Patent Description:
Technology is known that forms a three-dimensional image (a shaped object) by causing expansion of thermally expandable microspheres by selecting heating an image portion by irradiating with light a thermal expansion sheet that has a base sheet and a coating layer including the thermally expandable microspheres, a prescribed image being formed of an image-molding material having excellent light absorption characteristics on the thermally expansive sheet (for example, see Unexamined <CIT>).

<CIT> discloses a method and a system for foam molding capable of forming a half-stereoscopic image having an arranged shape. When a half-stereoscopic image is formed on a foamable sheet based on selected image data, the foaming height of the half-stereoscopic image is suppressed to a controllable control limit height Hc or less. A linear data conversion is conducted by using a linear function FL corresponding to the height Hc for the maximum height Zmax expressed by fundamental data, and forming data is generated from the fundamental data. When the half-stereoscopic image is formed based on the forming data, the height distribution of the half- stereoscopic image becomes the height Hc or less. Thus, since unexpected foaming is not generated in the sheet, forming of the half-stereoscopic image having an arranged shape can be formed.

<CIT> discloses an apparatus and a method for foam molding capable of obtaining a half-stereoscopic image accurately reproducing the rugged shape of a stereoscopic article to become an object to be copied. The apparatus <NUM> (<NUM>, <NUM>) for foam molding forms a half- stereoscopic image of a three dimensional article by foaming a sheet-like foamable material FB based on the shape data of the article, and comprises a foaming unit FM for foaming the material FB, and a controller for controlling the foaming operation of the unit FM based on the shape data of the article. The unit FM directly heats the interior by focusing an infrared laser beam to a focal point F in the material FB to foam the material. Thus, sufficient foam amount can be assured. Preferably, the objective OL of the optical system OP of the unit FM is moved, and the material FB is irradiated with the beam while moving the point F of the beam in the thickness direction of the material FB.

In Unexamined <CIT>, due to heating of the thermally expandable microspheres by heat generated from the image-molding material forming the image, in addition to the thermally expandable microspheres of the coating layer corresponding to the image, the thermally expandable microspheres are also heated in the vicinity of the thermally expandable microspheres of the coating layer corresponding to the image. Due to expansion also in the vicinity of the image portion of the thermally expandable sheet in this manner, manufacture of a shaped object having fine unevennesses is difficult.

In consideration of the aforementioned circumstances, an objective of the present disclosure is to provide a shaping system and a manufacturing method of a shaped object that are capable of manufacturing a shaped object having finer unevennesses.

In order to achieve the aforementioned objective, the inventions are set out in the appended set of claims.

A more complete understanding of this application can be obtained when the following detailed description is considered in conjunction with the following drawings, in which:.

An apparatus and a shaping system equipped with the expansion apparatus according an embodiment of the present disclosure is described below with reference to drawings.

In the present embodiment, a shaping system <NUM> manufactures a shaped object <NUM> from a molding sheet <NUM> that thermally expands. The shaped object <NUM> is used as a decorative sheet, wallpaper, or the like. In the present disclosure, the term "shaped object" refers to a sheet that includes unevennesses shaped (formed) on a predetermined surface, and the unevennesses form geometrical shapes, characters, patterns, decorations, or the like. The term "decorations" refers to objects that appeal to the aesthetic sense through visual and/or tactile sensation. The term "shaped (or molded)" refers to the forming of a shaped object, and is to be construed to also include concepts such as decoration and ornamentation by forming decorations. Moreover, although the shaped object <NUM> of the present embodiment is a three-dimensional object that includes unevennesses on a predetermined surface, to distinguish this three-dimensional object from three-dimensional objects formed using a so-called 3D printer, the shaped object <NUM> of the present embodiment is called a <NUM>-dimensional (<NUM>. 5D) object or a pseudo-three-dimensional (pseudo-3D) object. The technique used to produce the shaped object of the present embodiment is called <NUM>. 5D printing or pseudo-3D printing.

The molding sheet <NUM> and the shaped object <NUM> are firstly described with reference to <FIG>. As illustrated in <FIG>, the molding sheet <NUM> is provided with a base <NUM> and a thermal expansion layer <NUM> laminated onto a first main surface 12a of the base <NUM>. In the present embodiment, the thermal expansion layer <NUM> is laminated onto the entire surface of the first main surface 12a.

The base <NUM> of the molding sheet <NUM> has a first main surface 12a to which the thermal expansion layer <NUM> is laminated and a second main surface 12b on the side opposite to the first main surface 12a. The base <NUM> supports the thermal expansion layer <NUM>. The base <NUM> is formed, for example, in a sheet-like shape. Examples of the material of the base <NUM> include thermoplastic resins such as polyolefin resins (polyethylene (PE), polypropylene (PP), or the like) and polyester resins (polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or the like). The type of material of the base <NUM> and the thickness of the base <NUM> are selected according to the intended application of the shaped object <NUM>.

The thermal expansion layer <NUM> of the molding sheet <NUM> is laminated onto the first main surface 12a of the base <NUM>. The thermal expansion layer <NUM> includes a binder and a non-illustrated thermal expansion material dispersed in the binder. Any thermoplastic resin, such as a vinyl acetate-type polymer or an acrylic-type polymer, may be used as the binder. The thermal expansion material expands as a result of being heated to a predetermined temperature or higher, and expands to a size in accordance with the heat amount of the heating, that is, specifically a heating temperature, a heating time, or the like. The thermal expansion material expands as a result of being heated to <NUM> to <NUM> or higher, for example. The thermal expansion material is thermally expandable microcapsules, for example.

The thermally expandable microcapsules are microcapsules that encapsulate a foaming agent including propane, butane, or another low boiling point substance in shells made from a thermoplastic resin. The shells of the thermally expandable microcapsules are formed from a thermoplastic resin such as, for example, polystyrene, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyacrylic acid ester, polyacrylonitrile, polybutadiene, and copolymers thereof. When the thermally expandable microcapsules are heated to the predetermined temperature or higher, the shells soften, the foaming agent vaporizes, and the pressure resulting from the vaporization of the foaming agent causes the shells to expand in a balloon-like manner. The thermally expandable microcapsules expand to a size about five-times larger than that prior to expansion. The average particle size of the thermally expandable microcapsules prior to expansion is about <NUM> to <NUM>, for example.

The thermal expansion layer <NUM> of the molding sheet <NUM> distends due to the expansion of the thermal expansion material, and a below-described first unevenness <NUM> and a second unevenness <NUM> are formed on a surface 20a opposite to the base <NUM>.

As illustrated in <FIG>, the shaped object <NUM> is provided with: the base <NUM>; the thermal expansion layer <NUM> laminated onto the first main surface 12a of the base <NUM> and having the first unevenness <NUM> and the second unevenness <NUM> on the side opposite to the base <NUM>; and a thermal conversion layer <NUM> laminated in a pattern corresponding to the first unevenness <NUM>.

The shaped object <NUM> is a sheet-like shaped object and has the first unevenness <NUM> and the second unevenness <NUM> of a surface. The configuration of the base <NUM> of the shaped object <NUM> is similar to the base <NUM> of the molding sheet <NUM>, and thus the thermal expansion layer <NUM> and the thermal conversion layer <NUM> of the shaped object <NUM> are described here.

The thermal expansion layer <NUM> of the shaped object <NUM> is a layer in which a portion of the thermal expansion layer <NUM> of the molding sheet <NUM> is expanded. The thermal expansion layer <NUM> of the shaped object <NUM> includes a binder similarly to the binder of the thermal expansion layer <NUM> of the molding sheet <NUM>, a thermal expansion material (thermal expansion material prior to thermal expansion) similarly to the thermal expansion material of the thermal expansion layer <NUM> of the molding sheet <NUM>, and a thermal expansion material that is the expanded thermal expansion material of the thermal expansion layer <NUM> of the molding sheet <NUM>.

The first unevenness <NUM> of the thermal expansion layer <NUM> is an unevenness due to a first convexity <NUM> formed by expansion of the thermal expansion material of the thermal expansion layer <NUM> of the molding sheet <NUM>. The first unevenness <NUM> includes a first convexity <NUM> and a first concavity <NUM>. Moreover, the second unevenness <NUM> of the thermal expansion layer <NUM> of the shaped object <NUM> is an unevenness due to a second convexity <NUM> formed by expansion of the thermal expansion material of the thermal expansion layer <NUM> of the molding sheet <NUM>. The second unevenness <NUM> includes the second convexity <NUM> and a second concavity <NUM>. Here, for the first convexity <NUM>, width (length in the longitudinal direction of the shaped object <NUM>) and length (length in the transverse direction of the shaped object <NUM>) are each greater than or equal to a respective threshold, and for the second convexity, the width and length are each smaller than the respective threshold. That is to say, when the first unevenness <NUM> and the second unevenness <NUM> are compared with each other, the unevenness of the second unevenness <NUM> is finer than the unevenness of the first unevenness <NUM>.

The thermal conversion layer <NUM> of the shaped object <NUM> is laminated, onto the second main surface 12b of the base <NUM>, in a pattern corresponding to the first unevenness <NUM> of the thermal expansion layer <NUM>. The thermal conversion layer <NUM> converts the irradiated electromagnetic waves into heat and releases the converted heat. The thermal expansion material is heated by the heat released from the thermal conversion layer <NUM>. The heated thermal expansion material expands to a size in accordance with a heating temperature, a heating period, or the like. Due to such operation, the expanded thermal expansion material is formed, and the thermal expansion layer <NUM> expands. Due to conversion of the electromagnetic waves by at the thermal conversion layer <NUM> to heat more rapidly than at other portions of the molding sheet <NUM>, a region, that is, the thermal expansion material, in the vicinity of the thermal conversion layer <NUM> can be heated.

The thermal conversion layer <NUM> is formed from a thermal conversion material that absorbs and converts the electromagnetic waves to heat. Examples of the thermal conversion material include carbon black, metal hexaboride compounds, and tungsten oxide compounds. Carbon black, for example, absorbs and converts visible light, infrared light, or the like to heat. Metal hexaboride compounds and tungsten oxide compounds absorb and convert near-infrared light to heat. Among the metal hexaboride compounds and the tungsten oxide compounds, lanthanum hexaboride (LaB<NUM>) and cesium tungsten oxide may be used from the perspectives of obtaining high light absorptivity in the near-infrared region and high transmittance in the visible light spectrum.

The shaping system <NUM> for manufacturing of the shaped object <NUM> from the molding sheet <NUM> is described next. As illustrated in <FIG>, the shaping system <NUM> is provided with: a control unit <NUM>; a printing device <NUM> for printing the thermal conversion layer <NUM> onto the molding sheet <NUM>; and an expansion apparatus <NUM> for causing expansion of at least a portion of the thermal expansion layer <NUM> of the molding sheet <NUM> to form the first convexity <NUM> and the second convexity <NUM>, that is, to form the first unevenness <NUM> and the second unevenness <NUM>.

The control unit <NUM> controls the printing device <NUM> and the expansion apparatus <NUM>. As illustrated in <FIG>, the control unit <NUM> is provided with a controller <NUM>, a storage <NUM>, a communication unit <NUM>, a recording medium drive <NUM>, an operation unit <NUM>, and a display <NUM>.

The controller <NUM> of the control unit <NUM> controls various components of the control unit <NUM>. Moreover, the controller <NUM> controls operations of the printing device <NUM> and the expansion apparatus <NUM>. Further, the controller <NUM>, based on unevenness data associating position on the thermal expansion layer <NUM> and height for causing expansion that represents the unevenness shape of the shaped object <NUM>, generates data for forming the first convexity <NUM> and the second convexity <NUM>. Further, the controller <NUM> functions as control means.

The controller <NUM> has a determiner <NUM> (determination means) for determining the first convexity <NUM> and the second convexity <NUM> based on the unevenness data, and a generator <NUM> (generation means) for generation of first convexity data for forming the distinguished first convexity <NUM> and the second convexity data for forming the distinguished second convexity <NUM>. The determiner <NUM> and the generator <NUM> function respectively as a determiner and a generation unit.

The determiner <NUM> of the controller <NUM>, for example, determines the convexity portions of the unevenness shape represented by the unevenness data. Next, the determiner <NUM> determines that a convexity portion having a height, width, and length that are each greater than or equal to the respective prescribed threshold is the first convexity <NUM>, and determines that a convexity portion having at least one of a width or a length that is less than the respective threshold value is the second convexity <NUM>. Then the determiner <NUM> generates, and outputs to the generator <NUM> of the controller <NUM>, the position data representing the positions of the determined first convexity <NUM> and second convexity <NUM>.

The generator <NUM> of the controller <NUM>, for example, based on the unevenness data and the position data output from the determiner <NUM>, generates the first convexity data associating a height for causing expansion of the first convexity <NUM> and the position thereof on the thermal expansion layer <NUM>, and the second convexity data associating a height for causing expansion of the second convexity <NUM> and the position thereof on the thermal expansion layer <NUM>. The first convexity data is data representing the first convexity <NUM>, and the second convexity data is data representing the second convexity <NUM>. The controller <NUM> controls operations of the printing device <NUM> and the expansion apparatus <NUM> based on the generated first convexity data and second convexity data.

The storage <NUM> of the control unit <NUM> stores data and programs used for control of the printing device <NUM> and the expansion apparatus <NUM>. The communication unit <NUM> of the control unit <NUM> communicates with the printing device <NUM> and the expansion apparatus <NUM>.

The recording medium drive <NUM> of the control unit <NUM> reads programs or data recorded on a portable recording medium. The term "portable recording medium" means a compact disc (CD)-ROM, a digital versatile disc (DVD)-ROM, a flash memory having a universal serial bus (USB) specification connector, or the like.

The operation unit <NUM> of the control unit <NUM> receives an operation from the user. The user can inputs a command for the control unit <NUM> by operation of the operation unit <NUM>.

The display <NUM> of the control unit <NUM> displays data, information representing status of the printing device <NUM> and the expansion apparatus <NUM>, or the like.

<FIG> illustrates configuration of hardware of the control unit <NUM>. The controller <NUM> includes a central processing unit (CPU) <NUM> and a random access memory (RAM) <NUM>. The functions of the controller <NUM> are achieved by the CPU <NUM> executing programs stored in the storage <NUM>. The storage <NUM> includes a read only memory (ROM) <NUM> and a hard disc <NUM>. The communication unit <NUM> is a communication interface <NUM>. The recording medium drive <NUM> is an optical disc drive <NUM>, for example. The operation unit <NUM> is a touch panel <NUM>, a keyboard, or a mouse, for example. An example of display <NUM> is a liquid crystal display <NUM>. The CPU <NUM> and various components are connected together via a bus <NUM>.

Again with reference to <FIG>, the printing device <NUM> is controlled by the control unit <NUM>. The printing device <NUM> prints the thermal conversion layer <NUM> onto the second main surface 12b of the base <NUM> of the molding sheet <NUM>. The printing device <NUM> is an ink jet printer, for example. The printing device <NUM> is provided with a controller including a CPU and a storage including ROM and RAM, although such components are not illustrated.

The printing device <NUM> prints the thermal conversion layer <NUM> in a pattern corresponding to the first unevenness <NUM>, on the basis of the first convexity data, generated by the controller <NUM> of the control unit <NUM>, associating position on the thermal expansion layer <NUM> with height for causing expansion of the first convexity <NUM>. Specifically, the amount of heat released from the thermal conversion layer <NUM> depends on the concentration of the thermal conversion material (that is, lightness-darkness of the ink), a unit surface area of the electromagnetic waves irradiated on the thermal conversion layer <NUM>, and the energy amount per unit time, and thus the printing device <NUM> prints a lightness-darkness pattern in accordance with the height and position of the first convexity <NUM> on the second main surface 12b of the base <NUM>. Such operation causes lamination of the thermal conversion layer <NUM> to the second main surface 12b of the base <NUM>.

The expansion apparatus <NUM> is controlled by the control unit <NUM>. The expansion apparatus <NUM> causes expansion of at least a portion of the thermal expansion layer <NUM> of the molding sheet <NUM>, thereby forming the first convexity <NUM>, that is, the first unevenness <NUM>, and the second convexity <NUM>, that is, the second unevenness <NUM>. As illustrated in <FIG>, the expansion apparatus <NUM>, within a housing <NUM>, is equipped with transport rollers 302a, 302b, 304a, and 304b (transportation means), a first expander <NUM> (first expansion means), and a second expander <NUM> (second expansion means). Moreover, the expansion apparatus <NUM> is equipped with a controller including a CPU and a storage including ROM and RAM, although these components are not illustrated. For ease of understanding in the present detailed description, in <FIG>, the length-wise rightward direction (rightward direction on the page) of the expansion apparatus <NUM> is described as the +X-axis direction, the upward direction (upward direction on the page) is described as the +Z-axis direction, and the direction perpendicular to the +X-axis direction and the +Z-axis direction is described as the +Y-axis direction (out the front of the page).

The transport roller 302a and the transport roller 302b form a pair of rollers, and the transport roller 304a and the transport roller 304b form a pair of rollers. The pair of transport rollers 302a and 302b nip and the pair of transport rollers 304a and 304b nip the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated. The transport rollers 302a, 302b, 304a, and 304b rotate and thus transport, from the -X side to the +X side, the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated. The transport rollers 302a, 302b, 304a, and 304b function as a transporter (transportation means) configured to transport the molding sheet <NUM> to which the thermal layer conversion layer <NUM> is laminated.

In the present embodiment, the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated is guided by a non-illustrated transport guide and is transported from the -X side to the +X side with the thermal expansion layer <NUM> facing the +Z-axis direction and the second main surface 12b of the base <NUM> facing the -Z-axis direction. While transporting the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, the expansion apparatus <NUM> causes expansion of the thermal expansion layer <NUM> of the molding sheet <NUM> by the first expander <NUM> and the second expander <NUM>.

The first expander <NUM> of the expansion apparatus <NUM> causes expansion of at least a portion of the thermal expansion layer <NUM> by irradiating with the electromagnetic waves the thermal conversion layer <NUM> laminated onto the molding sheet <NUM>. Specifically, the first expander <NUM> irradiates with the electromagnetic waves the thermal conversion layer <NUM> laminated onto the molding sheet <NUM>, thereby causing release of heat by the thermal conversion layer <NUM> within a region A irradiated with the electromagnetic waves. The first expander <NUM>, by the heat released from the thermal conversion layer <NUM>, causes heating and expansion of the thermal expansion material at a portion of the thermal expansion layer <NUM> corresponding to the thermal conversion layer <NUM>. Due to such operation, the first expander <NUM> causes expansion of the portion of the thermal expansion layer <NUM> corresponding to the thermal conversion layer <NUM>. Due to formation of the thermal conversion layer <NUM> on the basis of the first convexity data that associates the height for causing expansion as the first convexity <NUM> with the position on the thermal expansion layer <NUM>, the first convexity <NUM> is formed on the thermal expansion layer <NUM>. In the present embodiment, the first expander <NUM> is disposed to the -Z side relative to transportation path of the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, and irradiates with the electromagnetic waves from the -Z side, that is, from the second main surface 12b side of the base <NUM>. Moreover, the first expander <NUM> is disposed more to the -X side than the second expander <NUM>. In the present embodiment, the region A irradiated by the first expander <NUM> with the electromagnetic waves is wider than a region C irradiated with laser light by the second expander <NUM> as described below.

The first expander <NUM> is equipped with, for example, a cover <NUM>, a lamp <NUM>, a reflection plate <NUM>, and a fan <NUM>. The cover <NUM> contains the lamp <NUM>, the reflection plate <NUM>, and the fan <NUM>. The lamp <NUM> includes a straight tube-type halogen lamp, for example. The lamp <NUM> irradiates the molding sheet <NUM> with the electromagnetic waves in the near infrared region (<NUM> to <NUM>,<NUM> wavelength), the visible light region (<NUM> to <NUM>), the middle infrared region (<NUM>,<NUM> to <NUM>,<NUM>), or the like. The reflection plate <NUM> reflects toward the molding sheet <NUM> the electromagnetic waves irradiated from the lamp <NUM>. The fan <NUM> blows air into the cover <NUM> and cools the lamp <NUM> and the reflection plate <NUM>.

The second expander <NUM> of the expansion apparatus <NUM> heats and causes expansion of the region C by irradiating with the laser light the region C that is smaller in size that the region, that is, the region B of the first convexity <NUM> in the present embodiment, made to expand by the first expander <NUM> on the thermal expansion layer <NUM>. Specifically, based on the second convexity data generated by the control unit <NUM>, the second expander <NUM> causes heating and expansion of the thermal expansion material by irradiation with the laser light of an intensity corresponding to the height of the second convexity <NUM> at the position of formation of the second convexity <NUM> on the thermal expansion layer <NUM>. Due to such operation, the thermal expansion layer <NUM> expands, and the second convexity <NUM> is formed on the thermal expansion layer <NUM>. In the present embodiment, the second expander <NUM> is disposed further to the +Z side relative to the transport path of the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, and irradiates with the laser light from the +Z side, that is, from the thermal expansion layer <NUM> side. Moreover, the second expander <NUM> is disposed further to the +X side than the first expander <NUM>.

The second expander <NUM> is a carbon dioxide gas laser irradiator, for example. The second expander <NUM> includes non-illustrated components such as a carbon dioxide gas laser oscillation unit, a polygonal mirror, a lens, or the like. By the polygonal mirror reflecting the carbon dioxide gas laser light emitted by the carbon dioxide gas laser oscillation unit, and by scanning of the carbon dioxide gas laser light in the +Y and -Y directions, the second expander <NUM> irradiates with the carbon dioxide gas laser light the position of formation of the second convexity <NUM> on the thermal expansion layer <NUM>.

In the present embodiment, the second expander <NUM> irradiates with the laser light the small region C of the thermal expansion layer <NUM> of the molding sheet <NUM>, and thus locally heats the small region C. Thus the expansion apparatus <NUM> can manufacture the shaped object <NUM> that has the finer second unevenness <NUM>, that is, that has the finer second convexity <NUM>. Further, in the present disclosure, the expression "heat by irradiation with the laser light" indicates heating with the laser light without conversion of the energy of the laser light to thermal energy, that is, without heating via the thermal conversion layer <NUM>.

The manufacturing method of the shaped object <NUM> is described next with reference to <FIG>. In the present embodiment, the shaped object <NUM> is manufactured from the molding sheet <NUM> that is sheet-like, such as an A4 paper-sized sheet.

<FIG> is a flowchart illustrating the manufacturing method of the shaped object <NUM>. The manufacturing method of the shaped object <NUM> includes a preparation step of preparing the molding sheet <NUM> and the data (step S10), a thermal conversion layer laminating step of laminating to the molding sheet <NUM> the thermal conversion layer <NUM> for conversion of the electromagnetic waves into heat (step S20), a first expansion step of causing heating and expansion of at least a portion of the thermal expansion layer <NUM> of the molding sheet <NUM> by irradiation of the thermal conversion layer <NUM> with the electromagnetic waves to release of heat from the thermal conversion layer <NUM> (step S30), and a second expansion step of causing heating and expansion of a region with the laser light by irradiating the region of a size smaller than the region of the thermal expansion layer <NUM> expanded in the first expansion step that is step S30 (step S40).

The molding sheet <NUM>, the first convexity data associating the position of the thermal expansion layer <NUM> with the height for causing expansion of the first convexity <NUM>, and the second convexity data associating the position on the thermal expansion layer <NUM> and the height for causing expansion of the second convexity <NUM> are prepared in the preparation step (step S10).

The molding sheet <NUM> is manufactured by screen printing, for example, onto the first main surface 12a of the base <NUM> a coating liquid formed by mixing the binder and the thermal expansion material, and then drying the printed coating liquid.

As illustrated in <FIG>, the first convexity data and the second convexity data are generated from the unevenness data by data generation processing executed by the control unit <NUM>. The unevenness data represents the unevenness shape of the shaped object <NUM>, and is data that associates the position on the thermal expansion layer <NUM> with the height for causing expansion. In the data generation processing, firstly the determiner <NUM> of the controller <NUM>, by a command from the user, acquires the unevenness data stored in the storage <NUM>, and determines the convexity portions represented by the unevenness data (step S2). Then the determiner <NUM> determines that the convexity portion for which the height, the width, and the length are each greater than or equal to the respective threshold is the first convexity <NUM>, and determines that the convexity portion for which at least one of the width or the length is less than the respective threshold value is the second convexity <NUM> (step S4). The determiner <NUM> generates the position data representing the positions of the determined first convexity <NUM> and second convexity <NUM>, and outputs such position data to the generator <NUM> of the controller <NUM> (step S6). Next, the generator <NUM> generates the first convexity data and the second convexity data based on the unevenness data and the position data output from the determiner <NUM> (step S8). The first convexity data and the second convexity data are prepared by such processing. Further, the unevenness data can be generated from computer-aided design (CAD) data of the shaped object <NUM>.

Again with reference to <FIG>, in the thermal conversion layer laminating step (step S20), based on the first convexity data, the printing device <NUM> prints a lightness-darkness pattern, that is, a pattern corresponding to the first unevenness <NUM>, onto the second main surface 12b of the base <NUM> of the molding sheet <NUM> in accordance with height and position of the first convexity <NUM> using ink that includes the thermal conversion material. Due to this operation, as illustrated in <FIG>, the thermal conversion layer <NUM> is laminated onto the second main surface 12b of the base <NUM> of the molding sheet <NUM>.

Then in the first expansion step (step S30), while transporting the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, the first expander <NUM> of the expansion apparatus <NUM> irradiates the thermal conversion layer <NUM> with the electromagnetic waves that the thermal conversion layer <NUM> converts into heat. Then due to the heat released from the thermal conversion layer <NUM>, the portion of the thermal expansion layer <NUM> of the molding sheet <NUM> corresponding to the thermal conversion layer <NUM> is heated and expands. The first convexity <NUM> is formed by this operation.

Finally in a second expansion step (step S40), during transporting of the molding sheet <NUM> on which the first convexity <NUM> is formed, the second expander <NUM> of the expansion apparatus <NUM> irradiates with the laser light the thermal expansion layer <NUM> of the molding sheet <NUM> on which the first convexity <NUM> is formed. Specifically, on the basis of the second convexity data, the second expander <NUM> causes heating and expansion of the region C by irradiation with the laser light of the region C that is smaller in size that the size of the region B expanded in the first expansion step (step S30) of the thermal expansion layer <NUM>. Due to such operation, the thermal expansion layer <NUM> expands, and the second convexity <NUM> is formed. The above processing enables manufacture of the shaped object <NUM>.

In the present embodiment, the second expander <NUM> of the expansion apparatus <NUM> locally heats the small region C of the thermal expansion layer <NUM> of the molding sheet <NUM>, thereby enabling the expansion apparatus <NUM> to manufacture the shaped object <NUM> that has the further finely-detailed second unevenness <NUM>. Moreover, the first expander <NUM> of the expansion apparatus <NUM> heats the large region B of the thermal expansion layer <NUM> across an entire thickness direction of the thermal expansion layer <NUM> via the thermal conversion layer <NUM>, and thus can form a large and tall first unevenness <NUM>. Therefore, the expansion apparatus <NUM> can manufacture the shaped object <NUM> that has tall and fine unevennesses.

Although the second convexity <NUM> is formed in Embodiment <NUM> after formation of the first convexity <NUM>, the first convexity <NUM> may be formed after the second convexity <NUM>.

The molding sheet <NUM>, the shaped object <NUM>, the control unit <NUM>, and the printing device <NUM> of the present embodiment are similar to those of Embodiment <NUM>, and thus the shaping system <NUM> of the expansion apparatus <NUM> is described below.

As illustrated in <FIG>, the expansion apparatus <NUM> of the present embodiment includes, within the housing <NUM>, the transport rollers 302a, 302b, 304a, and 304b, the first expander <NUM>, and the second expander <NUM>. Moreover, the expansion apparatus <NUM> includes a controller including a CPU and a storage including ROM and RAM, although these components are not illustrated. In the present embodiment, the disposal of the first expander <NUM> and the second expander <NUM> differs from the disposal of the first expander <NUM> and the second expander <NUM> in Embodiment <NUM>. The other components are configured similarly to those of Embodiment <NUM>.

In the same manner as the first expander <NUM> of Embodiment <NUM>, the first expander <NUM> of the present embodiment irradiates with the electromagnetic waves the thermal conversion layer <NUM> laminated onto the molding sheet <NUM>, thereby causing expansion of the portion corresponding to the thermal conversion layer <NUM> of the thermal expansion layer <NUM>. The first expander <NUM> of the present embodiment is disposed further to the +X side than the second expander <NUM>. Moreover, the first expander <NUM> of the present embodiment irradiates with the electromagnetic waves from the second main surface 12b side of the base <NUM>. Similarly to the first expander <NUM> of Embodiment <NUM>, the first expander <NUM> of the present embodiment includes the cover <NUM>, the lamp <NUM>, the reflection plate <NUM>, and the fan <NUM>. The cover <NUM>, the lamp <NUM>, the reflection plate <NUM>, and the fan <NUM> are configured similarly to such components in Embodiment <NUM>.

Similarly to the second expander <NUM> of Embodiment <NUM>, the second expander <NUM> of the present embodiment causes heating and expansion of the region C by irradiating with the laser light the region C that is smaller in size than the region, that is, the region B, of the first convexity <NUM> of the thermal expansion layer <NUM>, made to expand by the first expander <NUM>. The second expander <NUM> of the present embodiment is disposed further to the -X side than the first expander <NUM>. Therefore, in the present embodiment, the first expander <NUM> and the second expander <NUM> are disposed, along the direction of transport of the molding sheet <NUM> by the transport rollers 302a, 302b, 304a, and 304b in order as the second expander <NUM> and the first expander <NUM>.

Moreover, the second expander <NUM> of the present embodiment irradiates with the laser light from the thermal expansion layer <NUM> side. Similarly to the second expander <NUM> of Embodiment <NUM>, the second expander <NUM> of the present embodiment is a carbon dioxide gas laser irradiator.

The manufacturing method of the shaped object <NUM> of the present embodiment is described next. <FIG> is a flowchart illustrating the manufacturing method of the shaped object <NUM> of the present embodiment. The manufacturing method of the shaped object <NUM> of the present embodiment includes the preparation step (step S10), the thermal conversion layer laminating step (step S20), a second expansion step (step S50), and a first expansion step (step S60). The preparation step (step S10) and the thermal conversion layer laminating step (step S20) of the present embodiment are similar to the preparation step (step S10) and the thermal conversion layer laminating step (step S20) of Embodiment <NUM>, and thus the second expansion step (step S50) and the first expansion step (step S60) are described below.

In the second expansion step (step S50), during transporting the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, based on the second convexity data, the second expander <NUM> of the present embodiment irradiates with the laser light the region C that is smaller in size than the region B of the thermal expansion layer <NUM> expanded in the first expansion step (step S60). Thereafter, the region C is heated and expanded by the laser light. Due to such operation, the thermal expansion layer <NUM> expands, and the second convexity <NUM> is formed.

In the first expansion step (step S60), while the molding sheet <NUM> on which the second convexity <NUM> is formed is transported, the first expander <NUM> of the present embodiment irradiates with the electromagnetic waves the thermal conversion layer <NUM> laminated to the molding sheet <NUM> on which is formed the second convexity <NUM>. Thereafter, the portion of the thermal expansion layer <NUM> corresponding to the thermal conversion layer <NUM> is expanded by the heat released from the thermal conversion layer <NUM>. The first convexity <NUM> is formed by such operation. Due to the aforementioned operations, the shaped object <NUM> can be manufactured.

Due to localized heating of the small region C of the molding sheet <NUM> by the second expander <NUM> also in the present embodiment, the expansion apparatus <NUM> can manufacture the shaped object <NUM> that has the more finely-detailed second unevenness <NUM>. Moreover, the first expander <NUM> heats the large region B of the molding sheet <NUM> along the entire thickness direction of the thermal expansion layer <NUM> via the thermal conversion layer <NUM>, and thus can form a large and tall first unevenness <NUM>. Therefore, the expansion apparatus <NUM> can manufacture the shaped object <NUM> that has the tall and fine unevenness.

Further, the second expander <NUM> locally heats the region C of the thermal expansion layer <NUM> with the laser light, and hardly heats the periphery of the region C. Therefore by formation of the first convexity <NUM> by the first expander <NUM> after formation of the second convexity <NUM> by the second expander <NUM>, the first convexity <NUM> can be more accurately formed without undergoing the effects of heating in order to form the second convexity <NUM>. In the present embodiment, the first expander <NUM> and the second expander <NUM> of the expansion apparatus <NUM> may be disposed in order as the second expander <NUM> and the first expander <NUM> along the transport direction of the molding sheet <NUM>.

In Embodiment <NUM> and Embodiment <NUM>, the first expander <NUM> and the second expander <NUM> are fixed to the housing <NUM>, and the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated is transported. The first expander <NUM> and the second expander <NUM> may be moved without transporting the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated. Moreover, the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated may be irradiated from the same side with both the electromagnetic waves of the first expander <NUM> and the laser light of the second expander <NUM>.

The molding sheet <NUM>, the shaped object <NUM>, the control unit <NUM>, and the printing device <NUM> of the present embodiment are similar to such components of Embodiment <NUM>, and thus the expansion apparatus <NUM> of the shaping system <NUM> is described below.

As illustrated in <FIG>, the expansion apparatus <NUM> of the present embodiment includes, within the housing <NUM>, a tray <NUM>, the first expander <NUM>, and the second expander <NUM>. Moreover, the expansion apparatus <NUM> includes a controller including a CPU and a storage including ROM and RAM, although such components are not illustrated.

The tray <NUM> of the expansion apparatus <NUM> is used to dispose the molding sheet <NUM> carried thereon at a prescribed position in the expansion apparatus <NUM>. The tray <NUM> is a box-shaped case that has an open surface in the +Z direction, for example. The molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated is carried on the tray <NUM> such that the thermal expansion layer <NUM> faces the +Z-axis direction.

As illustrated in <FIG>, while moving above the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, the first expander <NUM> of the present embodiment irradiates with the electromagnetic waves the thermal conversion layer <NUM> laminated to the molding sheet <NUM>. Due to such operation, the first expander <NUM> of the present embodiment causes the release of heat of the thermal conversion layer <NUM> within the region A irradiated with the electromagnetic waves, and causes heating and expansion of the portion of the thermal expansion layer <NUM> corresponding to the thermal conversion layer <NUM>. Similarly to Embodiment <NUM>, the thermal conversion layer <NUM> is formed based on the first convexity data, and thus the first convexity <NUM> is formed in the thermal expansion layer <NUM>.

The first expander <NUM> in the present embodiment irradiates with the electromagnetic waves from the thermal expansion layer <NUM> side while moving in the -X-axis direction from the +X-side standby position. Moreover, similarly to Embodiment <NUM>, the region A irradiated with the electromagnetic waves by the first expander <NUM> of the present embodiment is wider than the region C irradiated by the laser light of the second expander <NUM> of the present embodiment. Further, the term "standby position" refers to the position of withdrawal from above the molding sheet <NUM>.

The first expander <NUM> of the present embodiment, similarly to Embodiment <NUM>, includes the cover <NUM>, the lamp <NUM>, the reflection plate <NUM>, and the fan <NUM>. Moreover, the first expander <NUM> of the present embodiment is moved above the molding sheet <NUM> in the -X-axis direction and +X-axis direction by a non-illustrated movement mechanism. The configurations of the cover <NUM>, the lamp <NUM>, the reflection plate <NUM>, and the fan <NUM> are similar to such configurations in Embodiment <NUM>.

The second expander <NUM> of the present embodiment, based on the second convexity data, moves in the +X-axis direction and repeatedly irradiates, that is, scans, with the laser light. The second expander <NUM> causes heating and expansion of the region C by irradiating with the laser light the region C that is smaller is size than the region B expanded by the first expander <NUM> in the thermal expansion layer <NUM>. Specifically, as illustrated in <FIG>, the second expander <NUM> of the present embodiment moves above the molding sheet <NUM> to which the thermal conversion layer <NUM> is laminated, and based on the second convexity data, causes heating and expansion of the thermal expansion material by irradiation with the laser light. Due to such operation, the thermal expansion layer <NUM> expands, and the second convexity <NUM> is formed in the thermal expansion layer <NUM>.

In the present embodiment, the second expander <NUM> moves from the standby position of the -X side to the +X-axis direction, and irradiation with the laser light is performed from the thermal expansion layer <NUM> side.

Similarly to Embodiment <NUM>, the second expander <NUM> of the present embodiment is a carbon dioxide gas laser irradiator. The second expander <NUM> of the present embodiment moves above the molding sheet <NUM> in the +X-axis direction and the -X-axis direction due to a non-illustrated movement mechanism.

Next, the manufacturing method of the shaped object <NUM> of the present embodiment is described. <FIG> is a flowchart illustrating the manufacturing method of the shaped object <NUM> of the present embodiment. The manufacturing method of the shaped object <NUM> of the present embodiment includes the preparation step (step S10), the thermal conversion layer laminating step (step S20), a second expansion step (step S70), and a first expansion step (step S80). The preparation step (step S10) and the thermal conversion layer laminating step (step S20) of the present embodiment are similar to the preparation step (step S10) and the thermal conversion layer laminating step (step S20) of Embodiment <NUM>, and thus the second expansion step (step S70) and the first expansion step (step S80) are described.

As illustrated in <FIG>, in the second expansion step (step S70), the second expander <NUM> is moved, and based on the second convexity data, the second expander <NUM> irradiates with the laser light the region C that is smaller in size than the region B expanded in the thermal expansion layer <NUM> in the first expansion step (step S80). Then the region C is heated and expanded with the laser light. The second convexity <NUM> is formed by repeatedly moving the second expander <NUM> and irradiating with the laser light by the second expander <NUM>.

As illustrated in <FIG>, in the first expansion step (step S80), while the first expander <NUM> is moved, the first expander <NUM> irradiates with the electromagnetic waves the thermal conversion layer <NUM> laminated onto the molding sheet <NUM> on which is formed the second convexity <NUM>. Then the heat released from the thermal conversion layer <NUM> causes heating and expansion of the portion of the thermal expansion layer <NUM> corresponding to the thermal conversion layer <NUM>. Due to such operation, the first convexity <NUM> is formed. The shaped object <NUM> can be manufactured by the aforementioned operations.

The second expander <NUM> locally heats the small region C also in the present embodiment, and thus the expansion apparatus <NUM> can manufacture the shaped object <NUM> that has a more finely detailed second unevenness <NUM>. Moreover, similarly to Embodiment <NUM>, the expansion apparatus <NUM> can manufacture the shaped object <NUM> that has a high and fine unevenness. Further, after formation of the second convexity <NUM> by the second expander <NUM>, the first convexity <NUM> is further formed by the first expander <NUM>. Therefore, similarly to Embodiment <NUM>, the first convexity <NUM> can be formed accurately without undergoing the effects of heating due to the forming of the second convexity <NUM>.

Although in Embodiment <NUM> to Embodiment <NUM> the first expander <NUM> irradiates with the electromagnetic waves the thermal conversion layer <NUM> laminated to the molding sheet <NUM>, a means other than the first expander <NUM> may be used.

Firstly, the molding sheet <NUM> and the shaped object <NUM> of the present embodiment are described with reference to <FIG>. As illustrated in <FIG>, the molding sheet <NUM> includes the base <NUM> and the thermal expansion layer <NUM>. In the present embodiment, the thermal expansion layer <NUM> is laminated onto the first main surface 12a of the base <NUM> in a prescribed pattern that corresponds to the shape and disposal of the first convexity <NUM> of the below-described shaped object <NUM>. Other configuration of the base <NUM> and the thermal expansion layer <NUM> is similar to that in Embodiment <NUM>.

As illustrated in <FIG> and <FIG>, the shaped object <NUM> of the present embodiment includes the base <NUM>, and the thermal expansion layers <NUM> including the first convexity <NUM> and the second convexity <NUM> laminated onto the first main surface 12a of the base <NUM>. The shaped object <NUM> of the present embodiment has the first unevenness <NUM> formed from the first convexities <NUM> and the first concavities <NUM>, and the second unevennesses <NUM> formed from the second convexities <NUM> and the second concavities <NUM>. The first unevenness <NUM> is an unevenness due to the first convexities <NUM>, and the second unevenness <NUM> is an unevenness due to the second convexities <NUM>. The base <NUM> of the shaped object <NUM> of the present embodiment is configured similarly to the base <NUM> of Embodiment <NUM>, and thus the thermal expansion layer <NUM> of the shaped object <NUM> is described here. In the present embodiment, the shaped object <NUM> does not include the thermal conversion layer <NUM>.

The thermal expansion layer <NUM> of the shaped object <NUM> is the layer that is the expanded thermal expansion layer <NUM> of the molding sheet <NUM>. The thermal expansion layer <NUM> includes the binder similarly to the binder of the thermal expansion layer <NUM> of the molding sheet <NUM>, and the thermal expansion material that is the expanded material of the thermal expansion layer <NUM> of the molding sheet <NUM>.

Moreover, the thermal expansion layer <NUM> includes the first convexity <NUM> and the second convexity <NUM>. Similarly to the first convexity <NUM> of Embodiment <NUM>, the first convexity <NUM> of the present embodiment has a width and a length that are each greater than or equal to the respective determined threshold. Moreover, similarly to the second convexity <NUM> of Embodiment <NUM>, the second convexity <NUM> of the present embodiment has at least one of a width or a length that is smaller than the respective threshold. That is to say, when the first unevenness <NUM> and the second unevenness <NUM> are compared, the second unevenness <NUM> is finer than the first unevenness <NUM>.

The shaping system <NUM> of the present embodiment is described next. As illustrated in <FIG>, the shaping system <NUM> of the present embodiment is provided with the control unit <NUM>, and the expansion apparatus <NUM> for forming the first convexity <NUM> and the second convexity <NUM>, that is, the first unevenness <NUM> and the second unevenness <NUM>. The shaping system <NUM> of the present embodiment is not provided with the printing device <NUM>.

The control unit <NUM> of the present embodiment controls the expansion apparatus <NUM>. Similarly to Embodiment <NUM>, the control unit <NUM> includes the controller <NUM>, the storage <NUM>, the communication unit <NUM>, the recording medium drive <NUM>, the operation unit <NUM>, and the display <NUM>. The storage <NUM>, the communication unit <NUM>, the recording medium drive <NUM>, the operation unit <NUM>, and the display <NUM> of the present embodiment are configured similarly to Embodiment <NUM>.

The controller <NUM> of the present embodiment controls the various components of the control unit <NUM>. Moreover, the controller <NUM> controls operation of the expansion apparatus <NUM>. The controller <NUM> of the present embodiment operates similarly to the controller <NUM> of Embodiment <NUM>, except for not controlling the printing device <NUM> and not generating the first convexity data and the second convexity data. In the present embodiment, the second convexity data associating the position on the thermal expansion layer <NUM> and the height for causing expansion as the second convexity <NUM> is created by the user and is stored beforehand in the storage <NUM>.

As illustrated in <FIG>, the expansion apparatus <NUM> of the present embodiment includes, within the housing <NUM>, the transport rollers 302a, 302b, 304a, and 304b, the first expander <NUM>, and the second expander <NUM>. Moreover, the expansion apparatus <NUM> is equipped with a controller including a CPU and a storage including ROM and RAM, none of which are illustrated.

Similarly to Embodiment <NUM>, the transport rollers 302a, 302b, 304a, and 304b function as a transporter for transporting the molding sheet <NUM>. In the present embodiment, the molding sheet <NUM> is guided by a non-illustrated transport guide and is transported from the -X side to the +X side with the thermal expansion layer <NUM> facing the +Z-axis direction.

The first expander <NUM> of the present embodiment heats the transported molding sheet <NUM> and thus causes expansion of at least a portion of the thermal expansion layer <NUM>. The first expander <NUM> of the present embodiment, for example, is an electrical heater than heats the region A. In the present embodiment, the thermal expansion layer <NUM> of the molding sheet <NUM> is formed in a pattern corresponding to the shape and position of the first convexity <NUM>. Therefore, by the first expander <NUM> of the present embodiment heating the molding sheet <NUM> that is being transported, the thermal expansion layer <NUM> of the molding sheet <NUM> is expanded, and the first convexity <NUM> is formed.

In the present embodiment, the first expander <NUM> is disposed at the -Z side of the transport path of the molding sheet <NUM> and heats the molding sheet <NUM> from the second main surface 12b side of the base <NUM>. Moreover, the first expander <NUM> is disposed to the +X side of the second expander <NUM>. In the present embodiment, the region A heated by the first expander <NUM> is wider than the region C irradiated with the laser light by the second expander <NUM>.

Similarly to the second expander <NUM> of Embodiment <NUM>, the second expander <NUM> of the present embodiment irradiates with the laser light the region C that is smaller in size than the region, that is, the region B of the first convexity <NUM>, of the thermal expansion layer <NUM> expanded by the first expander <NUM>. The second expander <NUM> of the present embodiment causes heating and expansion of the region C by use of the laser light. Specifically, the second expander <NUM> of the present embodiment, on the basis of the second convexity data stored in the storage <NUM> of the control unit <NUM>, irradiates the position of the thermal expansion layer <NUM> for formation of the second convexity <NUM> with the laser light having a strength in accordance with the height of the second convexity <NUM>. Then the second expander <NUM> of the present embodiment heats and expands the thermal expansion material with the laser light. Due to such operation, the thermal expansion layer <NUM> is expanded, and the second convexity <NUM> is formed.

The second expander <NUM> of the present embodiment is disposed to the -X side of the first expander <NUM>, and irradiates with the laser light from the thermal expansion layer <NUM> side. Similarly to Embodiment <NUM>, the second expander <NUM> of the present embodiment is a carbon dioxide gas laser irradiator.

Next, the manufacturing method of the shaped object <NUM> of the present invention is explained below. In the present embodiment, the shaped object <NUM> is manufactured from the molding sheet <NUM> that is sheet-like, such as an A4 paper-sized sheet.

<FIG> is a flowchart illustrating the manufacturing method of the shaped object <NUM> of the present embodiment. The manufacturing method of the shaped object <NUM> of the present embodiment includes: the preparation step of preparation of the molding sheet <NUM> and the data (step S10); a second expansion step of heating and expanding a region, smaller in size than the region expanded in the first expansion step (step S100), with laser light (step S90); and a first expansion step of heating the molding sheet <NUM> and expanding at least a portion of the thermal expansion layer <NUM> (step S <NUM>). The present embodiment does not include the thermal conversion layer laminating step (step S20).

In the preparation step (step S10), the molding sheet <NUM> and the second convexity data associating the position on the thermal expansion layer <NUM> with the height for causing expansion of the second convexity <NUM> are prepared. The molding sheet <NUM>, for example, is manufactured by screen printing, onto the first main surface 12a of the base <NUM> in a pattern in accordance with the position and shape of the first convexity <NUM> of the shaped object <NUM>, the coating liquid formed by mixing the binder and the thermal expansion material, and then drying the printed coating liquid. The second convexity data is created by the user.

Similarly to the second expansion step (step S30) of Embodiment <NUM>, in the second expansion step (step S90), the position of formation of the second convexity <NUM> of the thermal expansion layer <NUM> is irradiated by the second expander <NUM> with the laser light of an intensity in accordance with the height of the second convexity <NUM> based on the second convexity data. Then the thermal expansion material is heated and expanded with the laser light. Due to such operation, the second convexity <NUM> is formed in the thermal expansion layer <NUM>.

While the molding sheet <NUM> is transported in the first expansion step (step S <NUM>), the first expander <NUM> of the expansion apparatus <NUM> heats the molding sheet <NUM> and thus expands the thermal expansion layer <NUM>. The first convexity <NUM> is formed due to such operation. Due to the aforementioned operations, the shaped object <NUM> can be manufactured.

In the present embodiment, the thermal expansion layer <NUM> is laminated in the prescribed pattern to the first main surface 12a of the base <NUM>, and therefore the shaped object <NUM> can be manufacture without lamination of the thermal conversion layer <NUM> to the base <NUM>. Moreover, the second expander <NUM> in the present embodiment also locally heats the region C that is small, and thus expansion apparatus <NUM> can manufacture the shaped object <NUM> that has the second unevenness <NUM> that is further detailed. Due to heating of the large region B of the molding sheet <NUM> over the entire thickness direction of the thermal expansion layer <NUM>, the first expander <NUM> can form the first unevenness <NUM> that is large and high. Therefore, the expansion apparatus <NUM> is capable of manufacturing the shaped object <NUM> that has the unevenness that is high and finely detailed. Furthermore, after the second expander <NUM> forms the second convexity <NUM>, the first expander <NUM> forms the first convexity <NUM>. Therefore, similarly to Embodiment <NUM>, the first convexity <NUM> can be formed accurately without undergoing the effects of heating for formation of the second convexity <NUM>.

Although embodiments of the present disclosure are described above, various types of modifications are possible within a scope that does not depart from the gist of the present disclosure.

For example, the shaped object <NUM> may be manufactured in a roll shape from a roll-like molding sheet <NUM>.

The material included in the base <NUM> is not limited to thermoplastic resins. The material included in the base <NUM> may be paper, fabric, or the like. The thermoplastic resin included in the base <NUM> is not limited to polyolefin resins and polyester resins. The thermoplastic resin included in the base <NUM> may be a polyamide resin, a polyvinyl chloride (PVC) resin, a polyimide resin, or the like.

In Embodiment <NUM> to Embodiment <NUM>, the thermal conversion layer <NUM> is laminated onto the second main surface 12b of the base <NUM>. The thermal conversion layer <NUM> may be laminated onto the thermal expansion layer <NUM>. Moreover, the thermal conversion layer <NUM> may be laminated to a release layer provided on the second main surface 12b of the base <NUM>. Due to such configuration, by peeling away the release layer from the shaped object <NUM>, the thermal conversion layer <NUM> can be removed from the shaped object <NUM>.

The molding sheet <NUM> and the shaped object <NUM> may be formed with another layer of a freely-selected material between the various layers. For example, an adhesive layer may be formed between the base <NUM> and the thermal expansion layer <NUM> for causing stronger adhesion between the base <NUM> and the thermal expansion layer <NUM>. The adhesive layer, for example, includes a surface modifier.

Moreover, a color image may be printed onto the shaped object <NUM>. For example, a color ink layer representing the color image and including the four colors of cyan, magenta, yellow, and black may be laminated onto the thermal expansion layer <NUM> of the shaped object <NUM>.

The printing device <NUM> is not limited to an ink jet printer. For example, the printing device <NUM> may be a laser printer. Moreover, the printing device <NUM> may print the color image onto the shaped object <NUM>.

The direction in which the first expander <NUM> of Embodiment <NUM> to Embodiment <NUM> irradiates with the electromagnetic waves is freely-selected. For example, although the first expander <NUM> of Embodiment <NUM> and Embodiment <NUM> irradiates with the electromagnetic waves from the second main surface 12b side of the base <NUM>, the first expander <NUM> of Embodiment <NUM> and Embodiment <NUM> may irradiate with the electromagnetic waves from the thermal expansion layer <NUM> side. Moreover, in Embodiment <NUM>, the first expander <NUM> may irradiate with the electromagnetic waves from the second main surface 12b side of the base <NUM> when irradiating the molding sheet <NUM> placed in the tray <NUM> with the thermal conversion layer <NUM> facing in the +Z-axis direction. In this case, the tray <NUM> may have a opening part at the bottom in order not to impede expansion of the thermal expansion layer <NUM>.

The direction in which the second expander <NUM> irradiates the molding sheet <NUM> with the laser light is freely-selected. In order to avoid absorption of the laser light by the thermal conversion layer <NUM>, the second expander <NUM> may irradiate the thermal expansion layer <NUM> with the laser light from the side opposite to the side to which the thermal conversion layer <NUM> is laminated.

Furthermore, although in Embodiment <NUM> and Embodiment <NUM> the first convexity <NUM> is formed after formation of the second convexity <NUM>, the second convexity <NUM> may be formed after the first convexity <NUM>.

In Embodiment <NUM> to Embodiment <NUM>, the region A in the thermal conversion layer <NUM> irradiated with the electromagnetic waves by the first expander <NUM> is wider than the region C in the thermal expansion layer <NUM> irradiated with the laser light by the second expander <NUM>. Therefore an irradiation width of the laser light of the second expander <NUM> irradiated onto thermal expansion layer <NUM> is indicated as narrower than an irradiation width of the electromagnetic waves of the first expander <NUM> irradiated onto the thermal conversion layer <NUM>.

In Embodiment <NUM> to Embodiment <NUM>, the control unit <NUM> is equipped with the CPU <NUM>, and the printing device <NUM> and the expansion apparatus <NUM> are controlled by functions of the CPU <NUM>. In the present disclosure, the control unit <NUM> may be provided with dedicated hardware such as an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a control circuit, or the like in place of the CPU <NUM>. In this case, the individual processes may be executed by separate hardware. Alternatively, each of the processes may be executed collectively by a single hardware unit. Part of the processing may be executed by dedicated hardware, and the remaining other part of the processing may be executed by software or firmware. Moreover, the functions of the controller <NUM> of the control unit <NUM> may be executed by the controller of the expansion apparatus <NUM>.

Furthermore, by providing a configuration for achieving the functions according to the present disclosure to a previously provided expansion apparatus, all of the functional configuration of the expansion apparatus <NUM> cited in the aforementioned embodiments can be achieved by control of the expansion apparatus by use of a program. That is, a program for achieving all of the functional configuration of the expansion apparatus <NUM> cited in the aforementioned embodiments can be used for enabling execution by a processor such as a CPU that controls a device such as a preexisting information processing device.

Moreover, the method of using such a program is freely-selected. The program may be used by storage on a computer-readable recording medium such as a flexible disc, a CD-ROM, a DVD-ROM, a memory card, or the like. Further, the program may be used via a communication medium such as the Internet by superposition on a carrier wave. For example, the program may be posted on, and distributed from, a bulletin board system (BBS) on the communication network. Moreover, a configuration may be used that executes the aforementioned processing by starting the program, and under control of the operating system (OS), executing the program similarly to execution of other application programs.

Claim 1:
A shaping system (<NUM>) for manufacturing a shaped object (<NUM>) having unevenness due to expansion of a molding sheet (<NUM>) including a base (<NUM>) and a thermal expansion layer (<NUM>) laminated onto a first main surface (12a) of the base (<NUM>), the shaping system (<NUM>) comprising:
a control unit (<NUM>) comprising determination means (<NUM>), and generation means (<NUM>);
a printing device (<NUM>); and
an expansion apparatus (<NUM>) comprising first expansion means (<NUM>), and second expansion means (<NUM>),
wherein
the determination means (<NUM>) determines, based on unevenness data representing the unevenness, that a convexity having a width and a length that are each greater than or equal to a respective threshold is a first convexity (<NUM>), and that a convexity having at least one of a width or a length that is smaller than the respective threshold is a second convexity (<NUM>);
the generation means (<NUM>) generates, based on (i) positions of the first convexity (<NUM>) and the second convexity (<NUM>) determined by the determination means (<NUM>) and (ii) the unevenness data, first convexity data representing the first convexity (<NUM>) and second convexity data representing the second convexity (<NUM>);
the printing device (<NUM>) is configured to print, based on the first convexity data generated by the generation means (<NUM>), onto a second main surface (12b) of the base (<NUM>) that is located on a side opposite to the first main surface (12a), a thermal conversion layer (<NUM>) for conversion of electromagnetic waves into heat;
the first expansion means (<NUM>) causes heating and expansion of at least a portion of the thermal expansion layer (<NUM>) of the molding sheet (<NUM>) by heat released from the thermal conversion layer (<NUM>) by irradiating with the electromagnetic waves emitted from a lamp (<NUM>), the thermal conversion layer (<NUM>) printed onto the molding sheet (<NUM>), and
the second expansion means (<NUM>) causes, based on the second convexity data generated by the generation means (<NUM>), heating and expansion of a region (C) of the thermal expansion layer (<NUM>) by irradiating the region (C) of the thermal expansion layer (<NUM>) with laser light, the region (C) of the thermal expansion layer (<NUM>) being smaller in size than a predetermined region (B) of the thermal expansion layer (<NUM>) in which the first expansion means (<NUM>) causes expansion.