ink applied to form the colored layer in the upper
layers is very unlikely to drop downward. No support material may
be necessary at the time of manufacturing the upper-half
structure.
[0120] In the shaped article of FIG. 2 according to this
embodiment, the bottom layer and layers nearby, and the top layer
and layers nearby include: a layer solely having the part 52 of the
first transparent layer, part 53 of the colored layer, and part 54
of the second transparent layer; a layer solely having the part 53
of the colored layer and the part 54 of the second transparent
layer; and a layer solely having the part 54 of the second
transparent layer. This multilayered structure may effectuate a
shaped article whose entire surface is covered with the second
transparent layer 4, colored layer 3, and first transparent layer
2. This disclosure, however, is not limited to such a multilayered
structure. For example, the top and bottom surfaces of the shaped
article may include none of the second transparent layer, colored
layer, or first transparent layer, as in the multilayered structure
of FIG. 9 described later.
[0121] [8] Modified Example
[0122] First Modified Example
[0123] The shaped article 50 according to this embodiment includes
the first transparent layer 2, colored layer 3, and second
transparent layer 4 that are formed along the surface of the light
reflective layer 1. However, this disclosure may include but is not
limited to such a structure, and may optionally have a shaped
article illustrated in FIG. 8.
[0124] In the shaped articles illustrated in (a).about.(d) of FIG.
8, the second transparent layer 4 may have a shape described below
instead of the shape along the surface of the light reflective
layer 1. Because the parts 54 of the second transparent layer
constitute the ends of the layers 50a (FIG. 2), the second
transparent layer 4 may be formed in an adequate shape that
contains therein the shaped article (structure described in the
earlier embodiment including the colored layer 3, first transparent
layer, and light reflective layer), as illustrated in (a).about.(d)
of FIG. 8.
[0125] Containing the shaped article in the shape formed by the
second transparent layer 4, as described in this first modified
example, may be useful for any shaped articles that are
mechanically fragile. For example, this modified example may be
effectively applicable when, for example, molding insects' legs and
wings, and stems and petals of flowering plants. When molding
organisms and plants in the form of decorative ornaments or
specimens, they can be scanned alive by a three-dimensional scanner
and released again into the nature when the molding is over. A
further benefit may be eco-friendliness because no support material
is necessary, producing no waste material.
[0126] In the shaped article illustrated in (a) of FIG. 8, the
second transparent layer 4 has a hexahedral shape that contains a
spherical body including the colored layer 3, first transparent
layer, and light reflective layer. The structure illustrated in (a)
of FIG. 8 may be obtained by a manufacturing method similar to the
method of FIG. 4.
[0127] In FIG. 8, (b) illustrates a shaped article 50 of
frame-mounted type, wherein a figure including the colored layer 3,
first transparent layer, and light reflective layer is contained in
the second transparent layer 4. This is a free-standing shaped
article 50 supported by the second transparent layer 4. This shaped
article 50 of frame-mounted type may be manufactured (fabricated)
by the manufacturing method described in the earlier
embodiment.
[0128] In FIG. 8, (c) illustrates a shaped article 50 for use as a
strap, wherein a figure including the colored layer 3, first
transparent layer, and light reflective layer is contained in the
second transparent layer 4, and a hole 70 is formed in a part of
the second transparent layer 4. This may be used as a strap or a
key holder attachable to, for example, a mobile telephone. The hole
70 of the second transparent layer 4 may be formed at the same time
when the outer shape is formed by the second transparent layer 4.
By punching a hole in the second transparent layer 4, the figure
including the colored layer 3, first transparent layer, and light
reflective layer can avoid being damaged with a hole.
[0129] In the shaped article 50 illustrated in (d) of FIG. 8, the
upper-half of a figure's body including the colored layer 3, first
transparent layer, and light reflective layer is contained in the
second transparent layer 4. This article 50 has, on the surface or
inside of the second transparent layer 4, a three-dimensional image
71 decorated with a mark or a frame or painted in a pale color.
This shaped article 50 further has, on the surface or inside of the
second transparent layer 4, a letter/character area 72 with letters
and/or characters representing date, name, or place. The decorated
three-dimensional image 71 and the letter/character area 72 may be
formed at the same time when the outer shape is formed by the
second transparent layer 4. Instead of the decorated
three-dimensional image 71 and the letter/character area 72, other
additional information may be displayed on the surface or inside of
the second transparent layer 4.
[0130] In (b).about.(d) of FIG. 8, one figure is contained in the
second transparent layer 4; however, the number of figures
containable in the second transparent layer 4 may be other than
one.
[0131] In case the shaped article according to this embodiment has
a ring-like shape, the colored layer may be formed near an inner
peripheral end of the ring shape as well as an outer peripheral end
thereof. In conclusion, the colored layer may be formed on the
surface of the shaped article, and the second transparent layer may
be further formed thereon.
[0132] Instead of forming the second transparent layer 4 in any
desired shape as described in this modified example, the second
transparent layer 4 may be formed in a shape suitable for the
surface of the light reflective layer 1 similarly to the earlier
embodiment. In that case, the obtained shaped article may be sealed
in an optionally-shaped resin.
[0133] Second Modified Example
[0134] The shaped article 50 according to this embodiment has the
second transparent layer 4 on its outermost side. This disclosure
may achieve its goal in so far as the first transparent layer is
interposed between the colored layer and the light reflective
layer. This disclosure, therefore, may include, as an embodiment, a
shaped article 50' illustrated in cross section in FIG. 9. A second
modified example is hereinafter described referring to FIG. 9 to
FIG. 11. FIG. 9 is a cross-sectional view of the shaped article 50'
according to the second modified example, illustrated similarly to
FIG. 2. FIG. 10 is a schematic drawing of the lower surface of an
inkjet head device according to the second modified example used in
manufacturing of the shaped article 50'. FIG. 11 shows drawings of
manufacturing steps for the shaped article 50' according to the
second modified example.
[0135] A difference between the shaped article 50' according to the
second modified example and the shaped article 50 according to the
earlier embodiment is that the shaped article 50' according to the
second modified example has the colored layer 3 as its outermost
layer, unlike the shaped article 50 whose outermost layer is the
second transparent layer 4.
[0136] Referring to FIG. 9, layers 50'a constituting the shaped
article 50' according to the second modified example include no
part 54 of the second transparent layer, unlike the layers 50a
according to the earlier embodiment (FIG. 2) having these parts 54
at their ends.
[0137] In the layers 50'a of the shaped article 50' illustrated in
FIG. 9, the parts 52 of the first transparent layer are interposed
between the parts 53 of the colored layer and the parts 51 of the
light reflective layer. This may prevent the coloring inks applied
to form the parts 53 of the colored layer from blending into the
ink of the parts 51 of the light reflective layer. Even if the
coloring inks of the part 53 of the colored layer are mixed with
the transparent ink of the part 52 of the first transparent layer,
intermixing of these inks may cause no undesirable change to the
color tone of the part 53 of the colored layer. Therefore, the
resulting shaped article exhibits a desired color tone expressed by
the colored layer.
[0138] A manufacturing method for the shaped article 50' of FIG. 9
is hereinafter described. The shaped article 50' of FIG. 9 may be
manufactured by an inkjet head device 10' illustrated in FIG.
10.
[0139] The inkjet head device 10' illustrated in FIG. 10 has, on
its lower surface, roughly two inkjet heads 11H' and 12H'. As
illustrated in FIG. 10, the first inkjet head 11H' and the second
inkjet head 12H' are displaced from each other in both of the X and
Y directions.
[0140] The first inkjet head 11H' is the same as the first inkjet
head 11H illustrated in FIG. 3.
[0141] The second inkjet head 12H' includes a white ink nozzle 10
(W) for discharging a white ink (W) used to form the light
reflective layer 1 (parts 51 of the light reflective layer), and a
transparent ink nozzle 10 (CL) for discharging a transparent ink
(CL).
[0142] The steps of manufacturing the shaped article 50' using the
inkjet head device 10' are hereinafter described referring to FIG.
11.
[0143] In step S1' illustrated in (a) of FIG. 11, the part 52 of
the first transparent layer is formed from the transparent ink, and
the part 51 of the light reflective layer is formed from the white
ink (W). In this step, the inkjet head device 10' is moved in a
negative direction along the X axis, and the transparent ink is
discharged at a predetermined timing through the transparent ink
nozzle 10 (CL), and the white ink (W) is discharged at a
predetermined timing through the white ink nozzle 10 (W). The
discharged inks land on a position at which the part 52 of the
first transparent layer should be formed and a position at which
the part 51 of the light reflective layer should be formed. Then,
the discharged inks pooled at the respective positions are
irradiated with ultraviolet light to be cured. As a result, the
part 52 of the first transparent layer and the part 51 of the light
reflective layer are formed as illustrated in (a) of FIG. 11.
[0144] In step S2' illustrated in (b) of FIG. 11, the inkjet head
device 10' is moved in a positive direction along the X axis, and
the colored layer forming inks including the coloring inks are
discharged at a predetermined timing to land on a position at which
the part 53 of the colored layer should be formed. Then, the
discharged ink pooled at the position is irradiated with
ultraviolet light to be cured.
[0145] As a result of steps S1' and S2', the formation of a layer
50'a is completed. The support material 60 described in the earlier
embodiment is formed in the second modified example as well.
[0146] After the layer 50'a illustrated in (b) of FIG. 11 is
formed, a new layer 50'a is formed on the layer 50'a of (b) of FIG.
11 in steps similar to steps S1' and S2'.
[0147] Specifically, step S3' illustrated in (c) of FIG. 11 forms
the part 52 of the first transparent layer and the part 51 of the
light reflective layer in a manner similar to step S1'. In step
S3', the upper layer 50'a needs to be formed in a greater size
(area) along the X-Y plane than the lower layer 50'a, as described
in the earlier embodiment. To this end, as illustrated in (c) of
FIG. 11, the transparent ink is discharged so that the part 52 of
the first transparent layer in the upper layer 50'a overlaps the
part 53 of the colored layer in the lower layer 50'a already formed
by the time when step S2' is completed. At the same time, the white
ink (W) is discharged and pooled so that the part 51 of the light
reflective layer in the upper layer 50'a overlaps the part 51 of
the light reflective layer and the part 52 of the first transparent
layer in the lower layer 50'a. Then, the pooled ink is irradiated
with ultraviolet light to be cured.
[0148] In step S4' illustrated in (d) of FIG. 11, the colored layer
forming inks are discharged at a predetermined timing in a manner
similar to step S1' to land on a position at which the part 53 of
the colored layer should be formed and pooled at the position. The
predetermined timing refers to a timing of discharging the colored
layer forming inks on the outer side of the part 52 of the first
transparent layer in the upper layer 50'a with no overlap with the
part 53 of the colored layer in the lower layer 50'a. The pooled
ink is irradiated with ultraviolet light and thereby cured. Then,
the part 53 of the colored layer in the upper layer 50'a is
formed.
[0149] By repeatedly forming and stacking the layers 50'a on one
another, the shaped article 50' illustrated in FIG. 9 may be
manufactured.
[0150] Third Modified Example
[0151] In the embodiment described earlier, the shaped article 50
is manufactured by the inkjet head device 10 illustrated in FIG. 3.
In the second modified example, the shaped article 50' is
manufactured by the inkjet head device 10' illustrated in FIG. 10.
Instead of these inkjet head devices, inkjet head devices
illustrated in FIG. 12 to FIG.14 may be used.
[0152] FIG. 12 is a drawing of a modified example of the inkjet
head device, illustrated similarly to FIG. 3 and FIG. 10. In an
inkjet head device 10a illustrated in FIG. 12, a cyan ink nozzle 10
(C), a magenta ink nozzle 10 (M), a yellow ink nozzle 10 (Y), a
black ink nozzle 10 (K), a white ink nozzle 10 (W), and a
transparent ink nozzle 10 (CL) are arranged in the mentioned order
in the X direction.
[0153] FIG. 13 is a drawing of another modified example of the
inkjet head device, illustrated similarly to FIG. 3 and FIG10. In
an inkjet head device 10b illustrated in FIG. 13, a white ink
nozzle 10 (W), a transparent ink nozzle 10 (CL), a yellow ink
nozzle 10 (Y), a magenta ink nozzle 10 (M), a cyan ink nozzle 10
(C), a black ink nozzle 10 (K), a transparent ink nozzle 10 (CL),
and a white ink nozzle 10 (W) are arranged in the mentioned order
in the X direction.
[0154] FIG. 14 is a drawing of yet another modified example of the
inkjet head device. An inkjet head device 10b illustrated in FIG.
14 has a carriage 21 allowed to reciprocate along the X axis, a
plurality of nozzle arrays mounted in the carriage 21, and
ultraviolet irradiators 24a and 24b mounted in the carriage 21. The
carriage 21 is moved in the Y direction to perform a scan, in which
the inks of ultraviolet curing type are discharged from the nozzle
arrays and irradiated with ultraviolet light emitted from the
ultraviolet irradiators 24a and 24b.
[0155] The nozzle arrays are aligned along the X direction as
illustrated in FIG. 14. From the left to right in the X direction
on the drawing are arranged a cyan ink nozzle array C, a magenta
ink nozzle array M, a yellow ink nozzle array Y, a black ink nozzle
array K, a white ink nozzle array W, and a transparent ink nozzle
array CL are aligned in the mentioned order. Since the nozzle
arrays are mounted in the carriage 21, the inks of ultraviolet
curing type are dischargeable from these nozzle arrays while moving
in the X direction with the carriage 21.
[0156] Because all of the nozzles are aligned in the X direction in
FIG. 12, FIG. 13, and FIG. 14, the formation of one layer may be
completed by moving the nozzles once in the X direction and
discharging all of the required ink during the movement. Referring
to FIG. 14, all of the inks may be discharged and irradiated with
ultraviolet light by moving the nozzles just once in the X
direction. This may also be applicable to a layer formed from the
inks of ultraviolet curing type, which may be cured as soon as the
inks are discharged.
[0157] [Additional Remarks]
[0158] The shaped article 50 according to one aspect has the first
transparent layer 2 formed from the transparent ink between the
light reflective layer 1 formed from the light reflective ink and
the colored layer 3, wherein the colored layer 3, first transparent
layer 2, and light reflective layer 1 are formed in the mentioned
order from the outer-layer side toward the inner side of the shaped
article 50.
[0159] By interposing the first transparent layer 2 between the
light reflective layer 1 and the colored layer 3, intermixing of
the coloring inks and the underlayer ink, if occurs, may be
intermixing of the coloring inks and the transparent ink of the
first transparent layer 2, while avoiding intermixing of the
coloring inks and the light reflective ink. This may avoid any
negative impact on the color tone of the colored layer 3 formed
from the coloring inks. The shaped article 50 may accordingly
exhibit a color tone as desired.
[0160] The shaped article 50 according to one aspect may be more
advantageous when a white pigment-containing ink is used to form
the light reflective layer 1, because rays of light entering from
the outer-layer side of the shaped article may be better reflected
by the white pigment-containing ink.
[0161] The shaped article 50 according to one aspect further
includes the second transparent layer 4 on the outer-layer side of
the colored layer 3.
[0162] The second transparent layer 4 may serve to protect the
colored layer 3 and may also contribute to elaborateness and high
accuracy of the shaped article 50.
[0163] The shaped article 50 according to one aspect is further
characterized in that the colored layer 3 formed has its ink
density filled by the transparent ink in parts of the colored layer
3 in which the coloring inks alone are insufficient to meet a
predetermined ink density.
[0164] By having the ink density of the colored layer 3 filled by
the transparent ink, the colored layer 3 may avoid any voids and
uneven parts that would otherwise be generated. This may contribute
to the formation of an elaborate and very accurate
three-dimensional structure.
[0165] The shaped article 50 according to one aspect is further
characterized in that plural layers 50a, 50'a are stacked on one
another, a part of the colored layer 3 (part 53 of the colored
layer), a part of the first transparent layer 2 (part 52 of the
first transparent layer), and a part of the light reflective layer
1 (part 51 of the light reflective layer) are formed in at least
one of the plural layers 50a, 50'a in the mentioned order from the
end side toward the center side of the layer.
[0166] The shaped article 50 according to one aspect is further
characterized in that the second transparent layer 4 is formed on
the outer-layer side of the colored layer 3, and a part of the
colored layer 3 (part 53 of the colored layer) in at least one of
the plural layers 50a, 50'a is interposed between a part of the
first transparent layer 2 (part 52 of the first transparent layer)
and a part of the second transparent layer 4 (part 54 of the second
transparent layer).
[0167] The shaped article 50 according to one aspect is further
characterized in having a region in which the layers 50a, 50'a are
stacked on one another, each layer having a part of the colored
layer 3 (part 53 of the colored layer) between a part of the first
transparent layer 2 (part 52 of the first transparent layer) and a
part of the second transparent layer 4 (part 54 of the second
transparent layer), and in a portion of the region with no overlap
between a part of the colored layer 3 (part 53 of the colored
layer) in one of the layers 50a, 50'a and a part of the colored
layer 3 (part 53 of the colored layer) in another one of the layers
50a, 50'a on or below the one of the layers 50a, 50'a, there is an
overlap between a part of the colored layer 3 (part 53 of the
colored layer) in one of the layers 50a, 50'a and a part of the
first transparent layer 2 (part 52 of the first transparent layer)
or a part of the second transparent layer 4 (part 54 of the second
transparent layer) in another one of the layers 50a, 50'a on or
below the one of the layers 50a, 50'a.
[0168] The manufacturing method for the shaped article 50 according
to one aspect is a manufacturing method for the shaped article 50
including the colored layer 3, first transparent layer 2, and light
reflective layer 1 formed from the light reflective ink, wherein
the colored layer 3, first transparent layer 2, and light
reflective layer 1 are formed in this order from the outer-layer
side toward the inner side of the shaped article 50. This method
employs the multilayer lamination technique to form the layers.
Further, the method includes a layer forming process including
forming a part of the colored layer 3 (part 53 of the colored
layer), a part of the first transparent layer 2 (part 52 of the
first transparent layer), and a part of the light reflective layer
1 (part 51 of the light reflective layer) in this order from the
end side toward the center side of each one of the layers 50a,
50'a.
[0169] By interposing the first transparent layer 2 between the
light reflective layer 1 and the colored layer 3, intermixing of
the coloring inks and the underlayer ink, if occurs, may be
intermixing of the coloring inks and the transparent ink of the
first transparent layer 2, while avoiding intermixing of the
coloring inks and the light reflective ink. Intermixing of the
coloring inks and the transparent ink, if occurs, may not adversely
affect a desired color tone. The shaped article 50 may accordingly
exhibit a color tone as desired.
[0170] The manufacturing method for the shaped article 50 according
to one aspect further includes forming the second transparent layer
4 on the outer-layer side of the colored layer 3, wherein the layer
forming process includes forming a part of the second transparent
layer 4 (part 54 of the second transparent layer) at a position
nearer to the end side than a part of the colored layer 3 (part 53
of the colored layer) in each of the layers 50a, 50'a formed.
[0171] In the shaped article in which the second transparent layer
4 is formed on the outer-layer side of the colored layer 3, the
second transparent layer 4 may serve to protect the colored layer 3
and may also contribute to elaborateness and high accuracy of the
shaped article 50.
[0172] Specifically, by forming the second transparent layer (part
54 of the second transparent layer) before the colored layer (part
53 of the colored layer) is formed in each of the layers 50a, 50'a,
the second transparent layer (part 54 of the second transparent
layer) may serve as the outer moat of the colored layer 3 (part 53
of the colored layer). This may prevent the ink forming the colored
layer (part 53 of the colored layer) from spreading unintendedly or
dropping downward.
[0173] In the upper and lower layers 50a, 50'a, the presence of the
second transparent layer (part 54 of the second transparent layer)
on the lower layer 50a, 50'a may allow a larger formation area to
be secured for the colored layer (part 53 of the colored layer) on
the upper layer 50a, 50'a. Such an increase of the colored layer
formation area may prevent the risk with the layers 50a, 50'a that
the coloring inks applied to form the colored layer (part 53 of the
colored layer) in one of the layers run off an edge of another one
of the layers therebelow, dropping downward. Hence, the shaped
article 50 may be successfully manufactured as desired.
[0174] The manufacturing method for the shaped article 50 according
to one aspect is further characterized in that the layer forming
process of forming the layer 50a, 50'a includes steps of: forming a
part of the colored layer 3 (part 53 of the colored layer) using
the coloring ink; forming a part of the first transparent layer 2
(part 52 of the first transparent layer) using the transparent ink;
forming a part of the light reflective layer 1 (part 51 of the
light reflective layer) using the light reflective ink; and forming
a part of the second transparent layer 4 (part 54 of the second
transparent layer) using the transparent ink, wherein the step of
forming a part of the colored layer 3 (part 53 of the colored
layer) from the coloring inks follows the step of forming a part of
the first transparent layer (part 52 of the first transparent
layer) and the step of forming a part of the second transparent
layer to form a part of the colored layer 3 (part 53 of the colored
layer) between a part of the first transparent layer 2 (part 52 of
the first transparent layer) and a part of the second transparent
layer 4 (part 54 of the second transparent layer).
[0175] By forming the first transparent layer (part 52 of the first
transparent layer) and the second transparent layer (part 54 of the
second transparent layer) before the colored layer (part 53 of the
colored layer) is formed, the first transparent layer (part 52 of
the first transparent layer) and the second transparent layer (part
54 of the second transparent layer) may serve as the outer moat of
the colored layer (part 53 of the colored layer). This may prevent
the colored layer (part 53 of the colored layer) from spreading
unintendedly. The shaped article 50, therefore, may be successfully
manufactured as desired.
[0176] The manufacturing method for the shaped article 50 according
to one aspect is further characterized in that, in a portion with
no overlap between a part of the colored layer 3 (part 53 of the
colored layer) in one of the layers 50a, 50'a and a part of the
colored layer 3 (part 53 of the colored layer) in another one of
the layers 50a, 50'a on or below the one of the layers 50a, 50'a,
there is an overlap between a part of the colored layer 3 (part 53
of the colored layer) in one of the layers 50a, 50'a and a part of
the first transparent layer 2 (part 52 of the first transparent
layer) or a part of the second transparent layer 4 (part 54 of the
second transparent layer) in another one of the layers 50a, 50'a on
or below the one of the layers 50a, 50'a.
[0177] The colored layer (part 53 of the colored layer) may be
interposed also in the layer-stacked direction between the
transparent ink layers (part 52 of the first transparent layer and
part 54 of the second transparent layer). This may avoid any
overlap between parts of the colored layer (parts 53 of the colored
layer) in the upper and lower layers 50a, 50'a. The shaped article
50 thus formed may not exhibit undesirable variability in color
tone when viewed in a certain direction and viewed in another
direction inclined from the direction.
[0178] The manufacturing method for the shaped article 50 according
to one aspect is further characterized in forming a part of the
decorative layer by filling the ink density of the decorative layer
using a transparent supplementary ink in a part of the decorative
layer in which decorative inks alone are insufficient to meet a
predetermined ink density. Thus, the ink density of the colored
layer 3 (part 53 of the colored layer) is filled by the transparent
ink.
[0179] By having the ink density of the colored layer 3 (part 53 of
the colored layer) filled by the transparent ink, the colored layer
3 (part 53 of the colored layer) may avoid any unintended voids and
uneven parts that would otherwise be generated. This may contribute
to elaborateness and high accuracy of the shaped article 50.
[0180] This disclosure is not necessarily limited to the embodiment
described so far and may be carried out in many other forms. The
technical scope of this disclosure encompasses any modifications
within its scope defined by the appended claims and embodiments
obtained by variously combining the technical means disclosed
herein. By variously combining the technical means disclosed in the
embodiment and modified examples, additional technical features may
be further presented.
Second Embodiment
[0181] The inventors of this application found a problem with the
known inkjet 3D molding. The problem is, irregularities and/or
voids were generated in layers formed from the decorative inks
(coloring inks of, for example, yellow, magenta, cyan, and black
inks) when these inks and a molding ink were discharged by inkjet
printing technique.
[0182] They studied what triggered the problem and finally found
out that the amounts of decorative inks discharged were variable
depending on intended decorative effects, which led to an
insufficient ink density of the decorative layer failing to meet a
predetermined ink density. As for coloring as an example of
decoration (recording of characters and images in colors through
subtractive color mixture), it is coloring inks that decide the
color tone of a colored layer. Naturally, the amounts of coloring
inks discharged may differ from one color tone to another desirably
expressed. When the coloring inks are discharged in relatively
small amounts, the ink density of the colored layer may fail to
meet a predetermined ink density. The inventors were led to the
fact that such shortage of the ink density would cause the
irregularities and/or voids described earlier. The irregularities
and/or voids are desirably avoided because they are likely to
impair a color tone to be attained by decoration and adversely
affect the whole structure of a shaped article.
[0183] To address the issue, this disclosure is directed to
providing a shaped article that may be decorated as desired and
also shaped as desired, and a manufacturing method for such a
shaped article.
[0184] To this end, a shaped article disclosed herein is a shaped
article formed by multilayer lamination technique, further
characterized in that the shaped article has a decorative layer,
and the decorative layer has its ink density filled by a
supplementary ink in parts of the decorative layer in which
decorative inks alone are insufficient to meet a predetermined ink
density.
[0185] By forming the decorative layer using the decorative inks
alone, the ink density of the decorative layer may be partly
insufficient, failing to meet a predetermined ink density. This may
generate irregularities and/or voids in the decorative layer. The
irregularities and/or voids may incur failure to obtain any desired
shape of the shaped article in the manufacturing process. On the
other hand, the shaped article characterized as described herein
may eliminate the risk of such irregularities and/or voids because
the ink density of the decorative layer is filled by the
supplementary ink. The shaped article, therefore, may be
successfully decorated as desired and also shaped as desired.
[0186] The shaped article disclosed herein according to an aspect
is further characterized in that the supplementary ink includes a
transparent ink.
[0187] Using the transparent ink may be unlikely to adversely
affect decorative effects expected for the decorative layer,
thereby successfully providing a shaped article decorated as
desired.
[0188] A manufacturing method for a shaped article disclosed herein
is a manufacturing method that employs multilayer lamination
technique to form a shaped article having a decorative layer,
further characterized in that the decorative layer has its ink
density filled by a supplementary ink in parts of the decorative
layer in which decorative inks alone are insufficient to meet a
predetermined ink density.
[0189] By forming the decorative layer using the decorative inks
alone, the ink density of the decorative layer may be partly
insufficient, failing to meet a predetermined ink density. This may
generate irregularities and/or voids in the decorative layer. The
irregularities and/or voids may incur failure to obtain any desired
shape of the shaped article in the manufacturing process. This
method, on the other hand, may eliminate the risk of such
irregularities and/or voids because the ink density of the
decorative layer is filled by the supplementary ink. The shaped
article, therefore, may be successfully decorated as desired and
also shaped elaborately.
[0190] The shaped article manufacturing method disclosed herein is
further characterized in including a layer forming process
including forming layers each having a part of the decorative
layer, in which one of the layers is newly formed on another one of
the layers so that the parts of the decorative layer in these
layers are continuous and thereby form the decorative layer, and
the layer forming process further includes filling the ink density
of the decorative layer using a supplementary ink in parts of the
decorative layer in which decorative inks alone are insufficient to
meet a predetermined ink density.
[0191] This method fills the ink density of the decorative layer in
parts of the decorative layer formed by the layer forming process.
This method thus advantageous may successfully form layers with
neither irregularity nor void.
[0192] This disclosure provides a shaped article that may be
decorated as desired and also shaped as desired, and a
manufacturing method for such a shaped article.
[0193] An embodiment of a shaped article and a shaped article
manufacturing method disclosed herein is hereinafter described
referring to FIG. 1 to FIG. 8. The shaped article disclosed herein
has a three-dimensional structure constructed of a laminate of
layers (formed by multilayer lamination technique). In the
embodiment hereinafter described, inkjet printing technique is
employed to manufacture the shaped article. This is, however, just
an option presented in this disclosure. This disclosure may be
applicable to any kinds of manufacturing methods that can obtain a
shaped article by leveraging the multilayer lamination technique
and decorate its surface (recording of characters and images in
colors).
[0194] [1] Structure of Shaped article
[0195] FIG. 1 is a perspective view of an outer shape of a shaped
article 50 according to an embodiment. The shaped article 50
according to this embodiment has a substantially cylindrical shape
with a curved side surface bulging outward. The shaped article
disclosed herein and the shaped article manufactured by the
manufacturing method disclosed herein may not be limited to the
shape illustrated in FIG. 1. There are many other examples of the
shape, including a hexahedral shape described later, a spherical
shape, a hollow structure, a ring-like shape, and a horseshoe-like
shape.
[0196] The shaped article 50 according to this embodiment includes
a second transparent layer, a colored layer (decorative layer)
formed from colorant-containing inks (decorative ink), a first
transparent layer formed from a transparent ink, and a light
reflective layer formed from an ink having light reflectiveness,
wherein these layers are formed in the mentioned order from an
outer-layer side (outer peripheral side) toward an inner side
(center) of the shaped article 50. This is a distinctive technical
feature of this disclosure. FIG. 1 is a drawing of the shaped
article 50. In this drawing, a second transparent layer 4 formed
from a transparent ink, which is the outermost layer, can be seen
on the curved side surface of the shaped article 50.
[0197] FIG. 2 is a cross-sectional view of the illustration of FIG.
1 taken along a cutting-plane line A-A'. The cross-sectional view
of the shaped article 50 illustrated in FIG. 2 is taken at a
central position of the shaped article 50 along the X-Z plane of
the XYZ coordinate system illustrated in FIG. 1.
[0198] The embodiment of FIG. 2 presents an example of the shaped
article 50 having a three-dimensional structure formed by stacking
21 layers 50a on one another in the Z direction. It should be
understood that the shaped article 50 may include less than or more
than 21 layers.
[0199] [2] Structures of Layers
[0200] FIG. 5 is a drawing of the X-Y plane of a layer 50a in the
vicinity of a mid-stage of the shaped article 50. The layers 50a
each include a part 54 of the second transparent layer, a part 53
of the colored layer, a part 52 of the first transparent layer, and
a part 51 of the light reflective layer. These layers are formed in
the mentioned order from an outer peripheral side toward a center
side of the shaped article. If the shaped article 50 according to
this embodiment is stated another way, the light reflective layer
1, which is the body of the shaped article, is coated with the
first transparent layer 2, colored layer 3, and second transparent
layer 4 in the mentioned order toward the outer-layer side (outer
peripheral side). Each one of the layers 50a has a thickness in the
Z direction (vertical direction in the drawing) between 5 .mu.m and
50 .mu.m. This is an adequate range of thickness values for
multicolor formation of the colored layer 3 using the subtractive
color mixture. For example, a preferable range of thickness values
is 10 .mu.m to 25 .mu.m when layers are formed from inks of
ultraviolet curing type by inkjet printing technique.
[0201] In this embodiment, the light reflective layer 1 is the body
of the shaped article; however, the light reflective layer may or
may not constitute the body of the shaped article. Specifically,
the shaped article may have, at its center, a body or a cavity
apart from the light reflective layer, wherein the light reflective
layer, first transparent layer, colored layer, and second
transparent layer are formed in the mentioned order from the body
(may or may not have light reflectiveness) toward the outer-layer
side (outer peripheral side). Alternatively, a core (may or may not
have light reflectiveness) and the light reflective layer 1 formed
on a surface of the core may be collectively regarded as the body
of the shaped article.
[0202] By stacking the layers 50a in the Z direction as illustrated
in FIG. 2, the parts 54 of the second transparent layer in the
respective layers 50a are substantially continuous in a direction
along the outermost surface of the shaped article 50, forming the
second transparent layer 4. The parts 53 of the colored layer in
the respective layers 50a are substantially continuous in the
direction along the outermost surface of the shaped article 50,
forming the colored layer 3. The parts 52 of the first transparent
layer in the respective layers 50a are substantially continuous in
the direction along the outermost surface of the shaped article 50,
forming the first transparent layer 2. The parts 51 of the light
reflective layer in the respective layers 50a are substantially
continuous in the direction along the outermost surface of the
shaped article 50, forming the light reflective layer 1.
[0203] Looking at, in any of the X, Y, and Z directions, the outer
surface of the shaped article 50 including the second transparent
layer, colored layer, first transparent layer, and light reflective
layer arranged in the mentioned order, a color tone produced by the
subtractive color mixture may be visually recognized.
[0204] The parts 52 of the first transparent layer may preferably
have a dimension in the direction of X-Y plane slightly greater
than the part 53 of the colored layer vertically in contact with
the parts 52. This may more reliably prevent intermixing of the
inks forming the colored layer 3 and the light reflective layer
1.
[0205] The parts 54 of the second transparent layer may preferably
have a dimension in the direction of X-Y plane slightly greater
than the parts 53 of the colored layer vertically in contact with
the parts 54 of the second transparent layer. This may provide for
better protection of the colored layer 3.
[0206] The width of the shaped article 50 along the Z direction
(hereinafter may be referred to as thickness or height in the Z
direction) is not particularly limited. The thickness (height) of
the layer 50a in the Z direction may be optionally decided
depending on the number of layers. As described later, this
embodiment constructs the multilayered structure using the inkjet
printing technique. Therefore, any feasible values in the technique
should be contemplated for the thickness of the layer 50a in the Z
direction. When inks of ultraviolet curing type are applied by
inkjet printing technique to form the layers (described later), the
layer 50a may have a thickness ranging from 5 .mu.m to 20 .mu.m
depending on the sizes of ink droplets. As for a large-sized shaped
article for which a high resolution is not particularly required,
plural layers may be formed based on the same data simply by
increasing the sizes of ink droplets. In such a case, a smaller
data volume and a higher molding rate may be anticipated.
[0207] [3] Structure of Light Reflective Layer 1 (Parts 51 of Light
Reflective Layer)
[0208] The light reflective layer 1 (parts 51 of the light
reflective layer) is a layer formed from a light reflective ink.
This layer, therefore, has light reflectiveness that allows rays of
light in the whole visible light region to be reflected on at least
the surface of the light reflective layer 1 in contact with the
colored layer.
[0209] Specific examples of ink of the light reflective layer 1
(parts 51 of the light reflective layer) may include metallic
powder-containing inks and white pigment-containing inks. The light
reflective layer 1 may preferably be formed from a white ink. The
light reflective layer 1 formed from a white ink may adequately
reflect rays of light entering from the outer-layer side of the
shaped article, allowing the shaped article to be colored by the
subtractive color mixture.
[0210] In this embodiment, the light reflective layer 1 constitutes
the body of the shaped article. In case the light reflective layer
1 is formed on the surface of the body of any shaped article for
which light reflectiveness is not required, the thickness of the
light reflective layer 1, i.e., the width of the part 51 of the
light reflective layer from the outer peripheral side to the center
side, as illustrated in FIG. 2, may be between 5 .mu.m and 20 .mu.m
at the least. The width in this disclosure may include but is not
limited to the range of values.
[0211] [4] Structure of First Transparent Layer 2 (Parts 52 of
First Transparent Layer)
[0212] The first transparent layer 2 (parts 52 of the first
transparent layer) is formed from a transparent ink.
[0213] The transparent ink may refer to an ink capable of forming a
transparent layer having light transmittance greater than or equal
to 50% per unit thickness. The light transmittance less than 50%
per unit thickness of the transparent layer may unintendedly block
the transmission of light. This may be a drawback that fails to
exhibit a desired color tone of the shaped article by way of the
subtractive color mixture. Preferably is used an ink having light
transmittance greater than or equal to 80% per unit thickness of
the transparent layer. Further, an ink having light transmittance
greater than or equal to 90% per unit thickness of the transparent
layer is particularly preferable.
[0214] By interposing the first transparent layer 2 (part 52 of the
first transparent layer) between the light reflective layer 1 (part
51 of the light reflective layer) and the colored layer 3 (part 53
of the colored layer), intermixing of the coloring inks of the
colored layer 3 and the ink of the light reflective layer 1 may be
avoidable. Even if the coloring inks applied to form the colored
layer are mixed with the transparent ink of the first transparent
layer, intermixing of these inks may not adversely affect colors of
the colored layer or cause any undesirable change to the color
tone. Therefore, the resulting shaped article exhibits a desired
color tone (decorated as desired) expressed by the colored layer
3.
[0215] The width of the part 52 of the first transparent layer from
the outer peripheral side to the center side (hereinafter, referred
to as the thickness of the first transparent layer) is between 5
.mu.m and 20 .mu.m at the least in a decorated portion on a surface
perpendicular to the layer-stacked direction. The width in this
disclosure may include but is not limited to the range of
values.
[0216] [5] Structure of Colored Layer 3 (Part 53 of Colored
Layer)
[0217] The colored layer 3 (part 53 of the colored layer) is formed
from a colorant-containing coloring ink.
[0218] Examples of the colorant-containing inks (hereinafter may be
referred to as coloring ink) may include but are not limited to
yellow (Y), magenta (M), cyan (C), black (K), and pale color inks.
Further, red (R), green (G), blue (B), and orange (Or) color inks
may be additionally used. Other usable inks may include metallic,
pearl, and phosphor inks. One or more than one of these coloring
inks may preferably be used to express a desired color tone.
[0219] The amounts of the coloring inks to form the colored layer 3
(parts 53 of the colored layer) may be variable depending on a
desired (desirably expressed) color tone. In case the coloring inks
alone are used to express a bright color tone at a relatively low
concentration, the ink density of the colored layer 3 may fail to
meet a predetermined ink density. This may generate irregularities
in the Z direction and/or ink-less dented parts at positions along
the X-Y direction. In any case, the shaped article formed by the
multilayer lamination technique, as described in this embodiment,
may consequently have an irregular, unattractive shape, which is
desirably avoided. In case one cross-sectional surface of the
colored layer 3 has the ink density of two lateral and two vertical
ink droplets; four ink droplets in total, formed by the error
diffusion method on a vertical mold surface near the mid position
of the multilayered structure illustrated in FIG. 2, the coloring
inks each form four ink droplets at the most (largest
concentration) and no ink droplet at the least (zero concentration,
meaning colorless). The number of ink droplets being zero may leave
an unfilled space as large as four ink droplets, significantly
degrading the shaped article in view of its shape and color
tone.
[0220] This embodiment, therefore, fills the ink density of the
colored layer 3 (part 53 of the colored layer) using a
supplementary ink in parts of the colored layer 3 (part 53 of the
colored layer) in which the coloring inks alone are insufficient to
meet a predetermined ink density. Specifically, the colored layer 3
(parts 53 of the colored layer) is formed at a constant total
density (number of ink droplets) of the coloring inks and the
supplementary ink. This may successfully prevent the formation of
dented parts, allowing the shaped article 50 to be elaborately
shaped.
[0221] The amounts of the coloring inks to be discharged and their
landing positions are known beforehand, based on which the amount
and position (landing position) of the supplementary ink to be
additionally discharged may be suitably determined. The amount and
position may be decided by an inkjet head device 10 or by a
controller not illustrated in the drawings.
[0222] Having the ink density filled by the supplementary ink may
allow a surface formed by the colored layer 3 to be flattened,
imparting glossiness to the surface.
[0223] The supplementary ink may be any ink unless it adversely
affects the color tone to be expressed by the colored layer 3
(parts 53 of the colored layer). An example of the supplementary
ink may be the transparent ink used to form the first transparent
layer 2 (parts 52 of the first transparent layer) and the second
transparent layer 4 (parts 54 of the first transparent layer).
[0224] The thickness of the colored layer 3, i.e., the width of the
part 53 of the colored layer from the outer peripheral side to the
center side illustrated in FIG. 2 (hereinafter, referred to as the
thickness of the colored layer 3) may be between 5 .mu.m and 20
.mu.m.
[0225] The colored layer 3 described in this embodiment is just an
option and may be any decorative layer.
[0226] [6] Structure of Second Transparent Layer 4 (Parts 54 of
Second Transparent Layer)
[0227] The second transparent layer 4 (parts 54 of the second
transparent layer) is formed from the same transparent ink as that
of the first transparent layer 2 (parts 52 of the first transparent
layer). The same transparent ink or different transparent inks may
be used to form the second transparent layer 4 and the first
transparent layer 2.
[0228] The thickness of the second transparent layer 4, i.e., the
width of the part 54 of the second transparent layer from the outer
peripheral side to the center side illustrated in FIG. 2
(hereinafter, referred to as the thickness of the second
transparent layer 4) may be between 10 .mu.m and 100 .mu.m.
[0229] The second transparent layer 4 functions as a protective
layer for the colored layer 3. In this disclosure that employs the
multilayer lamination technique (this embodiment), the second
transparent layer 4 may also advantageously contribute to
elaborateness of the shaped article.
[0230] Supposing that the colored layer 3 is the outermost layer of
the shaped article 50, i.e., the parts 53 of the colored layer are
located at the farthest ends of the respective layers 50a
illustrated in FIG. 2, the colored layer 3 (parts 53 of the colored
layer) formed may not be as accurate as expected. On the other
hand, the shaped article 50 whose outermost layer is the second
transparent layer 4 (parts 54 of the second transparent layer), as
described in this embodiment, may ensure the accuracy of the
colored layer 3 (parts 53 of the colored layer). Thus, the second
transparent layer 4 (parts 54 of the second transparent layer) may
greatly contribute to a desired color tone.
[0231] Another disadvantage in case the colored layer 3 is the
outermost layer of the shaped article 50 is that the exposed
colored layer 3 may be prone to decolorization under friction and
color fading by exposure to ultraviolet. However, as described in
this embodiment, the shaped article 50 whose outermost layer is the
second transparent layer 4 (parts 54 of the second transparent
layer) may prevent such unfavorable events as decolorization and
color fading.
[0232] [7] Manufacturing Method for Shaped Article
[0233] A manufacturing method for the shaped article 50 according
to this embodiment is hereinafter described. FIG. 3 is a drawing of
the lower surface of the inkjet head device 10 used in the
manufacturing method. FIG. 4 shows schematic drawings of ongoing
steps of manufacturing the shaped article 50 according to this
embodiment.
[0234] The inkjet head device 10 has, on its lower surface, roughly
three inkjet heads 11H to 13H. As illustrated in FIG. 3, the first
inkjet head 11H, second inkjet head 12H, and third inkjet head 13H
are displaced from one another in the X direction. As illustrated
in FIG. 3, the first inkjet head 11H, second inkjet head 12H, and
third inkjet head 13H are also displaced from one another in the Y
direction. Thus, the inkjet heads 11H to 13H are positioned in,
generally called, staggered arrangement.
[0235] The first inkjet head 11H has a cyan ink nozzle 10 (C) for
discharging a cyan ink, a magenta ink nozzle 10 (M) for discharging
a magenta ink, a yellow ink nozzle 10 (Y) for discharging a yellow
ink, and a black ink nozzle 10 (K) for discharging a black ink. The
number and the order of arrangement of the nozzles 10 (C), 10 (M),
10 (Y), and 10 (K) are not limited to the example illustrated in
FIG. 3. All of the inks discharged through these nozzles are
coloring inks used to form the colored layer 3 (parts 53 of the
colored layer) illustrated in FIG. 2.
[0236] The second inkjet head 12H has a white ink nozzle 10 (W) for
discharging a white ink (W). The white ink (W) is an ink used to
form the light reflective layer 1 (parts 51 of the light reflective
layer) illustrated in FIG. 2.
[0237] The third inkjet head 13H has a transparent ink nozzle 10
(CL) for discharging a transparent ink (CL). The transparent ink
(CL) is an ink used to form the first transparent layer 2 (parts 52
of the first transparent layer) and the second transparent layer 4
(parts 54 of the second transparent layer) illustrated in FIG.
2.
[0238] The inkjet head device 10 is located so as to have its lower
surface illustrated in FIG. 3 face the layer 50a currently being
formed. The inkjet head device 10 is configured to reciprocate in
the X direction and discharge the inks while moving in the
direction. The inkjet head device 10 is moved in a predetermined
direction in an XYZ coordinate system, or a table with the layers
50a placed thereon (FIG. 4 shows a layer formation surface B of the
table) is moved in a predetermined direction in the XYZ coordinate
system to change relative positions of the inkjet head device 10
and the layer 50a currently being formed. Which one of them should
be moved may be optionally decided.
[0239] Each of the inks is an ink of ultraviolet curing type that
needs to be irradiated with ultraviolet light after being
discharged. A ultraviolet irradiator may be mounted in the inkjet
head device 10 or may be installed as a separate device. The inks
are cured by being irradiated with ultraviolet light to form the
layers 50a illustrated in FIG. 2.
[0240] The manufacturing process for the shaped article 50 using
the inkjet head device 10 is hereinafter described referring to
FIG. 4.
[0241] To start with, a first one of the layers 50a (first layer
50a (1)) is formed on the layer formation surface B of the
table.
[0242] In the step of forming (manufacturing) the first layer 50a
(1), by using the inkjet printing technique, the respective inks
are discharged from the inkjet head device 10 at predetermined
timings to form a part of the second transparent layer, a part of
the colored layer, a part of the first transparent layer, and a
part of the light reflective layer in the mentioned order from the
end side toward the center side of the first layer 50a.
[0243] The steps of forming (manufacturing) the first layer 50a (1)
are described in further detail referring to (a).about.(c) of FIG.
4.
[0244] In step S1 illustrated in (a) of FIG. 4, the part 54 of the
second transparent layer is formed from the transparent ink, and
the part 52 of the first transparent layer is formed from the
transparent ink. In this step, the inkjet head device 10 is moved
in a positive direction along the X axis, and the transparent ink
is discharged at a predetermined timing through the transparent ink
nozzle 10 (CL) illustrated in FIG. 3. The discharged ink lands on a
position at which the part 54 of the second transparent layer
should be formed and a position at which the part 52 of the first
transparent layer should be formed. Then, the discharged ink pooled
at the respective positions is irradiated with ultraviolet light to
be cured. As a result, the part 52 of the first transparent layer
and the part 54 of the second transparent layer are formed as
illustrated in (a) of FIG. 4.
[0245] In step S2 illustrated in (b) of FIG. 4, the inkjet head
device 10 is moved in a negative direction along the X axis, and
the white ink (W), which is the light reflective ink, is discharged
at a predetermined timing through the white ink nozzle 10 (W).
Then, the discharged ink pooled there is irradiated with
ultraviolet light to be cured. As a result, the part 51 of the
light reflective layer is formed as illustrated in (b) of FIG.
4.
[0246] In step S3 illustrated in (c) of FIG. 4, the inkjet head
device 10 is moved in the positive direction along the X axis, and
the colored layer forming inks including the coloring inks and the
supplementary ink are discharged at a predetermined timing so that
the total amount of these inks discharged is constant, and then
irradiated with ultraviolet light. The predetermined timing refers
to a timing at which the nozzles of the first inkjet head 11H are
located at positions at which the colored layer forming inks are
dischargeable in a region between the part 52 of the first
transparent layer and the part 54 of the second transparent layer
formed in step S 1. The ink droplets in a predetermined amount are
discharged by inkjet printing technique at this timing to form a
pool of ink. Then, the pooled ink is irradiated with ultraviolet
light to be cured. This forms the part 53 of the colored layer
exhibiting a desired color tone between the part 52 of the first
transparent layer and the part 54 of the second transparent layer
as illustrated in (c) of FIG. 4.
[0247] As a result of steps S1 to S3, the formation of the first
layer 50a (1) is completed. The first layer 50a (1) has the same
structure as illustrated in the upper view of the layer 50a in FIG.
5. Optionally, step 1 and step 2 may be performed in the reversed
order. Likewise, step S2 and step S3 may be performed in the
reversed order.
[0248] After the first layer 50a (1) is formed, a new layer 50a
(second layer 50a (2)) is formed on the first layer 50a (1)
(laminate of layers).
[0249] In the shaped article 50 according to this embodiment, the
layers 50a stacked on one another along the X-Y plane are
progressively increased in size (area) from the bottom toward the
mid stage of the multilayered body as illustrated in FIG. 2. In the
shaped article 50 manufactured in such a shape that increases in
size along the layer-stacked direction when viewed in cross
section, the end of one layer 50a is sticking out sideways further
than the end of another layer 50a already formed below the one
layer 50a. To form the layers 50a thus characterized, support
material layers may preferably be formed.
[0250] In FIG. 4, (d) is a drawing of the step of forming the
second layer 50a (2). Referring to this drawing, a part 53 (2) of
the colored layer in the second layer 50a (2) is formed so as to
overlap a part 54 (1) of the second transparent layer in the first
layer 50a (1). Since the second layer 50a (2) is greater in size
(area) along the X-Y plane than the first layer 50a (1), the part
54 (2) of the second transparent layer forming the end of the
second layer 50a (2) is sticking out sideways further than the part
54 (1) of the second transparent layer forming the end of the first
layer 50a (1). Because of this structure, the ink to be deposited
on a part of the layer 50a (2) where the stick-out part should be
formed possibly runs off this part and drops downward. To avoid
that, a support material 60 is formed on the outer side (on the
lateral side) than the part 54 (1) of the second transparent layer
in the first layer 50a (1).
[0251] The support material 60 may preferably be formed from any
ink that can be discharged by inkjet printing technique. The
support material 60 should preferably have enough strength not to
collapse under the weight of another layer formed thereon. The
support material 60 per se will not be left in the finalized shaped
article 50. The ink forming the support material 60, therefore,
should preferably be selected from inks that can be stripped off
afterwards. The ink of the support material 60 may preferably be
curable by ultraviolet light (to a degree of cure at which the ink
is stripped off in subsequent steps), or may be a water-soluble ink
that can be dissolved in water and removed in subsequent steps.
[0252] The steps of forming the layers 50a are repeatedly performed
in the X and Y directions as many times as required to form one
layer, and then repeatedly performed again in the Z direction. As a
result, the shaped article 50 illustrated in FIG. 2 is finally
obtained. During the steps of forming one layer, the known
interlace scan conventionally employed to form two-dimensional
images may preferably be performed to obtain a shaped article with
less unevenness in shape and favorably decorated.
[0253] The shaped article manufacturing method according to this
embodiment is further characterized in that the layer forming
process includes steps of: forming the part 54 of the second
transparent layer using the transparent ink; forming the part 53 of
the colored layer using the coloring inks; forming the part 52 of
the first transparent layer using the transparent ink; and forming
the part 51 of the light reflective layer using the light
reflective ink, wherein the step of forming the part 53 of the
colored layer is performed subsequent to the step of forming the
part 52 of the first transparent layer and the step of forming the
part 54 of the second transparent layer to form the part 53 of the
colored layer between the part 52 of the first transparent layer
and the part 54 of the second transparent layer. When the part 53
of the colored layer is formed, the part 54 of the second
transparent layer may serve as the outer moat of the pooled inks to
form the colored layer. This may prevent the ink of the colored
layer from spreading unintendedly, ensuring a high accuracy of the
part 53 of the colored layer.
[0254] Further benefits delivered by forming the part 54 of the
second transparent layer are described referring to FIG. 6 and FIG.
7. FIG. 6 is a drawing of a part of the shaped article 50 according
to this embodiment, which is the part of (d) of FIG. 4 from which
the support material has been removed. FIG. 7 is a cross-sectional
view of a shaped article for comparison. The shaped article for
comparison is formed by the multilayer lamination technique
similarly to the shaped article 50 according to this embodiment.
Unlike the shaped article 50, however, this shaped article lacks
parts corresponding to the part 52 of the first transparent layer
and the part 54 of the second transparent layer. In this shaped
article for comparison, therefore, the light reflective layer is
directly coated with the colored layer. Provided that the upper
layer is larger in size (area) along the X-Y plane than the lower
layer in the shaped article for comparison, problems with this
shaped article are described.
[0255] In the shaped article for comparison illustrated in FIG. 7,
the end of the upper layer includes a colored layer 152 (2). The
colored layer 152 (2) is sticking out further than a colored layer
152 (1) formed on the end of the lower layer. This shaped article,
therefore, involves the risk that the inks for the colored layer
discharged to form the stick-out part run off a coloring position
and drop downward.
[0256] The colored layer is the deciding factor for the color tone
of the shaped article. Therefore, thus losing the inks of the
colored layer may cause an intended color tone of the shaped
article to change.
[0257] On the other hand, the shaped article 50 according to this
embodiment illustrated in FIG. 6 has the parts 54 of the second
transparent layer at the ends of the layers 50a. The ink applied to
form the parts 54 of the second transparent layer, even if it falls
downward in FIG. 6, may not adversely affect a color tone desirably
expressed because the colored layer is the deciding factor for the
color tone. This embodiment may thus successfully manufacture the
shaped article 50 that excels in reliability and exhibits a desired
color tone.
[0258] There are other benefits as well. One of them is, forming
the part 54 of the second transparent layer in the first layer 50a
(1) allow a larger formation area (formation allowable region) to
be secured for the colored layer of the second layer 50a (2). This
may help to mitigate a demanded degree of manufacturing accuracy to
some extent, conducing to an improved manufacturing efficiency.
[0259] The ability to secure a larger formation area is
advantageously effective even if the part 54 of the second
transparent layer is formed subsequent to the part 53 of the
colored layer. This disclosure, therefore, further includes forming
the part 54 of the second transparent layer subsequent to the part
53 of the colored layer.
[0260] In the shaped article 50 according to this embodiment, the
surface of the colored layer 3 is coated with the second
transparent layer 4. The second transparent layer 4 thus serves as
the protective layer of the colored layer 3.
[0261] FIG. 4 illustrates an example in which the upper layer is
greater in size (area) along the X-Y plane than the lower layer.
This example refers to the lower half of the shaped article 50 of
FIG. 1 split in two halves.
[0262] The manufacturing method described so far is basically
applicable to the upper-half structure of the shaped article 50 of
FIG. 1 split in two halves. As for the upper half of the shaped
article 50, as illustrated in FIG. 2, the upper colored layer is
nearer to the center side of the layer 50a than the lower colored
layer, and the parts 53 of the upper colored layer overlap the
parts 52 of the lower first transparent layer. Further, the parts
54 of the upper second transparent layer overlap the parts 53 of
the lower colored layer.
[0263] In the upper half of the shaped article 50, as illustrated
in FIG. 2, the lower layers are greater in size (area) along the
X-Y plane than the upper layers formed thereon. In this upper-half
structure, the ink applied to form the colored layer in the upper
layers is very unlikely to drop downward. No support material may
be necessary at the time of manufacturing the upper-half
structure.
[0264] In the shaped article of FIG. 2 according to this
embodiment, the bottom layer and layers nearby, and the top layer
and layers nearby include: a layer solely having the part 52 of the
first transparent layer, part 53 of the colored layer, and part 54
of the second transparent layer; a layer solely having the part 53
of the colored layer and the part 54 of the second transparent
layer; and a layer solely having the part 54 of the second
transparent layer. This multilayered structure may effectuate a
shaped article whose entire surface is covered with the second
transparent layer 4, colored layer 3, and first transparent layer
2. This disclosure, however, is not limited to such a multilayered
structure. For example, the top and bottom surfaces of the shaped
article may include none of the second transparent layer, colored
layer, or first transparent layer, as in the multilayered structure
of FIG. 9 described later.
[0265] [8] Modified Example
First Modified Example
[0266] The shaped article 50 according to this embodiment includes
the first transparent layer 2, colored layer 3, and second
transparent layer 4 that are formed along the surface of the light
reflective layer 1. However, this disclosure may include but is not
limited to such a structure, and may optionally have a shaped
article illustrated in FIG. 8.
[0267] In the shaped articles illustrated in (a).about.(d) of FIG.
8, the second transparent layer 4 may have a shape described below
instead of the shape along the surface of the light reflective
layer 1. Because the parts 54 of the second transparent layer
constitute the ends of the layers 50a (FIG. 2), the second
transparent layer 4 may be formed in an adequate shape that
contains therein the shaped article (structure described in the
earlier embodiment including the colored layer 3, first transparent
layer, and light reflective layer), as illustrated in (a).about.(d)
of FIG. 8.
[0268] Containing the shaped article in the shape formed by the
second transparent layer 4, as described in this first modified
example, may be useful for any shaped articles that are
mechanically fragile. For example, this modified example may be
effectively applicable when, for example, molding insects' legs and
wings, and stems and petals of flowering plants. When molding
organisms and plants in the form of decorative ornaments or
specimens, they can be scanned alive by a three-dimensional scanner
and released again into the nature when the molding is over. A
further benefit may be eco-friendliness because no support material
is necessary, producing no waste material.
[0269] In the shaped article illustrated in (a) of FIG. 8, the
second transparent layer 4 has a hexahedral shape that contains a
spherical body including the colored layer 3, first transparent
layer, and light reflective layer. The structure illustrated in (a)
of FIG. 8 may be obtained by a manufacturing method similar to the
method of FIG. 4.
[0270] In FIG. 8, (b) illustrates a shaped article 50 of
frame-mounted type, wherein a figure including the colored layer 3,
first transparent layer, and light reflective layer is contained in
the second transparent layer 4. This is a free-standing shaped
article 50 supported by the second transparent layer 4. This shaped
article 50 of frame-mounted type may be manufactured (fabricated)
by the manufacturing method described in the earlier
embodiment.
[0271] In FIG. 8, (c) illustrates a shaped article 50 for use as a
strap, wherein a figure including the colored layer 3, first
transparent layer, and light reflective layer is contained in the
second transparent layer 4, and a hole 70 is formed in a part of
the second transparent layer 4. This may be used as a strap or a
key holder attachable to, for example, a mobile telephone. The hole
70 of the second transparent layer 4 may be formed at the same time
when the outer shape is formed by the second transparent layer 4.
By punching a hole in the second transparent layer 4, the figure
including the colored layer 3, first transparent layer, and light
reflective layer can avoid being damaged with a hole.
[0272] In the shaped article 50 illustrated in (d) of FIG. 8, the
upper-half of a figure's body including the colored layer 3, first
transparent layer, and light reflective layer is contained in the
second transparent layer 4. This article 50 has, on the surface or
inside of the second transparent layer 4, a three-dimensional image
71 decorated with a mark or a frame or painted in a pale color.
This shaped article 50 further has, on the surface or inside of the
second transparent layer 4, a letter/character area 72 with letters
and/or characters representing date, name, or place. The decorated
three-dimensional image 71 and the letter/character area 72 may be
formed at the same time when the outer shape is formed by the
second transparent layer 4. Instead of the decorated
three-dimensional image 71 and the letter/character area 72, other
additional information may be displayed on the surface or inside of
the second transparent layer 4.
[0273] In (b).about.(d) of FIG. 8, one figure is contained in the
second transparent layer 4, however, the number of figures
containable in the second transparent layer 4 may be other than
one.
[0274] In case the shaped article according to this embodiment has
a ring-like shape, the colored layer may be formed near an inner
peripheral end of the ring shape as well as an outer peripheral end
thereof. In conclusion, the colored layer may be formed on the
surface of the shaped article, and the second transparent layer may
be further formed thereon.
[0275] Instead of forming the second transparent layer 4 in any
desired shape as described in this modified example, the second
transparent layer 4 may be formed in a shape suitable for the
surface of the light reflective layer 1 similarly to the earlier
embodiment. In that case, the obtained shaped article may be sealed
in an optionally-shaped resin.
Second Modified Example
[0276] The shaped article 50 according to this embodiment has the
second transparent layer 4 on its outermost side. This disclosure
may achieve its goal in so far as the first transparent layer is
interposed between the colored layer and the light reflective
layer. This disclosure, therefore, may include, as an embodiment, a
shaped article 50' illustrated in cross section in FIG. 9. A second
modified example is hereinafter described referring to FIG. 9 to
FIG11. FIG. 9 is a cross-sectional view of the shaped article 50'
according to the second modified example, illustrated similarly to
FIG. 2. FIG. 10 is a schematic drawing of the lower surface of an
inkjet head device according to the second modified example used in
manufacturing of the shaped article 50'. FIG. 11 shows drawings of
manufacturing steps for the shaped article 50' according to the
second modified example.
[0277] A difference between the shaped article 50' according to the
second modified example and the shaped article 50 according to the
earlier embodiment is that the shaped article 50' according to the
second modified example has the colored layer 3 as its outermost
layer, unlike the shaped article 50 whose outermost layer is the
second transparent layer 4.
[0278] Referring to FIG. 9, layers 50'a constituting the shaped
article 50' according to the second modified example include no
part 54 of the second transparent layer, unlike the layers 50a
according to the earlier embodiment (FIG. 2) having these parts 54
at their ends.
[0279] In the layers 50'a of the shaped article 50' illustrated in
FIG. 9, the parts 52 of the first transparent layer are interposed
between the parts 53 of the colored layer and the parts 51 of the
light reflective layer. This may prevent the coloring inks applied
to form the parts 53 of the colored layer from blending into the
ink of the parts 51 of the light reflective layer. Even if the
coloring inks of the part 53 of the colored layer are mixed with
the transparent ink of the part 52 of the first transparent layer,
intermixing of these inks may cause no undesirable change to the
color tone of the part 53 of the colored layer. Therefore, the
resulting shaped article exhibits a desired color tone expressed by
the colored layer.
[0280] A manufacturing method for the shaped article 50' of FIG. 9
is hereinafter described. The shaped article 50' of FIG. 9 may be
manufactured by an inkjet head device 10' illustrated in FIG.
10.
[0281] The inkjet head device 10' illustrated in FIG. 10 has, on
its lower surface, roughly two inkjet heads 11H' and 12H'. As
illustrated in FIG. 10, the first inkjet head 11H' and the second
inkjet head 12H' are displaced from each other in both of the X and
Y directions.
[0282] The first inkjet head 11H' is the same as the first inkjet
head 11H illustrated in FIG. 3.
[0283] The second inkjet head 12H' includes a white ink nozzle 10
(W) for discharging a white ink (W) used to form the light
reflective layer 1 (parts 51 of the light reflective layer), and a
transparent ink nozzle 10 (CL) for discharging a transparent ink
(CL).
[0284] The steps of manufacturing the shaped article 50' using the
inkjet head device 10' are hereinafter described referring to FIG.
11.
[0285] In step S1' illustrated in (a) of FIG. 11, the part 52 of
the first transparent layer is formed from the transparent ink, and
the part 51 of the light reflective layer is formed from the white
ink (W). In this step, the inkjet head device 10' is moved in a
negative direction along the X axis, and the transparent ink is
discharged at a predetermined timing through the transparent ink
nozzle 10 (CL), and the white ink (W) is discharged at a
predetermined timing through the white ink nozzle 10 (W). The
discharged inks land on a position at which the part 52 of the
first transparent layer should be formed and a position at which
the part 51 of the light reflective layer should be formed. Then,
the discharged inks pooled at the respective positions are
irradiated with ultraviolet light to be cured. As a result, the
part 52 of the first transparent layer and the part 51 of the light
reflective layer are formed as illustrated in (a) of FIG. 11.
[0286] In step S2' illustrated in (b) of FIG. 11, the inkjet head
device 10' is moved in a positive direction along the X axis, and
the colored layer forming inks including the coloring inks are
discharged at a predetermined timing to land on a position at which
the part 53 of the colored layer should be formed. Then, the
discharged ink pooled at the position is irradiated with
ultraviolet light to be cured.
[0287] As a result of steps S1 and S2, the formation of a layer
50'a is completed. The support material 60 described in the earlier
embodiment is formed in the second modified example as well.
[0288] After the layer 50'a illustrated in (b) of FIG. 11 is
formed, a new layer 50'a is formed on the layer 50'a of (b) of FIG.
11 in steps similar to steps S1' and S2'.
[0289] Specifically, step S3' illustrated in (c) of FIG. 11 forms
the part 52 of the first transparent layer and the part 51 of the
light reflective layer in a manner similar to step S1'. In step
S3', the upper layer 50'a needs to be formed in a greater size
(area) along the X-Y plane than the lower layer 50'a, as described
in the earlier embodiment. To this end, as illustrated in (c) of
FIG. 11, the transparent ink is discharged so that the part 52 of
the first transparent layer in the upper layer 50'a overlaps the
part 53 of the colored layer in the lower layer 50'a already formed
by the time when step S2' is completed. At the same time, the white
ink (W) is discharged and pooled so that the part 51 of the light
reflective layer in the upper layer 50'a overlaps the part 51 of
the light reflective layer and the part 52 of the first transparent
layer in the lower layer 50'a. Then, the pooled ink is irradiated
with ultraviolet light to be cured.
[0290] In step S4' illustrated in (d) of FIG. 11, the colored layer
forming inks are discharged at a predetermined timing in a manner
similar to step S1' to land on a position at which the part 53 of
the colored layer should be formed and pooled at the position. The
predetermined timing refers to a timing of discharging the colored
layer forming inks on the outer side of the part 52 of the first
transparent layer in the upper layer 50'a with no overlap with the
part 53 of the colored layer in the lower layer 50'a. The pooled
ink is irradiated with ultraviolet light and thereby cured. Then,
the part 53 of the colored layer in the upper layer 50'a is
formed.
[0291] By repeatedly forming and stacking the layers 50'a on one
another, the shaped article 50' illustrated in FIG. 9 may be
manufactured.
Third Modified Example
[0292] In the embodiment described earlier, the shaped article 50
is manufactured by the inkjet head device 10 illustrated in FIG. 3.
In the second modified example, the shaped article 50' is
manufactured by the inkjet head device 10' illustrated in FIG. 10.
Instead of these inkjet head devices, inkjet head devices
illustrated in FIG. 12 to FIG. 14 may be used.
[0293] FIG. 12 is a drawing of a modified example of the inkjet
head device, illustrated similarly to FIG. 3 and FIG10. In an
inkjet head device 10a illustrated in FIG. 12, a cyan ink nozzle 10
(C), a magenta ink nozzle 10 (M), a yellow ink nozzle 10 (Y), a
black ink nozzle 10 (K), a white ink nozzle 10 (W), and a
transparent ink nozzle 10 (CL) are arranged in the mentioned order
in the X direction.
[0294] FIG. 13 is a drawing of another modified example of the
inkjet head device, illustrated similarly to FIG. 3 and FIG. 10. In
an inkjet head device 10b illustrated in FIG. 13, a white ink
nozzle 10 (W), a transparent ink nozzle 10 (CL), a yellow ink
nozzle 10 (Y), a magenta ink nozzle 10 (M), a cyan ink nozzle 10
(C), a black ink nozzle 10 (K), a transparent ink nozzle 10 (CL),
and a white ink nozzle 10 (W) are arranged in the mentioned order
in the X direction.
[0295] FIG. 14 is a drawing of yet another modified example of the
inkjet head device. An inkjet head device 10b illustrated in FIG.
14 has a carriage 21 allowed to reciprocate along the X axis, a
plurality of nozzle arrays mounted in the carriage 21, and
ultraviolet irradiators 24a and 24b mounted in the carriage 21. The
carriage 21 is moved in the Y direction to perform a scan, in which
the inks of ultraviolet curing type are discharged from the nozzle
arrays and irradiated with ultraviolet light emitted from the
ultraviolet irradiators 24a and 24b.
[0296] The nozzle arrays are aligned along the X direction as
illustrated in FIG. 14. From the left to right in the X direction
on the drawing are arranged a cyan ink nozzle array C, a magenta
ink nozzle array M, a yellow ink nozzle array Y, a black ink nozzle
array K, a white ink nozzle array W, and a transparent ink nozzle
array CL are aligned in the mentioned order. Since the nozzle
arrays are mounted in the carriage 21, the inks of ultraviolet
curing type are dischargeable from these nozzle arrays while moving
in the X direction with the carriage 21.
[0297] Because all of the nozzles are aligned in the X direction in
FIG. 12, FIG. 13, and FIG. 14, the formation of one layer may be
completed by moving the nozzles once in the X direction and
discharging all of the required ink during the movement. Referring
to FIG. 14, all of the inks may be discharged and irradiated with
ultraviolet light by moving the nozzles just once in the X
direction. This may also be applicable to a layer formed from the
inks of ultraviolet curing type, which may be cured as soon as the
inks are discharged.
[0298] [Additional Remarks]
[0299] The shaped article 50 according to one aspect is a shaped
article 50 formed by the multilayer lamination technique and having
the colored layer 3. This shaped article is further characterized
in that the colored layer 3 has its ink density filled by the
supplementary ink in parts of the colored layer 3 in which the
coloring inks alone are insufficient to meet a predetermined ink
density.
[0300] By forming the colored layer using the coloring inks alone,
the ink density of the colored layer may be partly insufficient,
failing to meet a predetermined ink density. This may generate
irregularities and/or voids in the decorative layer. The
irregularities and/or voids may incur failure to obtain any desired
shape of the shaped article in the manufacturing process. On the
other hand, the shaped article 50 according to one aspect may
eliminate the risk of such irregularities and/or voids because the
ink density of the colored layer 3 is filled by the supplementary
ink. This may allow the shaped article 50 to exhibit a desired
color tone (decorated as desired) and allow the shaped article 50
to be shaped as desired.
[0301] The shaped article 50 according to one aspect is further
characterized in that the supplementary ink includes a transparent
ink. Using the transparent ink may be unlikely to adversely affect
decorative effects expected for the colored layer, successfully
providing a shaped article exhibiting a desired color tone.
[0302] A manufacturing method for the shaped article 50 according
to one aspect is a manufacturing method that employs the multilayer
lamination technique to form the shaped article having the colored
layer 3, further characterized in that the colored layer 3 has its
ink density filled by the supplementary ink in parts of the colored
layer 3 in which coloring inks alone are insufficient to meet a
predetermined ink density.
[0303] By forming the colored layer using the coloring inks alone,
the ink density of the colored layer may be partly insufficient,
failing to meet a predetermined ink density. This may generate
irregularities and/or voids in the decorative layer. The
irregularities and/or voids may incur failure to obtain any desired
shape of the shaped article in the manufacturing process. The
method according to one aspect, on the other hand, may eliminate
the risk of such irregularities and/or voids because the ink
density of the colored layer 3 is filled by the supplementary ink.
This may allow the shaped article 50 to exhibit a desired color
tone (decorated as desired) and allow the shaped article 50 to be
shaped as desired.
[0304] The manufacturing method for the shaped article 50 according
to one aspect is further characterized in including a layer forming
process including forming layers 50a each including a part 53 of
the colored layer, in which one of the layers 50a is newly formed
on another one of the layers 50a so that the parts 53 of the
colored layer in these layers are continuous and thereby form the
colored layer 3, and the layer forming process further includes
filling the ink density of the colored layer using the
supplementary ink in the parts 53 of the colored layer in which the
coloring inks alone are insufficient to meet a predetermined ink
density.
[0305] This method fills the ink density of the colored layer in
the parts 53 of the colored layer formed by the layer forming
process. This method thus advantageous may successfully form layers
with neither irregularity nor void.
[0306] This disclosure is not necessarily limited to the embodiment
described so far and may be carried out in many other forms. The
technical scope of this disclosure encompasses any modifications
within its scope defined by the appended claims and embodiments
obtained by variously combining the technical means disclosed
herein. By variously combining the technical means disclosed in the
embodiment and modified examples, additional technical features may
be further presented.
Third Embodiment
[0307] The inventors of this application found a problem with the
known inkjet 3D molding when a molding ink and decorative inks
(coloring inks of, for example, yellow, magenta, cyan, and black
inks) were discharged by inkjet printing technique. The problem is
that a shaped article may fail to be decorated as desired
(recording of characters and images in colors through subtractive
color mixture). They studied what triggered this problem, and found
out that, when forming a decorative layer formed from decorative
inks as the outermost layer of a shaped article, the decorative
inks for the decorative layer discharged in the gravitational
direction (downward) would possibly fail to arrive at a target
position, dropping downward.
[0308] To address the issue, this disclosure is directed to
providing a shaped article that may be decorated as desired, and a
manufacturing method for such a shaped article.
[0309] A shaped article disclosed herein includes: a light
reflective layer formed from an ink having light reflectiveness; a
decorative layer; and a transparent layer formed from a transparent
ink, wherein the decorative layer is formed on an outer side of the
light reflective layer, and the transparent layer is formed on an
outer side of the decorative layer.
[0310] In this shaped article, a larger formation area including an
area overlapping a part of the transparent layer in addition to an
area overlapping a part of the decorative layer in the lower layer
may be secured for a part of the decorative layer in the upper
layer, as compared to layers lacking the parts of the transparent
layer at positions nearer to the end side than the parts of the
decorative layer. This may help to mitigate a demanded degree of
manufacturing accuracy to some extent, contributing to an improved
manufacturing efficiency.
[0311] To this end, a shaped article manufacturing method disclosed
herein is a manufacturing method for manufacturing a shaped article
by stacking a plurality of layers on one another, the shaped
article including: a transparent layer formed from a transparent
ink; and a decorative layer, wherein the transparent layer and the
decorative layer are formed in this order from an outer-layer side
toward an inner side of the shaped article. This method includes a
layer forming process including forming a part of the transparent
layer and a part of the decorative layer in this order from an end
side toward a center side of at least two of the layers.
[0312] Two or more of the formed layers have the parts of the
transparent layer at positions nearer to the end side than the
parts of the decorative layer. When two or more layers are formed,
even if a layer forming ink applied on the end side of the upper
layer drops downward, the layer formed on the end side is the
transparent layer, not the decorative layer. This may avoid loss of
the decorative layer inks, successfully forming a shaped article
decorated as desired.
[0313] According to this method, a larger formation area including
an area overlapping a part of the transparent layer in addition to
an area overlapping a part of the decorative layer in the lower
layer may be secured for a part of the decorative layer in the
upper layer, as compared to layers lacking the parts of the
transparent layer at positions nearer to the end side than the
parts of the decorative layer. This may help to mitigate a demanded
degree of manufacturing accuracy to some extent, contributing to an
improved manufacturing efficiency.
[0314] The shaped article manufacturing method disclosed herein
according to one aspect is further characterized in that the layer
forming process includes steps of: forming a part of the
transparent layer; and forming a part of the decorative layer,
wherein the step of forming a part of the transparent layer
precedes the step of forming a part of the decorative layer.
[0315] According to this method that forms, in a layer, a part of
the transparent layer before a part of the decorative layer, the
part of the transparent layer may serve as the outer moat of the
part of the decorative layer to be later formed. This may prevent
the ink applied to form the part of the decorative layer from
spreading unintendedly or dropping downward.
[0316] The shaped article manufacturing method disclosed herein
according to one aspect is further characterized in that one of the
layers is newly formed on another one of the layers formed by the
layer forming process, so that a part of the decorative layer in
the layer newly formed overlaps a part of the transparent layer in
the layer below previously formed.
[0317] The shaped article manufacturing method disclosed herein
according to one aspect is further characterized in that one of the
layers is newly formed on another one of the layers formed by the
layer forming process, so that a part of the transparent layer in
the layer newly formed overlaps a part of the decorative layer in
the layer below previously formed.
[0318] This disclosure may provide a shaped article exhibiting a
desired color tone.
[0319] An embodiment of a shaped article and a shaped article
manufacturing method disclosed herein is hereinafter described
referring to FIG. 1 to FIG8. The shaped article disclosed herein
has a three-dimensional structure constructed of a laminate of
layers (formed by multilayer lamination technique). In the
embodiment hereinafter described, inkjet printing technique is
employed to manufacture the shaped article. This is, however, just
an option presented in this disclosure. This disclosure may be
applicable to any kinds of manufacturing methods that can obtain a
shaped article by leveraging the multilayer lamination technique
and decorate its surface (recording of characters and images in
colors).
[0320] [1] Structure of Shaped article
[0321] FIG. 1 is a perspective view of an outer shape of a shaped
article 50 according to an embodiment. The shaped article 50
according to this embodiment has a substantially cylindrical shape
with a curved side surface bulging outward. The shaped article
disclosed herein and the shaped article manufactured by the
manufacturing method disclosed herein may not be limited to the
shape illustrated in FIG. 1. There are many other examples of the
shape, including a hexahedral shape described later, a spherical
shape, a hollow structure, a ring-like shape, and a horseshoe-like
shape.
[0322] The shaped article 50 according to this embodiment includes
a second transparent layer, a colored layer (decorative layer)
formed from colorant-containing inks (decorative ink), a first
transparent layer formed from a transparent ink, and a light
reflective layer formed from an ink having light reflectiveness,
wherein these layers are formed in the mentioned order from an
outer-layer side (outer peripheral side) toward an inner side
(center) of the shaped article 50. This is a distinctive technical
feature of this disclosure. FIG. 1 is a drawing of the shaped
article 50. In this drawing, a second transparent layer 4 formed
from a transparent ink, which is the outermost layer, can be seen
on the curved side surface of the shaped article 50.
[0323] FIG. 2 is a cross-sectional view of the illustration of FIG.
1 taken along a cutting-plane line A-A'. The cross-sectional view
of the shaped article 50 illustrated in FIG. 2 is taken at a
central position of the shaped article 50 along the X-Z plane of
the XYZ coordinate system illustrated in FIG. 1.
[0324] The embodiment of FIG. 2 presents an example of the shaped
article 50 having a three-dimensional structure formed by stacking
21 layers 50a on one another in the Z direction. It should be
understood that the shaped article 50 may include less than or more
than 21 layers.
[0325] [2] Structures of Layers
[0326] FIG. 5 is a drawing of the X-Y plane of a layer 50a in the
vicinity of a mid-stage of the shaped article 50. The layers 50a
each include a part 54 of the second transparent layer, a part 53
of the colored layer, a part 52 of the first transparent layer, and
a part 51 of the light reflective layer. These layers are formed in
the mentioned order from an outer peripheral side toward a center
side of the shaped article. If the shaped article 50 according to
this embodiment is stated another way, the light reflective layer
1, which is the body of the shaped article, is coated with the
first transparent layer 2, colored layer 3, and second transparent
layer 4 in the mentioned order toward the outer-layer side (outer
peripheral side). Each one of the layers 50a has a thickness in the
Z direction (vertical direction in the drawing) between 5 .mu.m and
50 .mu.m. This is an adequate range of thickness values for
multicolor formation of the colored layer 3 using the subtractive
color mixture. For example, a preferable range of thickness values
is 10 .mu.m to 25 .mu.m when layers are formed from inks of
ultraviolet curing type by inkjet printing technique.
[0327] In this embodiment, the light reflective layer 1 is the body
of the shaped article; however, the light reflective layer may or
may not constitute the body of the shaped article. Specifically,
the shaped article may have, at its center, a body or a cavity
apart from the light reflective layer, wherein the light reflective
layer, first transparent layer, colored layer, and second
transparent layer are formed in the mentioned order from the body
(may or may not have light reflectiveness) toward the outer-layer
side (outer peripheral side). Alternatively, a core (may or may not
have light reflectiveness) and the light reflective layer 1 formed
on a surface of the core may be collectively regarded as the body
of the shaped article.
[0328] By stacking the layers 50a in the Z direction as illustrated
in FIG. 2, the parts 54 of the second transparent layer in the
respective layers 50a are substantially continuous in a direction
along the outermost surface of the shaped article 50, forming the
second transparent layer 4. The parts 53 of the colored layer in
the respective layers 50a are substantially continuous in the
direction along the outermost surface of the shaped article 50,
forming the colored layer 3. The parts 52 of the first transparent
layer in the respective layers 50a are substantially continuous in
the direction along the outermost surface of the shaped article 50,
forming the first transparent layer 2. The parts 51 of the light
reflective layer in the respective layers 50a are substantially
continuous in the direction along the outermost surface of the
shaped article 50, forming the light reflective layer 1.
[0329] Looking at, in any of the X, Y, and Z directions, the outer
surface of the shaped article 50 including the second transparent
layer, colored layer, first transparent layer, and light reflective
layer arranged in the mentioned order, a color tone produced by the
subtractive color mixture may be visually recognized.
[0330] The parts 52 of the first transparent layer may preferably
have a dimension in the direction of X-Y plane slightly greater
than the part 53 of the colored layer vertically in contact with
the parts 52. This may more reliably prevent intermixing of the
inks forming the colored layer 3 and the light reflective layer
1.
[0331] The parts 54 of the second transparent layer may preferably
have a dimension in the direction of X-Y plane slightly greater
than the parts 53 of the colored layer vertically in contact with
the parts 54. This may provide for better protection of the colored
layer 3.
[0332] The width of the shaped article 50 along the Z direction
(hereinafter may be referred to as thickness or height in the Z
direction) is not particularly limited. The thickness (height) of
the layer 50a in the Z direction may be optionally decided
depending on the number of layers. As described later, this
embodiment constructs the multilayered structure using the inkjet
printing technique. Therefore, any feasible values in the technique
should be contemplated for the thickness of the layer 50a in the Z
direction. When inks of ultraviolet curing type are applied by
inkjet printing technique to form the layers (described later), the
layer 50a may have a thickness ranging from 5 .mu.m to 20 .mu.m
depending on the sizes of ink droplets. As for a large-sized shaped
article for which a high resolution is not particularly required,
plural layers may be formed based on the same data simply by
increasing the sizes of ink droplets. In such a case, a smaller
data volume and a higher molding rate may be anticipated.
[0333] [3] Structure of Light Reflective Layer 1 (Parts 51 of Light
Reflective Layer)
[0334] The light reflective layer 1 (parts 51 of the light
reflective layer) is a layer formed from a light reflective ink.
This layer, therefore, has light reflectiveness that allows rays of
light in the whole visible light region to be reflected on at least
the surface of the light reflective layer 1 in contact with the
colored layer.
[0335] Specific examples of ink of the light reflective layer 1
(parts 51 of the light reflective layer) may include metallic
powder-containing inks and white pigment-containing inks. The light
reflective layer 1 may preferably be formed from a white ink. The
light reflective layer 1 formed from a white ink may adequately
reflect rays of light entering from the outer-layer side of the
shaped article, allowing the shaped article to be colored by the
subtractive color mixture.
[0336] In this embodiment, the light reflective layer 1 constitutes
the body of the shaped article. In case the light reflective layer
1 is formed on the surface of the body of any shaped article for
which light reflectiveness is not required, the thickness of the
light reflective layer 1, i.e., the width of the part 51 of the
light reflective layer from the outer peripheral side to the center
side, as illustrated in FIG. 2, may be between 5 .mu.m and 20 .mu.m
at the least. The width in this disclosure may include but is not
limited to the range of values.
[0337] [4] Structure of First Transparent Layer 2 (Parts 52 of
First Transparent Layer)
[0338] The first transparent layer 2 (parts 52 of the first
transparent layer) is formed from a transparent ink.
[0339] The transparent ink may refer to an ink capable of forming a
transparent layer having light transmittance greater than or equal
to 50% per unit thickness. The light transmittance less than 50%
per unit thickness of the transparent layer may unintendedly block
the transmission of light. This may be a drawback that fails to
exhibit a desired color tone of the shaped article by way of the
subtractive color mixture. Preferably is used an ink having light
transmittance greater than or equal to 80% per unit thickness of
the transparent layer. Further, an ink having light transmittance
greater than or equal to 90% per unit thickness of the transparent
layer is particularly preferable.
[0340] By interposing the first transparent layer 2 (part 52 of the
first transparent layer) between the light reflective layer 1 (part
51 of the light reflective layer) and the colored layer 3 (part 53
of the colored layer), intermixing of the coloring inks of the
colored layer 3 and the ink of the light reflective layer 1 may be
avoidable. Even if the coloring inks applied to form the colored
layer are mixed with the transparent ink of the first transparent
layer, intermixing of these inks may not adversely affect colors of
the colored layer or cause any undesirable change to the color
tone. Therefore, the resulting shaped article exhibits a desired
color tone (decorated as desired) expressed by the colored layer
3.
[0341] The width of the part 52 of the first transparent layer from
the outer peripheral side to the center side (hereinafter, referred
to as the thickness of the first transparent layer) is between 5
.mu.m and 20 .mu.m at the least in a decorated portion on a surface
perpendicular to the layer-stacked direction. The width in this
disclosure may include but is not limited to the range of
values.
[0342] [5] Structure of Colored Layer 3 (Part 53 of Colored
Layer)
[0343] The colored layer 3 (part 53 of the colored layer) is formed
from a colorant-containing coloring ink.
[0344] Examples of the colorant-containing inks (hereinafter may be
referred to as coloring ink) may include but are not limited to
yellow (Y), magenta (M), cyan (C), black (K), and pale color inks.
Further, red (R), green (G), blue (B), and orange (Or) color inks
may be additionally used. Other usable inks may include metallic,
pearl, and phosphor inks. One or more than one of these coloring
inks may preferably be used to express a desired color tone.
[0345] The amounts of the coloring inks to form the colored layer 3
(parts 53 of the colored layer) may be variable depending on a
desired (desirably expressed) color tone. In case the coloring inks
alone are used to express a bright color tone at a relatively low
concentration, the ink density of the colored layer 3 may fail to
meet a predetermined ink density. This may generate irregularities
in the Z direction and/or ink-less dented parts at positions along
the X-Y direction. In any case, the shaped article formed by the
multilayer lamination technique, as described in this embodiment,
may consequently have an irregular, unattractive shape, which is
desirably avoided. In case one cross-sectional surface of the
colored layer 3 has the ink density of two lateral and two vertical
ink droplets; four ink droplets in total, formed by the error
diffusion method on a vertical mold surface near the mid position
of the multilayered structure illustrated in FIG. 2, the coloring
inks each form four ink droplets at the most (largest
concentration) and no ink droplet at the least (zero concentration,
meaning colorless). The number of ink droplets being zero may leave
an unfilled space as large as four ink droplets, significantly
degrading the shaped article in view of its shape and color
tone.
[0346] This embodiment, therefore, fills the ink density of the
colored layer 3 (part 53 of the colored layer) using a
supplementary ink in parts of the colored layer 3 (part 53 of the
colored layer) in which the coloring inks alone are insufficient to
meet a predetermined ink density. Specifically, the colored layer 3
(parts 53 of the colored layer) is formed at a constant total
density (number of ink droplets) of the coloring inks and the
supplementary ink. This may successfully prevent the formation of
dented parts, allowing the shaped article 50 to be elaborately
shaped.
[0347] The amounts of the coloring inks to be discharged and their
landing positions are known beforehand, based on which the amount
and position (landing position) of the supplementary ink to be
additionally discharged may be suitably determined. The amount and
position may be decided by an inkjet head device 10 or by a
controller not illustrated in the drawings.
[0348] Having the ink density filled by the supplementary ink may
allow a surface formed by the colored layer 3 to be flattened,
imparting glossiness to the surface.
[0349] The supplementary ink may be any ink unless it adversely
affects the color tone to be expressed by the colored layer 3
(parts 53 of the colored layer). An example of the supplementary
ink may be the transparent ink used to form the first transparent
layer 2 (parts 52 of the first transparent layer) and the second
transparent layer 4 (parts 54 of the second transparent layer).
[0350] The thickness of the colored layer 3, i.e., the width of the
part 53 of the colored layer from the outer peripheral side to the
center side illustrated in FIG. 2 (hereinafter, referred to as the
thickness of the colored layer 3) may be between 5 .mu.m and 20
.mu.m.
[0351] The colored layer 3 described in this embodiment is just an
option and may be any decorative layer.
[0352] [6] Structure of Second Transparent Layer 4 (Parts 54 of
Second Transparent Layer)
[0353] The second transparent layer 4 (parts 54 of the second
transparent layer) is formed from the same transparent ink as that
of the first transparent layer 2 (parts 52 of the first transparent
layer). The same transparent ink or different transparent inks may
be used to form the second transparent layer 4 and the first
transparent layer 2.
[0354] The thickness of the second transparent layer 4, i.e., the
width of the part 54 of the second transparent layer from the outer
peripheral side to the center side illustrated in FIG. 2
(hereinafter, referred to as the thickness of the second
transparent layer 4) may be between 10 .mu.m and 100 .mu.m.
[0355] The second transparent layer 4 functions as a protective
layer for the colored layer 3. In this disclosure that employs the
multilayer lamination technique (this embodiment), the second
transparent layer 4 may also advantageously contribute to
elaborateness of the shaped article.
[0356] Supposing that the colored layer 3 is the outermost layer of
the shaped article 50, i.e., the parts 53 of the colored layer are
located at the farthest ends of the respective layers 50a
illustrated in FIG. 2, the colored layer 3 (parts 53 of the colored
layer) formed may not be as accurate as expected. On the other
hand, the shaped article 50 whose outermost layer is the second
transparent layer 4 (parts 54 of the second transparent layer), as
described in this embodiment, may ensure the accuracy of the
colored layer 3 (parts 53 of the colored layer). Thus, the second
transparent layer 4 (parts 54 of the second transparent layer) may
greatly contribute to a desired color tone.
[0357] Another disadvantage in case the colored layer 3 is the
outermost layer of the shaped article 50 is that the exposed
colored layer 3 may be prone to decolorization under friction and
color fading by exposure to ultraviolet. However, as described in
this embodiment, the shaped article 50 whose outermost layer is the
second transparent layer 4 (parts 54 of the second transparent
layer) may prevent such unfavorable events as decolorization and
color fading.
[0358] [7] Manufacturing Method for Shaped article
[0359] A manufacturing method for the shaped article 50 according
to this embodiment is hereinafter described. FIG. 3 is a drawing of
the lower surface of the inkjet head device 10 used in the
manufacturing method. FIG. 4 shows schematic drawings of ongoing
steps of manufacturing the shaped article 50 according to this
embodiment.
[0360] The inkjet head device 10 has, on its lower surface, roughly
three inkjet heads 11H to 13H. As illustrated in FIG. 3, the first
inkjet head 11H, second inkjet head 12H, and third inkjet head 13H
are displaced from one another in the X direction. As illustrated
in FIG. 3, the first inkjet head 11H, second inkjet head 12H, and
third inkjet head 13H are also displaced from one another in the Y
direction. Thus, the inkjet heads 11H to 13H are positioned in,
generally called, staggered arrangement.
[0361] The first inkjet head 11H has a cyan ink nozzle 10 (C) for
discharging a cyan ink, a magenta ink nozzle 10 (M) for discharging
a magenta ink, a yellow ink nozzle 10 (Y) for discharging a yellow
ink, and a black ink nozzle 10 (K) for discharging a black ink. The
number and the order of arrangement of the nozzles 10 (C), 10 (M),
10 (Y), and 10 (K) are not limited to the example illustrated in
FIG. 3. All of the inks discharged through these nozzles are
coloring inks used to form the colored layer 3 (parts 53 of the
colored layer) illustrated in FIG. 2.
[0362] The second inkjet head 12H has a white ink nozzle 10 (W) for
discharging a white ink (W). The white ink (W) is an ink used to
form the light reflective layer 1 (parts 51 of the light reflective
layer) illustrated in FIG. 2.
[0363] The third inkjet head 13H has a transparent ink nozzle 10
(CL) for discharging a transparent ink (CL). The transparent ink
(CL) is an ink used to form the first transparent layer 2 (parts 52
of the first transparent layer) and the second transparent layer 4
(parts 54 of the second transparent layer) illustrated in FIG.
2.
[0364] The inkjet head device 10 is located so as to have its lower
surface illustrated in FIG. 3 face the layer 50a currently being
formed. The inkjet head device 10 is configured to reciprocate in
the X direction and discharge the inks while moving in the
direction. The inkjet head device 10 is moved in a predetermined
direction in an XYZ coordinate system, or a table with the formed
layers 50a placed thereon (FIG. 4 shows a layer formation surface B
of the table) is moved in a predetermined direction in the XYZ
coordinate system to change relative positions of the inkjet head
device 10 and the layer 50a currently being formed. Which one of
them should be moved may be optionally decided.
[0365] Each of the inks is an ink of ultraviolet curing type that
needs to be irradiated with ultraviolet light after being
discharged. A ultraviolet irradiator may be mounted in the inkjet
head device 10 or may be installed as a separate device. The inks
are cured by being irradiated with ultraviolet light to form the
layers 50a illustrated in FIG. 2.
[0366] The manufacturing process for the shaped article 50 using
the inkjet head device 10 is hereinafter described referring to
FIG. 4.
[0367] To start with, a first one of the layers 50a (first layer
50a (1)) is formed on the layer formation surface B of the
table.
[0368] In the step of forming (manufacturing) the first layer 50a
(1), by using the inkjet printing technique, the respective inks
are discharged from the inkjet head device 10 at predetermined
timings to form a part of the second transparent layer, a part of
the colored layer, a part of the first transparent layer, and a
part of the light reflective layer in the mentioned order from the
end side toward the center side of the first layer 50a.
[0369] The steps of forming (manufacturing) the first layer 50a (1)
are described in further detail referring to (a).about.(c) of FIG.
4.
[0370] In step S1 illustrated in (a) of FIG. 4, the part 54 of the
second transparent layer is formed from the transparent ink, and
the part 52 of the first transparent layer is formed from the
transparent ink. In this step, the inkjet head device 10 is moved
in a positive direction along the X axis, and the transparent ink
is discharged at a predetermined timing through the transparent ink
nozzle 10 (CL) illustrated in FIG. 3. The discharged ink lands on a
position at which the part 54 of the second transparent layer
should be formed and a position at which the part 52 of the first
transparent layer should be formed. Then, the discharged ink pooled
at the respective positions is irradiated with ultraviolet light to
be cured. As a result, the part 52 of the first transparent layer
and the part 54 of the second transparent layer are formed as
illustrated in (a) of FIG. 4.
[0371] In step S2 illustrated in (b) of FIG. 4, the inkjet head
device 10 is moved in a negative direction along the X axis, and
the white ink (W), which is the light reflective ink, is discharged
at a predetermined timing through the white ink nozzle 10 (W).
Then, the discharged ink pooled there is irradiated with
ultraviolet light to be cured. As a result, the part 51 of the
light reflective layer is formed as illustrated in (b) of FIG.
4.
[0372] In step S3 illustrated in (c) of FIG. 4, the inkjet head
device 10 is moved in the positive direction along the X axis, and
the colored layer forming inks including the coloring inks and the
supplementary ink are discharged at a predetermined timing so that
the total amount of these inks discharged is constant, and then
irradiated with ultraviolet light. The predetermined timing refers
to a timing at which the nozzles of the first inkjet head 11H are
located at positions at which the colored layer forming inks are
dischargeable in a region between the part 52 of the first
transparent layer and the part 54 of the second transparent layer
formed in step S1. The ink droplets in a predetermined amount are
discharged by inkjet printing technique at this timing to form a
pool of ink. Then, the pooled ink is irradiated with ultraviolet
light to be cured. This forms the part 53 of the colored layer 53
exhibiting a desired color tone between the part 52 of the first
transparent layer and the part 54 of the second transparent layer
as illustrated in (c) of FIG. 4.
[0373] As a result of steps S1 to S3, the formation of the first
layer 50a (1) is completed. The first layer 50a (1) has the same
structure as illustrated in the upper view of the layer 50a in FIG.
5. Optionally, step 1 and step 2 may be performed in the reversed
order. Likewise, step S2 and step S3 may be performed in the
reversed order.
[0374] After the first layer 50a (1) is formed, a new layer 50a
(second layer 50a (2)) is formed on the first layer 50a (1)
(laminate of layers).
[0375] In the shaped article 50 according to this embodiment, the
layers 50a stacked on one another are progressively increased in
size (area) from the bottom toward the mid stage of the
multilayered body as illustrated in FIG. 2. In the shaped article
50 manufactured in such a shape that increases in size along the
layer-stacked direction when viewed in cross section, the end of
one layer 50a is sticking out sideways further than the end of
another layer 50a already formed below the one layer 50a. To form
the layers 50a thus characterized, support material layers may
preferably be formed.
[0376] In FIG. 4, (d) is a drawing of the step of forming the
second layer 50a (2). Referring to this drawing, a part 53 (2) of
the colored layer in the second layer 50a (2) is formed so as to
overlap a part 54 (1) of the second transparent layer in the first
layer 50a (1). Since the second layer 50a (2) is greater in size
(area) along the X-Y plane than the first layer 50a (1), the part
54 (2) of the second transparent layer forming the end of the
second layer 50a (2) is sticking out sideways further than the part
54 (1) of the second transparent layer forming the end of the first
layer 50a (1). Because of this structure, the ink to be deposited
on a part of the layer 50a (2) where the stick-out part should be
formed possibly runs off this part and drops downward. To avoid
that, a support material 60 is formed on the outer side (on the
lateral side) than the part 54 (1) of the second transparent layer
in the first layer 50a (1).
[0377] The support material 60 may preferably be formed from any
ink that can be discharged by inkjet printing technique. The
support material 60 should preferably have enough strength not to
collapse under the weight of another layer formed thereon. The
support material 60 per se will not be left in the finalized shaped
article 50. The ink forming the support material 60, therefore,
should preferably be selected from inks that can be stripped off
afterwards. The ink of the support material 60 may preferably be
curable by ultraviolet light (to a degree of cure at which the ink
is stripped off in subsequent steps), or may be a water-soluble ink
that can be dissolved in water and removed in subsequent steps.
[0378] The steps of forming the layers 50a are repeatedly performed
in the X and Y directions as many times as required to form one
layer, and then repeatedly performed again in the Z direction. As a
result, the shaped article 50 illustrated in FIG. 2 is finally
obtained. During the steps of forming one layer, the known
interlace scan conventionally employed to form two-dimensional
images may preferably be performed to obtain a shaped article with
less unevenness in shape and favorably decorated.
[0379] The shaped article manufacturing method according to this
embodiment is further characterized in that the layer forming
process includes steps of: forming the part 54 of the second
transparent layer using the transparent ink; forming the part 53 of
the colored layer using the coloring inks; forming the part 52 of
the first transparent layer using the transparent ink; and forming
the part 51 of the light reflective layer using the light
reflective ink, wherein the step of forming the part 53 of the
colored layer is performed subsequent to the step of forming the
part 52 of the first transparent layer and the step of forming the
part 54 of the second transparent layer to form the part 53 of the
colored layer between the part 52 of the first transparent layer
and the part 54 of the second transparent layer. When the part 53
of the colored layer is formed, the part 54 of the second
transparent layer may serve as the outer moat of the pooled inks to
form the colored layer. This may prevent the ink of the colored
layer from spreading unintendedly, ensuring a high accuracy of the
part 53 of the colored layer.
[0380] Further benefits delivered by forming the part 54 of the
second transparent layer are described referring to FIG. 6 and FIG.
7. FIG. 6 is a drawing of a part of the shaped article 50 according
to this embodiment, which is the part of (d) of FIG. 4 from which
the support material has been removed. FIG. 7 is a cross-sectional
view of a shaped article for comparison. The shaped article for
comparison is formed by the multilayer lamination technique
similarly to the shaped article 50 according to this embodiment.
Unlike the shaped article 50, however, this shaped article lacks
parts corresponding to the part 52 of the first transparent layer
and the part 54 of the second transparent layer. In this shaped
article for comparison, therefore, the light reflective layer is
directly coated with the colored layer. Provided that the upper
layer is larger in size (area) along the X-Y plane than the lower
layer in the shaped article for comparison, problems with this
shaped article are described.
[0381] In the shaped article for comparison illustrated in FIG. 7,
the end of the upper layer includes a colored layer 152 (2). The
colored layer 152 (2) is sticking out further than a colored layer
152 (1) formed on the end of the lower layer. This shaped article,
therefore, involves the risk that the inks for the colored layer
discharged to form the stick-out part run off a coloring position
and drop downward.
[0382] The colored layer is the deciding factor for the color tone
of the shaped article. Therefore, thus losing the inks of the
colored layer may cause an intended color tone of the shaped
article to change.
[0383] On the other hand, the shaped article 50 according to this
embodiment illustrated in FIG. 6 has the parts 54 of the second
transparent layer at the ends of the layers 50a. The ink applied to
form the parts 54 of the second transparent layer, even if it falls
downward in FIG. 6, may not adversely affect a color tone desirably
expressed because the colored layer is the deciding factor for the
color tone. This embodiment may thus successfully manufacture the
shaped article 50 that excels in reliability and exhibits a desired
color tone.
[0384] There are other benefits as well. One of them is, forming
the part 54 of the second transparent layer in the first layer 50a
(1) allow a larger formation area to be secured for the colored
layer of the second layer 50a (2). This may help to mitigate a
demanded degree of manufacturing accuracy to some extent, conducing
to an improved manufacturing efficiency.
[0385] The ability to secure a larger formation area is
advantageously effective even if the part 54 of the second
transparent layer is formed subsequent to the part 53 of the
colored layer. This disclosure, therefore, further includes forming
the part 54 of the second transparent layer subsequent to the part
53 of the colored layer.
[0386] In the shaped article 50 according to this embodiment, the
surface of the colored layer 3 is coated with the second
transparent layer 4. The second transparent layer 4 thus serves as
the protective layer of the colored layer 3.
[0387] FIG. 4 illustrates an example in which the upper layer is
greater in size (area) along the X-Y plane than the lower layer.
This example refers to the lower half of the shaped article 50 of
FIG. 1 split in two halves.
[0388] The manufacturing method described so far is basically
applicable to the upper-half structure of the shaped article 50 of
FIG. 1 split in two halves. As for the upper half of the shaped
article 50, as illustrated in FIG. 2, the upper colored layer is
nearer to the center side of the layer 50a than the lower colored
layer, and the parts 53 of the upper colored layer overlap the
parts 52 of the lower first transparent layer. Further, the parts
54 of the upper second transparent layer overlap the parts 53 of
the lower colored layer.
[0389] In the upper half of the shaped article 50, as illustrated
in FIG. 2, the lower layers are greater in size (area) along the
X-Y plane than the upper layers formed thereon. In this upper-half
structure, the ink applied to form the colored layer in the upper
layers is very unlikely to drop downward. No support material may
be necessary at the time of manufacturing the upper-half
structure.
[0390] In the shaped article of FIG. 2 according to this
embodiment, the bottom layer and layers nearby, and the top layer
and layers nearby include: a layer solely having the part 52 of the
first transparent layer, part 53 of the colored layer, and part 54
of the second transparent layer; a layer solely having the part 53
of the colored layer and the part 54 of the second transparent
layer; and a layer solely having the part 54 of the second
transparent layer. This multilayered structure may effectuate a
shaped article whose entire surface is covered with the second
transparent layer 4, colored layer 3, and first transparent layer
2. This disclosure, however, is not limited to such a structure.
For example, the top and bottom surfaces of the shaped article may
include none of the second transparent layer, colored layer, or
first transparent layer.
[8] Modified Example
First Modified Example
[0391] The shaped article 50 according to this embodiment includes
the first transparent layer 2, colored layer 3, and second
transparent layer 4 that are formed along the surface of the light
reflective layer 1. However, this disclosure may include but is not
limited to such a structure, and may optionally have a shaped
article illustrated in FIG. 8.
[0392] In the shaped articles illustrated in (a).about.(d) of FIG.
8, the second transparent layer 4 may have a shape described below
instead of the shape along the surface of the light reflective
layer 1. Because the parts 54 of the second transparent layer
constitute the ends of the layers 50a (FIG. 2), the second
transparent layer 4 may be formed in an adequate shape that
contains therein the shaped article (structure described in the
earlier embodiment including the colored layer 3, first transparent
layer, and light reflective layer), as illustrated in (a).about.(d)
of FIG. 8.
[0393] Containing the shaped article in the shape formed by the
second transparent layer 4, as described in this first modified
example, may be useful for any shaped articles that are
mechanically fragile. For example, this modified example may be
effectively applicable when, for example, molding insects' legs and
wings, and stems and petals of flowering plants. When molding
organisms and plants in the form of decorative ornaments or
specimens, they can be scanned alive by a three-dimensional scanner
and released again into the nature when the molding is over. A
further benefit may be eco-friendliness because no support material
is necessary, producing no waste material.
[0394] In the shaped article illustrated in (a) of FIG. 8, the
second transparent layer 4 has a hexahedral shape that contains a
spherical body including the colored layer 3, first transparent
layer, and light reflective layer. The structure illustrated in (a)
of FIG. 8 may be obtained by a manufacturing method similar to the
method of FIG. 4.
[0395] In FIG. 8, (b) illustrates a shaped article 50 of
frame-mounted type, wherein a figure including the colored layer 3,
first transparent layer, and light reflective layer is contained in
the second transparent layer 4. This is a free-standing shaped
article 50 supported by the second transparent layer 4. This shaped
article 50 of frame-mounted type may be manufactured (fabricated)
by the manufacturing method described in the earlier
embodiment.
[0396] In FIG. 8, (c) illustrates a shaped article 50 for use as a
strap, wherein a figure including the colored layer 3, first
transparent layer, and light reflective layer is contained in the
second transparent layer 4, and a hole 70 is formed in a part of
the second transparent layer 4. This may be used as a strap or a
key holder attachable to, for example, a mobile telephone. The hole
70 of the second transparent layer 4 may be formed at the same time
when the outer shape is formed by the second transparent layer 4.
By punching a hole in the second transparent layer 4, the figure
including the colored layer 3, first transparent layer, and light
reflective layer can avoid being damaged with a hole.
[0397] In the shaped article 50 illustrated in (d) of FIG. 8, the
upper-half of a figure's body including the colored layer 3, first
transparent layer, and light reflective layer is contained in the
second transparent layer 4. This article 50 has, on the surface or
inside of the second transparent layer 4, a three-dimensional image
71 decorated with a mark or a frame or painted in a pale color.
This shaped article 50 further has, on the surface or inside of the
second transparent layer 4, a letter/character area 72 with letters
and/or characters representing date, name, or place. The decorated
three-dimensional image 71 and the letter/character area 72 may be
formed at the same time when the outer shape is formed by the
second transparent layer 4. Instead of the decorated
three-dimensional image 71 and the letter/character area 72, other
additional information may be displayed on the surface or inside of
the second transparent layer 4.
[0398] In (b).about.(d) of FIG. 8, one figure is contained in the
second transparent layer 4, however, the number of figures
containable in the second transparent layer 4 may be other than
one.
[0399] In case the shaped article according to this embodiment has
a ring-like shape, the colored layer may be formed near an inner
peripheral end of the ring shape as well as an outer peripheral end
thereof. In conclusion, the colored layer may be formed on the
surface of the shaped article, and the second transparent layer may
be further formed thereon.
[0400] Instead of forming the second transparent layer 4 in any
desired shape as described in this modified example, the second
transparent layer 4 may be formed in a shape suitable for the
surface of the light reflective layer 1 similarly to the earlier
embodiment. In that case, the obtained shaped article may be sealed
in an optionally-shaped resin.
Second Modified Example
[0401] In the embodiment described earlier, the shaped article 50
is manufactured by the inkjet head device 10 illustrated in FIG. 3.
Instead of the inkjet head device 10, inkjet head devices
illustrated in FIG. 10, FIG.12, FIG.13, and FIG.14 may be used.
[0402] FIG. 10 is a drawing of a modified example of the inkjet
head device, illustrated similarly to FIG. 3. The inkjet head
device 10' illustrated in FIG. 10 has, on its lower surface,
roughly two inkjet heads 11H' and 12H'. As illustrated in FIG. 10,
the first inkjet head 11H' and the second inkjet head 12H' are
displaced from each other in both of the X and Y directions. The
first inkjet head 11H' is the same as the first inkjet head 11H
illustrated in FIG. 3. The second inkjet head 12H' includes a white
ink nozzle 10 (W) for discharging a white ink (W) used to form the
light reflective layer 1 (parts 51 of the light reflective layer),
and a transparent ink nozzle 10 (CL) for discharging a transparent
ink (CL).
[0403] FIG. 12 is a drawing of another modified example of the
inkjet head device, illustrated similarly to FIG. 3. In an inkjet
head device 10a illustrated in FIG. 12, a cyan ink nozzle 10 (C), a
magenta ink nozzle 10 (M), a yellow ink nozzle 10 (Y), a black ink
nozzle 10 (K), a white ink nozzle 10 (W), and a transparent ink
nozzle 10 (CL) are arranged in the mentioned order in the X
direction.
[0404] FIG. 13 is a drawing of yet another modified example of the
inkjet head device, illustrated similarly to FIG. 3. In an inkjet
head device 10b illustrated in FIG. 13, a white ink nozzle 10 (W),
a transparent ink nozzle 10 (CL), a yellow ink nozzle 10 (Y), a
magenta ink nozzle 10 (M), a cyan ink nozzle 10 (C), a black ink
nozzle 10 (K), a transparent ink nozzle 10 (CL), and a white ink
nozzle 10 (W) are arranged in the mentioned order in the X
direction.
[0405] FIG. 14 is a drawing of yet another modified example of the
inkjet head device. An inkjet head device 10b illustrated in FIG.
14 has a carriage 21 allowed to reciprocate along the X axis, a
plurality of nozzle arrays mounted in the carriage 21, and
ultraviolet irradiators 24a and 24b mounted in the carriage 21. The
carriage 21 is moved in the Y direction to perform a scan, in which
the inks of ultraviolet curing type are discharged from the nozzle
arrays and irradiated with ultraviolet light emitted from the
ultraviolet irradiators 24a and 24b.
[0406] The nozzle arrays are aligned along the X direction as
illustrated in FIG. 14. From the left to right in the X direction
on the drawing, a cyan ink nozzle array C, a magenta ink nozzle
array M, a yellow ink nozzle array Y, a black ink nozzle array K, a
white ink nozzle array W, and a transparent ink nozzle array CL are
aligned in the mentioned order. Since the nozzle arrays are mounted
in the carriage 21, the inks of ultraviolet curing type are
dischargeable from these nozzle arrays while moving in the X
direction with the carriage 21.
[0407] Because all of the nozzles are aligned in the X direction in
FIG. 12, FIG.13, and FIG.14, the formation of one layer may be
completed by moving the nozzles once in the X direction and
discharging all of the required ink during the movement. Referring
to FIG. 14, since all of the inks may be discharged and irradiated
with ultraviolet light by moving the nozzles just once in the X
direction, a layer formed from the inks of ultraviolet curing type
may be cured as soon as the inks are discharged.
[0408] [Additional Remarks]
[0409] A shaped article 50 according to one aspect includes: a
light reflective layer 1 formed from a light reflective ink; a
colored layer 3; and a second transparent layer 4 formed from a
transparent ink, wherein the colored layer 3 is formed on an outer
side of the light reflective layer 1, and the second transparent
layer 4 is formed on an outer side of the colored layer 3.
[0410] In this shaped article, a larger formation area including an
area overlapping the part 54, 54 (2) of the second transparent
layer in addition to an area overlapping the part 53, 53 (1) of the
colored layer in the lower layer may be secured for the part 53, 53
(2) of the colored layer in the upper layer, as compared to layers
lacking the parts 54 of the second transparent layer at positions
nearer to the end side than the parts 53 of the colored layer. This
may help to mitigate a demanded degree of manufacturing accuracy to
some extent, contributing to an improved manufacturing
efficiency.
[0411] The manufacturing method for the shaped article 50 according
to one aspect is a manufacturing method for forming the shaped
article 50 by stacking a plurality of layers 50a on one another,
the shaped article 50 including a second transparent layer 4 formed
from a transparent ink; and a colored layer 3, wherein the second
transparent layer 4 and the colored layer 3 are formed in this
order from an outer-layer side toward an inner side of the shaped
article 50. This method includes a layer forming process including
forming the parts 54 of the second transparent layer and the parts
53 of the colored layer in this order from an end side toward a
center side of at least two of the layers 50a.
[0412] According to the manufacturing method wherein the parts 54
of the second transparent layer are formed at positions nearer to
the end side than the parts 53 of the colored layer, the ink
applied to form the parts 54 of the second transparent layer, if
dropping downward from positions at which the parts 54 should be
formed during the manufacturing process, may be unlikely to
adversely affect the color tone, because it is the colored layer 3
(parts 53 of the colored layer) that decides the color tone. This
method may thus successfully manufacture the shaped article 50 that
excels in reliability and exhibits a desired color tone (decorated
as desired).
[0413] According to this method, a larger formation area including
an area overlapping the part 54, 54 (2) of the second transparent
layer in addition to an area overlapping the part 53, 53 (1) of the
colored layer 3 in the lower layer may be secured for the part 53,
53 (2) of the colored layer 3 in the upper layer, as compared to
layers lacking the parts 54 of the second transparent layer at
positions nearer to the end side than the parts 53 of the colored
layer. This may help to mitigate a demanded degree of manufacturing
accuracy to some extent, contributing to an improved manufacturing
efficiency.
[0414] The shaped article manufacturing method according to one
aspect is further characterized in that the layer forming process
includes steps of: forming the part 54 of the second transparent
layer; and forming the part 53 of the colored layer, wherein the
step of forming the part 54 of the transparent layer precedes the
step of forming the part 53 of the colored layer.
[0415] According to this method that forms the part 54 of the
second transparent layer in one layer 50a before the part 53 of the
colored layer, the part 54 of the second transparent layer may
serve as the outer moat of the part 53 of the colored layer to be
later formed. This may prevent the ink applied to form the part 53
of the colored layer from spreading unintendedly or dropping
downward.
[0416] The shaped article manufacturing method disclosed herein
according to one aspect is further characterized in that one of the
layers 50a is newly formed on another one of the layers 50a by the
layer forming process, so that the part 53 of the colored layer in
the layer 50a newly formed overlaps the part 54 of the second
transparent layer in the layer 50a previously formed.
[0417] The shaped article manufacturing method disclosed herein
according to one aspect is further characterized in that one of the
layers 50a is newly formed on another one of the layers 50a by the
layer forming process, so that the part 54 of the second
transparent layer in the layer 50a newly formed overlaps the part
53 of the colored layer in the layer 50a previously formed.
[0418] This disclosure is not necessarily limited to the embodiment
described so far and may be carried out in many other forms. The
technical scope of this disclosure encompasses any modifications
within its scope defined by the appended claims and embodiments
obtained by variously combining the technical means disclosed
herein. By variously combining the technical means disclosed in the
embodiment and modified examples, additional technical features may
be further presented.
INDUSTRIAL APPLICABILITY
[0419] This disclosure may be applicable to shaped article
manufacturing methods and manufacturing apparatuses for
implementing the methods. This disclosure is particularly useful in
manufacturing a three-dimensional shaped article decorated as
desired, for example, decorated in full colors.
* * * * *