U.S. patent number RE48,609 [Application Number 15/468,119] was granted by the patent office on 2021-06-29 for three-dimensional printing apparatus.
This patent grant is currently assigned to Young Optics Inc.. The grantee listed for this patent is Young Optics Inc.. Invention is credited to Hsin-Han Hsu, Li-Han Wu.
United States Patent |
RE48,609 |
Wu , et al. |
June 29, 2021 |
Three-dimensional printing apparatus
Abstract
A three-dimensional printing apparatus is provided, including a
container, a display, a control unit and an optical film. The
container contains a photosensitive material. The display has a
plurality of display units. Each of the display units is capable of
emitting a light beam. The control unit is capable of controlling
the display units. The optical film is capable of projecting the
light beams emitted from the display units onto the photosensitive
material, forming a plurality of projected patterns. An arranging
sequence and an arranging direction of the projected patterns are
substantially the same as an arranging sequence and an arranging
direction of the display units.
Inventors: |
Wu; Li-Han (Hsinchu,
TW), Hsu; Hsin-Han (Hsinchu, TW) |
Applicant: |
Name |
City |
State |
Country |
Type |
Young Optics Inc. |
Hsinchu |
N/A |
TW |
|
|
Assignee: |
Young Optics Inc. (Hsinchu,
TW)
|
Family
ID: |
1000005400029 |
Appl.
No.: |
15/468,119 |
Filed: |
March 24, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
13663484 |
Oct 30, 2012 |
8985989 |
Mar 24, 2015 |
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Foreign Application Priority Data
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May 3, 2012 [TW] |
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101115784 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C
64/112 (20170801); B33Y 30/00 (20141201) |
Current International
Class: |
B29C
64/112 (20170101); B33Y 30/00 (20150101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2004223774 |
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Aug 2004 |
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JP |
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2009166447 |
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Jul 2009 |
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JP |
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2011508690 |
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Mar 2011 |
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JP |
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M389021 |
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Sep 2010 |
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TW |
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M420727 |
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Jan 2012 |
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TW |
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WO2011/024453 |
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Mar 2001 |
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WO |
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WO2005/025838 |
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Mar 2005 |
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WO |
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WO-2010101465 |
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Sep 2010 |
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WO |
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WO2010/150149 |
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Dec 2010 |
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WO |
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2012028747 |
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Mar 2012 |
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WO |
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Other References
"Office Action of Japan Counterpart Application", issued on Jul.
15, 2014, p. 1-2. cited by applicant .
"Office Action of Taiwan Counterpart Application", issued on Mar.
5, 2014, p. 1-6. cited by applicant.
|
Primary Examiner: McKane; Elizabeth L
Attorney, Agent or Firm: JCIPRNET
Claims
What is claimed is:
.[.1. A three-dimensional printing apparatus, comprising: a
container, containing a photosensitive material; a display, having
a plurality of display units, each of the display units being
capable of emitting a light beam; a control unit, connected to the
display and controlling the display units of the display; and an
optical film, disposed between the display and the container, the
optical film comprising a plurality of optical structures folined
thereon and arranged in a direction perpendicular to a transmission
direction of the light beams, and the optical structures
respectively projecting the light beams emitted from the
corresponding display units onto the photosensitive material to a
plurality of projected patterns, wherein an arranging sequence and
an arranging direction of the projected patterns are substantially
the same as an arranging sequence and an arranging direction of the
display units, and a dimension of each of the projected patterns is
substantially equal to a dimension of each of the display units, so
that the projected patterns are formed as not overlapping, and a
distance between the display and the upper surface of the container
is less than or equal to 3 cm..].
.[.2. The three-dimensional printing apparatus of claim 1, wherein
the container has a bottom, disposed between the display and the
photosensitive material, and the bottom is a light-transparent
bottom, the bottom of the container has an upper surface facing the
photosensitive material..].
.[.3. The three-dimensional printing apparatus of claim 2, wherein
a distance between the display and the upper surface of the
container is less than or equal to 3 cm..].
.[.4. The three-dimensional printing apparatus of claim 2, further
comprising: a work platform, dipped into the photosensitive
material, capable of moving relatively with the container, wherein
the work platform has a work surface; wherein the work platform is
controlled by the control unit, the control unit commands the
display to display a first image during a first time and locates
the work surface to a first location, the light beams emitted from
the display units corresponding to the first image are projected
onto a first layer of the photosensitive material between the work
surface and the upper surface through the optical film, so as to
cure the first layer of the photosensitive material to form a first
cured layer, and the control unit commands the display to display a
second image during a second time and locates the work surface to
the second location, the light beams emitted from the display units
corresponding to the second image are projected to a second layer
of the photosensitive material between the first cured layer and
the upper surface through the optical film, so as to cure the
second layer of the photosensitive material to form a second cured
layer..].
.[.5. The three-dimensional printing apparatus of claim 4, wherein
the work surface faces the bottom, the second cured layer is
located between the first cured layer and the bottom, and the first
location is located between the bottom and the second
location..].
.[.6. The three-dimensional printing apparatus of claim 1, wherein
each of the optical structures is aligned with at least one of the
display units..].
.[.7. The three-dimensional printing apparatus of claim 6, wherein
each of the optical structures is a lens, and each of the lenses is
aligned with one of the display units..].
.[.8. The three-dimensional printing apparatus of claim 6, wherein
each of the optical structures is a cylindrical lens, and each of
the cylindrical lenses is aligned with a row of the display
units..].
.[.9. The three-dimensional printing apparatus of claim 6, wherein
an image of the display units is projected on the photosensitive
material to form the projected patterns by the optical
structures..].
.[.10. The three-dimensional printing apparatus of claim 6, wherein
each of the display units comprises at least a pixel..].
.[.11. The three-dimensional printing apparatus of claim 10,
wherein a size of each of the optical structures is an integer
times a size of the pixel of the corresponding display unit..].
.[.12. The three-dimensional printing apparatus of claim 1, wherein
each of the display units is aligned with some of the optical
structures..].
.[.13. The three-dimensional printing apparatus of claim 12,
wherein a size of each of the display units is an integer times a
size of the corresponding optical structure..].
.[.14. The three-dimensional printing apparatus of claim 1, wherein
each of the optical structures is a pyramidal prism or a
triangular-shaped prism..].
.[.15. The three-dimensional printing apparatus of claim 1, wherein
the light beams emitted from the display units are visible
light..].
.[.16. The three-dimensional printing apparatus of claim 1, wherein
the optical film may be a single layer film or a multilayer
film..].
.[.17. A three-dimensional printing apparatus, comprising: a
container, containing a photosensitive material; a display, having
a plurality of display units, each of the display units being
capable of emitting a light beam; a control unit, connected to the
display and controlling the display units of the display; and an
optical film, disposed between the display and the container and
projecting the light beams emitted from the display units onto the
photosensitive material to form a plurality of projected patterns,
wherein an arranging sequence and an arranging direction of the
projected patterns are substantially the same as an arranging
sequence and an arranging direction of the display units, and the
projected patterns are formed as not overlapping, wherein the
container has a bottom, disposed between the display and the
photosensitive material, the bottom is a light-transparent bottom,
the bottom of the container has an upper surface facing the
photosensitive material, and a distance between the display and the
upper surface of the container is less than or equal to 3
cm..].
.Iadd.18. An optical assembly for a three-dimensional printing
apparatus, comprising: a container and a display, optically
connected with each other, wherein a plurality of display units are
located in the display, and each of the display units is capable of
emitting a light beam; and the container is disposed above the
display and comprises a light-transparent bottom being configured
to accommodate a photosensitive material, wherein the
light-transparent bottom of the container has an upper surface
facing the photosensitive material; wherein a distance between the
display and an upper surface of the transparent bottom of the
container is less than or equal to 3 cm..Iaddend.
.Iadd.19. The optical assembly of claim 18, wherein the optical
assembly further comprises: a control unit, connected to the
display and controlling the display units of the display; and an
optical film, comprising a plurality of optical structures formed
thereon and arranged in a direction perpendicular to a transmission
direction of the light beams, wherein the optical film is disposed
between the display and the container and projects the light beams
emitted from the display units onto the photosensitive material to
form a plurality of projected patterns, wherein an arranging
sequence and an arranging direction of the projected patterns are
substantially the same as an arranging sequence and an arranging
direction of the display units, and the three-dimensional printing
apparatus does not have a projection lens, wherein a dimension of
each of the projected patterns is substantially equal to a
dimension of each of the display units, so that the projected
patterns are formed as not overlapping..Iaddend.
.Iadd.20. The optical assembly of claim 19, further comprising: a
work platform, dipped into the photosensitive material, capable of
moving relatively with the container, wherein the work platform has
a work surface; wherein the work platform is controlled by the
control unit, the control unit is programmed to command the display
to display a first image during a first time and locates the work
surface to a first location, the light beams emitted from the
display units corresponding to the first image are projected onto a
first layer of the photosensitive material between the work surface
and the upper surface through the optical film, so as to cure the
first layer of the photosensitive material to form a first cured
layer, and the control unit commands the display to display a
second image during a second time and locates the work surface to
the second location, the light beams emitted from the display units
corresponding to the second image are projected to a second layer
of the photosensitive material between the first cured layer and
the upper surface through the optical film, so as to cure the
second layer of the photosensitive material to form a second cured
layer..Iaddend.
.Iadd.21. The optical assembly of claim 20, wherein the work
surface faces the bottom, the second cured layer is located between
the first cured layer and the bottom, and the first location is
located between the bottom and the second location..Iaddend.
.Iadd.22. The optical assembly of claim 19, wherein the optical
film comprises a plurality of optical structures, and each of the
optical structures is aligned with at least one of the display
units..Iaddend.
.Iadd.23. The optical assembly of claim 22, wherein an image of the
display units is projected on the photosensitive material to form
the projected patterns by the optical structures..Iaddend.
.Iadd.24. The optical assembly of claim 22, wherein each of the
display units comprises at least a pixel..Iaddend.
.Iadd.25. The optical assembly of claim 24, wherein a size of each
of the optical structures is an integer times a size of the pixel
of the corresponding display unit..Iaddend.
.Iadd.26. The optical assembly of claim 19, wherein the optical
film comprises a plurality of optical structures, and each of the
display units is aligned with some of the optical
structures..Iaddend.
.Iadd.27. The optical assembly of claim 26, wherein a size of each
of the display units is an integer times a size of the
corresponding optical structure..Iaddend.
.Iadd.28. The optical assembly of claim 19, wherein the optical
film comprises a plurality of optical structures, and each of the
optical structures is a lens, a cylindrical lens, a pyramidal prism
or a triangular-shaped prism..Iaddend.
.Iadd.29. The optical assembly of claim 19, wherein the optical
film is a Fresnel lens, diffusing film or a privacy
filter..Iaddend.
.Iadd.30. The optical assembly of claim 18, wherein the light beams
incident on a lower surface of a cured photosensitive material are
substantially perpendicular to the lower surface of the cured
photosensitive material..Iaddend.
.Iadd.31. A projection system for a three-dimensional printing
apparatus, comprising: a display, comprising a plurality of display
units; and a container disposed above the display and comprising a
light-transparent bottom being configured to accommodate a
photosensitive material, wherein the light-transparent bottom of
the container has an upper surface facing the photosensitive
material, wherein each of the display units is capable of emitting
light beams to the light-transparent bottom, and a distance between
the display and of the upper surface of the transparent bottom of
the container is less than or equal to 3 cm..Iaddend.
.Iadd.32. The projection system of claim 31, wherein the light
beams incident on a lower surface of a cured photosensitive
material are substantially perpendicular to the lower surface of
the cured photosensitive material..Iaddend.
.Iadd.33. A container for a three-dimensional printing apparatus
comprising a display and an optical film, comprising: a
light-transparent bottom, being configured to accommodate a
photosensitive material, and the light-transparent bottom of the
container has an upper surface facing the photosensitive material,
wherein a display is disposed under the light-transparent bottom of
the container and has a plurality of display units, each of the
display units being capable of emitting light beams, wherein a
single layer optical film is disposed between the display and the
light-transparent bottom of the container, and the single layer
optical film comprises a plurality of optical structures formed
thereon and is arranged in a direction perpendicular to a
transmission direction of the light beams, wherein the light beams
emitted from each of the display units pass through the single
layer optical film and subsequently pass through the
light-transparent bottom in a substantially parallel manner to
reach a lower surface of a cured photosensitive
material..Iaddend.
.Iadd.34. The container of claim 33, wherein the single layer
optical film projects the light beams emitted from the display
units onto the photosensitive material to form a plurality of
projected patterns..Iaddend.
.Iadd.35. The container of claim 34, wherein the projected patterns
are formed as not overlapping..Iaddend.
.Iadd.36. The container of claim 34, wherein an arranging sequence
and an arranging direction of the projected patterns are
substantially the same as an arranging sequence and an arranging
direction of the display units..Iaddend.
Description
CROSS-REFERENCE TO RELATED APPLICATION
This application .Iadd.is a Reissue Application of U.S. Pat. No.
8,985,989 issued on Mar. 24, 2015, application Ser. No. 13/663,484,
filed on Oct. 30, 2012, which .Iaddend.claims the priority benefit
of Taiwan application serial no. 101115784, filed on May 3, 2012.
The entirety of .Iadd.each of .Iaddend.the above-mentioned patent
.[.application.]. .Iadd.applications .Iaddend.is hereby
incorporated by reference herein and made a part of this
specification.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a printing apparatus, more particularly,
to a three-dimensional printing apparatus.
2. Description of Related Art
Rapid Prototyping (RP) is a new prototype manufacturing technology
developed in the mid-80s. Rapid Prototyping has combined
technologies such as mechanical engineering, Computer-aided design
(CAD), digital control technology, laser technology and material
science, allowing the design concept to be automatically, directly,
quickly and accurately transformed into a prototype with certain
functionalities or manufacturing parts, as a result, assessment,
modification and functionalities test to the design concept can be
quickly performed, thereby remarkably reducing the developing and
manufacturing process of the product. With advantages like agility,
adaptable for all sorts of forms, high flexibility and high
integration, it is widely applied in different technical fields
such as mechanical, motor vehicle, electronic, communication and
aerospace technology. During an initial stage of the development, a
CAD file of required drawings is designed, an original model is
manufactured before the actual production, and used for design
confirmation, product modification, functionality test and molding
process, such model is known as the prototype.
Different prototyping materials are used according to different
prototyping technologies, in which their prototyping principle and
system features are also different from each other. For example,
stereo lithography apparatus (SLA) is the first commercialized
system with biggest share of market. The processing principle
thereof is consisted of the following steps: scanning the liquid
photosensitive polymer by using HeCd laser or Argon laser; thereby
generating a polymerized cured thin-film; next, bringing the
lifting table down and then up again; applying another layer of
polymer resin on the surface of the desired processing area;
scraping off the liquid surface with a scraper until the surface is
horizontal; scanning the surface with laser so the processing area
is closely combined with the upper layer thereof; repeating above
steps until the desired three-dimensional work piece is generated.
In addition, the image-forming system using SLA technology is
either the laser scanning system or the light projector, since the
hardware of the system is complex and large in size, and the
image-forming distance for the laser scanning system or the
projector needs to be included in the machine, the overall size of
the such system cannot be miniaturized.
Regarding related art of the prototyping technology, U.S. Pat. No.
5,980,813 has disclosed a rapid prototyping method using multilayer
materials. US Patent Publication No. 20100262272 has also disclosed
an apparatus of manufacturing three-dimensional object by using
curable materials.
SUMMARY OF THE INVENTION
A three-dimensional printing apparatus is provided, and the
three-dimensional printing apparatus has structure to help reducing
overall size of the three-dimensional printing apparatus.
Other objects and advantages of the invention can be further
illustrated by the technical features broadly embodied and
described as follows.
A three-dimensional printing apparatus is provided according to an
embodiment of the invention. The three-dimensional printing
apparatus includes a container, a display, a control unit and an
optical film. The container contains a photosensitive material. The
display has a plurality of display units, and each of the display
units is capable of emitting a light beam. The control unit is
connected to the display, for controlling the display units. The
optical film is disposed between the display and the container, for
projecting the light beams emitted from the display units onto the
photosensitive material, so as to form a plurality of projected
patterns. An arranging sequence and an arranging direction of the
projected patterns are substantially the same as an arranging
sequence and an arranging direction of the display units.
In an embodiment of the invention, the container has a bottom,
disposed between the display and the photosensitive material, and
the bottom is a light-transparent bottom, the bottom of the
container has an upper surface facing the photosensitive
material.
In an embodiment of the invention, a distance between the display
and the upper surface of the container is less than or equal to 3
cm.
In an embodiment of the invention, the three-dimensional printing
apparatus further comprises a work platform, dipped into the
photosensitive material, capable of moving relatively with the
container. The work platform has a work surface, wherein the work
platform is controlled by the control unit, the control unit
commands the display to display a first image during a first time
and locates the work surface to a first location. The light beams
emitted from the display units corresponding to the first image are
projected onto a first layer of the photosensitive material between
the work surface and the upper surface through the optical film, so
as to cure the first layer of the photosensitive material to form a
first cured layer. And the control unit commands the display to
display a second image during a second time and locates the work
surface to the second location. The light beams emitted from the
display units corresponding to the second image are projected to a
second layer of the photosensitive material between the first cured
layer and the upper surface through the optical film, so as to cure
the second layer of the photosensitive material to form a second
cured layer.
In an embodiment of the invention, the work surface faces the
bottom. The second cured layer is located between the first cured
layer and the bottom, and the first location is located between the
bottom and the second location.
In an embodiment of the invention, the optical film comprises a
plurality of optical structures, and each of the optical structures
is aligned with at least one of the display units.
In an embodiment of the invention, each of the optical structures
is a lens, and each of the lenses is aligned with one of the
display units.
In an embodiment of the invention, each of the optical structures
is a cylindrical lens, and each of the cylindrical lenses is
aligned with a row of the display units.
In an embodiment of the invention, an image of the display units is
projected on the photosensitive material to form the projected
patterns by the optical structures.
In an embodiment of the invention, each of the display units
comprises at least a pixel. A size of each of the optical
structures is an integer times a size of the pixel of the
corresponding display unit.
In an embodiment of the invention, the optical film comprises a
plurality of optical structures, and each of the display units is
aligned with some of the optical structures. A size of each of the
display units is an integer times a size of the corresponding
optical structure.
In an embodiment of the invention, the optical film comprises a
plurality of optical structures, and each of the optical structures
is a pyramidal prism or a triangular-shaped prism.
In an embodiment of the invention, the optical film is a Fresnel
lens, diffusing film or a privacy filter.
In an embodiment of the invention, the light beams emitted from the
display units are visible light.
In an embodiment of the invention, the optical film may be a single
layer film or a multilayer film.
Based on above, the three-dimensional printing apparatus according
to the embodiment of the invention projects the display units of
the display onto the photosensitive material through the optical
film, and the arranging sequence and the arranging direction of the
projected patterns are substantially the same as the arranging
sequence and arranging direction of the display units. As a result,
a distance between the display and the photosensitive material may
be reduced, thereby reducing a size of the three-dimensional
printing apparatus, and providing good effect of three-dimensional
printing.
Other objectives, features and advantages of the present invention
will be further understood from the further technological features
disclosed by the embodiments of the present invention wherein there
are shown and described preferred embodiments of this invention,
simply by way of illustration of modes best suited to carry out the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A, FIG. 1B and FIG. 1C are schematic views of operations in a
three-dimensional printing apparatus according an embodiment of the
invention.
FIG. 2 is a schematic view of a plurality of display units of a
display.
FIG. 3A illustrates a corresponding relationship between the
display units of the display and a plurality of optical structures
of an optical film in a first embodiment of the invention.
FIG. 3B is a side view of FIG. 3A.
FIG. 4A illustrates a corresponding relationship between the
display units of the display and the optical film in a second
embodiment of the invention.
FIG. 4B is a side view of FIG. 4A.
FIG. 5A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a third embodiment of the invention.
FIG. 5B is a side view of FIG. 5A.
FIG. 6A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a fourth embodiment of the invention.
FIG. 6B is a side view of FIG. 6A.
FIG. 7A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a fifth embodiment of the invention.
FIG. 7B is a side view of FIG. 7A.
FIG. 8 illustrates a corresponding relationship between the display
units of the display and the optical structures of the optical film
in a sixth embodiment of the invention.
DESCRIPTION OF THE EMBODIMENTS
In the following detailed description of the preferred embodiments,
reference is made to the accompanying drawings which form a part
hereof, and in which are shown by way of illustration specific
embodiments in which the invention may be practiced. In this
regard, directional terminology, such as "top," "bottom," "front,"
"back," etc., is used with reference to the orientation of the
Figure(s) being described. The components of the present invention
can be positioned in a number of different orientations. As such,
the directional terminology is used for purposes of illustration
and is in no way limiting. On the other hand, the drawings are only
schematic and the sizes of components may be exaggerated for
clarity. It is to be understood that other embodiments may be
utilized and structural changes may be made without departing from
the scope of the present invention. Also, it is to be understood
that the phraseology and terminology used herein are for the
purpose of description and should not be regarded as limiting. The
use of "including," "comprising," or "having" and variations
thereof herein is meant to encompass the items listed thereafter
and equivalents thereof as well as additional items. Unless limited
otherwise, the terms "connected," "coupled," and "mounted" and
variations thereof herein are used broadly and encompass direct and
indirect connections, couplings, and mountings. Similarly, the
terms "facing," "faces" and variations thereof herein are used
broadly and encompass direct and indirect facing, and "adjacent to"
and variations thereof herein are used broadly and encompass
directly and indirectly "adjacent to". Therefore, the description
of "A" component facing "B" component herein may contain the
situations that "A" component directly faces "B" component or one
or more additional components are between "A" component and "B"
component. Also, the description of "A" component "adjacent to" "B"
component herein may contain the situations that "A" component is
directly "adjacent to" "B" component or one or more additional
components are between "A" component and "B" component.
Accordingly, the drawings and descriptions will be regarded as
illustrative in nature and not as restrictive.
FIG. 1A, FIG. 1B and FIG. 1C are schematic views of operations in
the three-dimensional printing apparatus according an embodiment of
the invention. A three-dimensional printing apparatus 100 includes
a container 110, a display 120 and an optical film 130. The
container 110 contains a photosensitive material 112, and the
photosensitive material 112 may be a fluid material or a semi-fluid
material. The display 120 has a plurality of display units 122, and
each of the display units 122 is capable of emitting a light beam
L. The optical film 130 is capable of projecting the light beams L
emitted from the display units 122 onto the photosensitive material
112, forming a plurality of projected patterns on the
photosensitive material 112. The optical film 130 may be a single
layer film or a stacked multilayer film.
Specifically, in the present embodiment, the display 120 is
disposed under a bottom 114 of the container 110, and the optical
film 130 is disposed between the display 120 and the bottom 114 of
the container 110. In addition, since the bottom 114 of the
container 110 is a light-transparent bottom, after the light beams
L emitted from the display units 122 pass through the optical film
130, the light beams L may go through the bottom 114 and project
the projected patterns on the photosensitive material 112, thereby
causing a chemical reaction (such as curing or hardening) with the
photosensitive material 112. An arranging sequence and an arranging
direction of the projected patterns on the photosensitive material
112 are substantially the same as an arranging sequence and an
arranging direction of the display units 122 on the display 120.
For example, referring to FIG. 1A, the display units 122A, 122B and
122C respectively project the projected patterns to a plurality of
locations a, b and c on the photosensitive material 112. The
arranging sequence and the arranging direction of the locations a,
b and c of the projected patterns on the photosensitive material
112 are substantially the same as the arranging sequence and
arranging direction of the display units 122A, 122B and 122C on the
display 120. That is, the display units 122A, 122B and 122C are
arranged from left to right, and the locations a, b and c
respectively correspond to the display units 122A, 122B and 122C
and are also arranged from left to right. Similarly, viewing along
a direction perpendicular to the paper plane of FIG. 1A, the
arranging sequence and the arranging direction of the projected
patterns on the photosensitive material 112 are the same as the
arranging sequence and the arranging direction of the display units
122 on the display 120, for example, both are arranged in the
direction toward the paper plane of FIG. 1A. In the embodiment, the
locations of the display units 122 on the display 120 correspond to
the projected patterns on the photosensitive material 112 in a
one-to-one manner. As a result, an image displayed by the entire
display units 122 may be formed correspondingly on the
photosensitive material 112. .Iadd.Referring again to FIG. 1A to
FIG. 1C, in some embodiments, an optical assembly configured for
the three-dimensional printing apparatus 100 can be formed by
including the container 110 and the display 120
therein..Iaddend.
It is noted that, in the three-dimensional printing apparatus 100
of the embodiment, the image displayed on the display 120 is
divided into multiple display units 122 for displaying, and the
light beams L of the display units 122 corresponding to the image
are projected onto the photosensitive material 112 to form the
projected patterns through the optical film 130 in the one-to-one
manner. The arranging sequence and the arranging direction of the
projected patterns on the photosensitive material 112 are
substantially the same as the arranging sequence and the arranging
direction of the display units 122 on the display 120. .Iadd.In the
present embodiment, a projection system configured for the
three-dimensional printing apparatus 100 can be formed by including
the container 110 and the display 120 comprising the display units
122 therein. .Iaddend.Comparatively, a conventional
three-dimensional device with the projection lens projects the
image of the display 120 by using whole surface image-forming
method via the projection lens, forming the image on the
photosensitive material 112. Based on the image-forming principle,
the image formed on the photosensitive material 112 is a 180 degree
reversed image. Therefore, design of an image-forming distance is
necessary in order to meet the image-forming requirement, thereby
increasing the size of the printing device.
In the embodiment, the image displayed on the display 120 is
divided into multiple display units 122, and the light beams L of
the display units 122 of the display 120 corresponding to the image
are projected on the photosensitive material 112 to form the
projected patterns through the optical film 130 in the one-to-one
manner. Since a size of each display unit 122 is smaller than the
entire image, the projecting distance between the display units 122
and the photosensitive material 112 may be reduced. As a result, a
required distance between the display 120 and the photosensitive
material 112 may be reduced, and the size of the three-dimensional
printing apparatus 100 may also be reduced. For example, in the
embodiment, a distance between the display 120 and an upper surface
114a of the bottom 114 of the container 110 is less than or equal
to 3 cm. On the other hand, the display 120 of the embodiment may
be a liquid crystal display. Therefore, a light source of the
display 120 provided for projecting may be a visible light.
However, an invisible light (such as UV light) source for curing or
hardening the photosensitive material 112 may also be used.
Referring to FIG. 1A, in particularly, the three-dimensional
apparatus 100 further includes a work platform 140 and a control
unit 150. The work platform 140 is dipped into the photosensitive
material 112 and capable of moving with respect to the container
110, wherein the work platform 140 has a work surface 140a facing
the bottom 114 of the container 110. The control unit 150 is
coupled with the work platform 140 and the display 120, for
controlling the work platform 140 and the display unit 122. In the
embodiment, the work platform 140 is capable of relatively moving
from top to bottom of the container 110 or from bottom to top of
the container 110.
Next, referring to FIG. 1A, FIG. 1B, and FIG. 1C in sequence. In
FIG. 1A, the control unit 150 commands the display 120 to display a
first image during a first time, and the first image is divided
into a plurality of corresponding display units 122, and the work
surface 140a is located at a first location (the location as shown
in FIG. 1A). Here, the light beams L emitted from the display units
122 corresponding to the first image are projected to a layer of
the photosensitive material 112 between the work surface 140a of
the work platform 140 and the upper surface 114a of the bottom 114
through the optical film 130, such that a first cured layer S1 is
formed by curing the layer of the photosensitive material 112
between the work surface 140a and the upper surface 114a and
corresponds to the first image. Next, in FIG. 1B, the work surface
140a moves to be located at a second location (the location as
shown in FIG. 1B) by the control unit 150 during a second time.
Here, the photosensitive material 112 in the container 110 is
filled between the first cured layer S1 and the upper surface 114a,
the control unit 150 commands the display 120 to display a second
image, and the second image is divided into a plurality of
corresponding display units 122. The light beams L emitted from the
display units 122 corresponding to the second image are projected
to a layer of the photosensitive material 112 between the first
cured layer S1 and the upper surface 114a through the optical film
130, such that a second cured layer S2 is formed by curing the
layer of the photosensitive material 112 between the first cured
layer S1 and the upper surface 114a and corresponds to the second
image. Subsequently, in FIG. 1C, the work surface 140a moves to be
located at a N.sup.th location (the location as shown in FIG. 1C)
by the control unit 150. The control unit 150 commands the display
120 to display an N.sup.th image during an N.sup.th time, the
N.sup.th image is divided into a plurality of corresponding display
units 122. The light beams L corresponding to the N.sup.th image
are projected to a layer of the photosensitive material 112 between
an N-1.sup.th cured layer SN-1 and the upper surface 114a through
the optical film 130, so that an N.sup.th cured layer SN is formed
by curing the layer of the photosensitive material 112 between an
N-1.sup.th cured layer SN-1 and the upper surface 114a and
corresponds to the N.sup.th image. In the embodiment, N, for
example, is a positive integer larger than or equal to 3.
Regarding the embodiment, the work surface 140a faces the upper
surface 114a of the bottom 114, the second cured layer S2 is
located between the first cured layer S1 and the upper surface 114a
of the bottom 114, and the first location is located between the
bottom 114 and the second location. More specifically, a slicing
process may be performed on the three-dimensional object, so as to
divide an object into multilayer image data. The control unit 150
commands the corresponding display units 122 to display the first
layer image of the object during the first time. Next, the
corresponding display units 122 are commanded to display the second
layer image of the object during the second time. After repeating
said process for a number of times, the images of different layers
are sequentially projected to the corresponding layers of photo
sensitive material 112 through the optical film 130, so that the
corresponding layers of the photosensitive material 112 are cured
in respond to each different layer of images, such that a
three-dimensional object is formed in a layer-by-layer manner.
In the embodiment, the display 120 is disposed under the bottom 114
of the container 110, so that the light beams L of the display
units 122 may be emitted from bottom to top onto the photosensitive
material 112 above the upper surface 114a of the bottom 114.
However, the invention is not limited thereto. In other
embodiments, the display 120 may also be disposed on a top of the
container 110 (not illustrated), so that the light beams L of the
display units 122 may be emitted from top to bottom onto the
photosensitive material 112.
FIG. 2 is a schematic view of the plurality of display units of the
display. Referring to FIG. 2, in the three-dimensional printing
apparatus 100, the display 120 may be a liquid crystal display
panel, and the display unit 122 may include at least one pixel 122a
in the liquid crystal display panel. For example, in FIG. 2, the
display units 122 are composed by nine pixels 122a. The number of
the pixels 122a included in the display units 122 may be adjusted
according to the required resolution of the image. On the other
hand, the conventional three-dimensional technology usually uses a
display with color filter. The three-dimensional printing apparatus
100 according to an embodiment of the invention may use a display
120 without color filter, each of the sub-pixels corresponding to
filters of different color in the original display may now be
referred to as one single pixel, such that the resolution of the
display 120 may be improved, thereby allowing the three-dimensional
printing technology in providing a higher resolution.
In the embodiment, the optical film 130 includes a plurality of
optical structures 132, for projecting the light beams L emitted
from the display unit 122 onto the photosensitive material 112.
Several preferable embodiments are provided below to further
illustrate the relative relation between the display unit 122 and
the optical film 130.
FIG. 3A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a first embodiment of the invention. FIG. 3A is a
top view illustrating the overlapping of the display 120 and an
optical film 130A, wherein the portion with dotted line surrounded
represents the display 120, and the portion with full line
surrounded represents the optical film 130A. FIG. 3B is a side view
of FIG. 3A.
Referring to FIG. 3A and FIG. 3B together. In the embodiment, the
optical film 130A has a plurality of optical structures 132A,
wherein each optical structure 132A is a lens (such as lens having
bent surface on both two directions that are perpendicular to each
other), a size of each optical structure 132A is substantially
equal to the size of each display unit 122.
FIG. 4A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a second embodiment of the invention. FIG. 4B is a
side view of FIG. 4A. Each optical structure 132B of the optical
film 130B of the embodiment is similar to the optical structure
132A shown in the FIG. 3A, namely, the lens. However, a size of
each optical structure 132B is substantially smaller than the size
of the display unit 122.
FIG. 5A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a third embodiment of the invention. FIG. 5B is a
side view of FIG. 5A. In the embodiment, each optical structure
132C on the optical film 130C is a cylindrical lens, and a width of
each optical structure 132C is substantially equal to the width of
the display unit 122.
According to the embodiments in FIG. 3A, FIG. 4A and FIG. 5A, an
image of the display units 122 is formed on the photosensitive
material 112 through the lens or the cylindrical lens. Therefore,
each of the optical structures 132A, 132B and 132C may be adjusted,
for aligning with at least one display unit 122. For example, in
FIG. 3A, each lens (the optical structure 132A) is aligned with one
corresponding display unit 122. In another embodiment, each of the
display unit 122 is aligned with a plurality of optical structures.
For example, in FIG. 4A, each of the display units 122 is align
with four lenses (the optical structures 132B). When one display
unit 122 includes a plurality of pixels 122a (referring to FIG. 2),
each lens is aligned with the plurality of pixels 122a, and when
one display unit 122 includes one pixel 122a, each lens is aligned
with one pixel 122a. In other words, in FIG. 3A, the size of each
optical structure 132A may be an integral times the size of the
pixel 122a of the corresponding display unit 122 (referring to FIG.
2). Whereas in FIG. 4A, the size of each display unit 122 is an
integral times the size of the corresponding optical structure
132B. In FIG. 5A, each cylindrical lens (the optical structure
132C) is aligned with a row of display units 122. Since the size of
each display unit 122 is smaller than the size of the entire image
displayed by the display 120, the image-forming distance for
projecting the image of the display units 122 respectively onto the
photosensitive material 112 by using the optical structures 132
(such as the plurality of lenses or cylindrical lenses) may be
smaller than the image-forming distance for projecting the entire
image onto the photosensitive material 112 by using whole surface
image-forming method. Therefore, the overall size of the
three-dimensional printing apparatus 100 may be effectively
reduced.
FIG. 6A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a fourth embodiment of the invention. FIG. 6B is a
side view of FIG. 6A. In the embodiment, each optical structure
132D of the optical film 130D is a triangular-shaped prism, and a
width of each optical structure 132D is substantially equal to the
width of the display unit 122.
FIG. 7A illustrates a corresponding relationship between the
display units of the display and the optical structures of the
optical film in a fifth embodiment of the invention. FIG. 7B is a
side view of FIG. 7A. In the embodiment, each optical structure
132E of the optical film 130E is a pyramidal prism, and a size of
each optical structure 132E is equal to the size of each display
unit 122.
However, in other embodiments, the size of the triangular-shaped
prism or the pyramidal prism may not be an integer times the
display unit 122, and the location of the triangular-shaped prism
or the pyramidal prism may not have corresponding relationship with
the location of the display unit 122, both are also possible.
FIG. 8 illustrates a corresponding relationship between the display
units of the display and the optical structures of the optical film
in a sixth embodiment of the invention. In the embodiment, the
optical film 130F is a diffusing film, and optical structures 132F
of the optical film 130F are provided for converging the light
beams L, whereas in the other embodiments, the optical film 130F
may also be a Fresnel lens or a privacy filter.
In the embodiments of FIG. 6A and FIG. 7A, the method for
projecting the display units 122 on the photosensitive material 112
is tended to use a projection method. Therefore, the locations of
each triangular-shaped prism (the optical structure 132D) and each
pyramidal prism (the optical structure 132E) may not have
corresponding relationship with the locations of the display units
122. However, the light beams L emitted from the corresponding
display units 122 may be converged onto the photosensitive material
112 (as shown in FIG. 1A, FIG. 1B and FIG. 1C). Similarly, the
optical film 130F (such as a Fresnel lens or a privacy filter)
shown in FIG. 8 is also capable of converging the light beams L
emitted from the display units 122. In addition, when the light
beams L emitted from the display 120 are converged more, the light
beams L of the display units 122 may still be projected on the
photosensitive material 122 (as shown in FIG. 1A, FIG. 1B and FIG.
1C) when the optical film 130F is the diffusing film.
Based on above, the three-dimensional printing apparatus according
to the embodiment of the invention projects the display units of
the display onto the photosensitive material through the optical
film, and the arranging sequence and the arranging direction of the
projected patterns are substantially the same as the arranging
sequence and arranging direction of the display units. As a result,
the distance between the display and the photosensitive material
may be reduced, thereby reducing the size of the three-dimensional
printing apparatus, and providing good effect of three-dimensional
printing.
The foregoing description of the preferred embodiments of the
invention has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form or to exemplary embodiments
disclosed. Accordingly, the foregoing description should be
regarded as illustrative rather than restrictive. Obviously, many
modifications and variations will be apparent to practitioners
skilled in this art. The embodiments are chosen and described in
order to best explain the principles of the invention and its best
mode practical application, thereby to enable persons skilled in
the art to understand the invention for various embodiments and
with various modifications as are suited to the particular use or
implementation contemplated. It is intended that the scope of the
invention be defined by the claims appended hereto and their
equivalents in which all terms are meant in their broadest
reasonable sense unless otherwise indicated. Therefore, the term
"the invention", "the present invention" or the like does not
necessarily limit the claim scope to a specific embodiment, and the
reference to particularly preferred exemplary embodiments of the
invention does not imply a limitation on the invention, and no such
limitation is to be inferred. The invention is limited only by the
spirit and scope of the appended claims. The abstract of the
disclosure is provided to comply with the rules requiring an
abstract, which will allow a searcher to quickly ascertain the
subject matter of the technical disclosure of any patent issued
from this disclosure. It is submitted with the understanding that
it will not be used to interpret or limit the scope or meaning of
the claims. Any advantages and benefits described may not apply to
all embodiments of the invention. It should be appreciated that
variations may be made in the embodiments described by persons
skilled in the art without departing from the scope of the present
invention as defined by the following claims. Moreover, no element
and component in the present disclosure is intended to be dedicated
to the public regardless of whether the element or component is
explicitly recited in the following claims. In addition, the terms
such as "first", "second" as recited in the specification or the
claims are used to give the elements names or distinguish different
embodiments or scopes, but not to limit the maximum number or the
minimum number of the elements.
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