CN103252891A - 具有编织纹路壳体的制造方法及制得的壳体 - Google Patents

具有编织纹路壳体的制造方法及制得的壳体 Download PDF

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CN103252891A
CN103252891A CN2012100390709A CN201210039070A CN103252891A CN 103252891 A CN103252891 A CN 103252891A CN 2012100390709 A CN2012100390709 A CN 2012100390709A CN 201210039070 A CN201210039070 A CN 201210039070A CN 103252891 A CN103252891 A CN 103252891A
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housing
braiding
lines
braided fiber
preimpregnation cloth
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廖凯荣
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Shenzhen Futaihong Precision Industry Co Ltd
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Priority to US13/593,632 priority patent/US20130216744A1/en
Priority to JP2013009941A priority patent/JP6025578B2/ja
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    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明提供一种具有编织纹路壳体的制造方法，包括如下步骤：提供未固化的编织纤维预浸布；于一透明或半透明的热塑性塑料薄膜的一表面涂覆一热固性胶粘剂涂层；将该编织纤维预浸布与热塑性塑料薄膜具有热固性胶粘剂的表面贴合，得到一组合体；将该组合体放入模具中进行热压，使该组合体成型所需的三维形状，由此获得一预制件；对预制件进行裁切，以去除余料而得到具有所需三维外形的壳体。本发明还提供一种通过上述方法制得的具有编织纹路的壳体。

Description

具有编织纹路壳体的制造方法及制得的壳体
技术领域
本发明是关于一种具有编织纹路壳体的制造方法及由该方法制得的壳体。
背景技术
纤维材料（如碳纤维、玻璃纤维等）具有较轻的质量、高强度的优点，且纤维材料通过不同的编织方法加工后可形成立体纹路，因此，编织纤维材料可使用在各种装置设备的外壳上，使这些装置设备凭借具有编织纤维纹路的壳体，呈现出特殊的表面质感与纹路。
现有的具有纤维编织纹路的壳体的制造方法，包括下列步骤：首先，提供复数个含浸热固性树脂的编织纤维预浸布；然后将这些编织纤维预浸布堆栈成预定厚度；之后将其裁切成预定形状尺寸；将这些栈且经裁切的编织纤维预浸布置入模具中，经模具热压成型后，形成预定形状的壳体；最后进行修补过程，即对壳体表面填补、研磨、喷漆，由此获得壳体成品。
在一般情况下，由于编织纤维布是由纤维交错编织而成，故在含浸树脂后难免会在纤维相交错处形成有未填满的空隙或凹洞，在热压过程中，编织纤维布表面的树脂会流动至所述未填满的空隙或凹洞，使表面产生坑洞而凹凸不平，因此必须进一步加工，针对这些不平坦用树脂加以填补，而后再磨平、喷漆。因此，现有制造过程需花费相当多的人力与时间进行修补，成本较高，所制得壳体成品的表面品质也难以提高。
发明内容
有鉴于此，有必要提供一种具有纤维编织纹路、表面平整光滑的壳体的制造方法，该方法制程简单，成本较低。
另外，还有必要提供一种由上述方法制得的壳体。
一种具有编织纹路壳体的制造方法，包括如下步骤：
提供未固化的编织纤维预浸布，该编织纤维预浸布是由编织纤维布含浸树脂形成；
于一透明或半透明的热塑性塑料薄膜的一表面涂覆一热固性胶粘剂涂层；
将该编织纤维预浸布与热塑性塑料薄膜具有热固性胶粘剂的表面贴合，得到一组合体；
将该组合体放入模具中进行热压，使该组合体成型所需的三维形状，由此获得一预制件；
对预制件进行裁切，以去除余料而得到具有所需三维外形的壳体。
一种具有编织纹路的壳体，其包括一纤维层，该纤维层由固化的含浸有树脂的编织纤维布形成，该壳体还包括一热塑性塑料薄膜，该热塑性塑料薄膜通过一热固性胶粘剂层粘合于该纤维层的表面。
上述具有编织纹路壳体的制造方法通过于编织纤维预浸布的表面粘合一热塑性树脂薄膜，再通过热压成型及裁切余料后获得具有编织纹路外观的壳体。由于热塑性树脂薄膜覆盖于编织纤维预浸布的表面，使壳体具有平整光滑的表面，避免了编织纤维预浸布直接形成壳体外表面时会产生坑洞而使壳体表面凹凸不平的缺陷。
附图说明
图1为本发明较佳实施例壳体的剖视示意图。
图2为本发明较佳实施例具有编织纹路壳体的制造方法的方块流程图。
图3为本发明较佳实施例具有编织纹路壳体的制造方法中不同步骤的示意图。
主要元件符号说明
编织纤维预浸布 10
热固性胶粘剂层 20
热塑性塑料薄膜 30
组合体 40
预制件 50
模具 60
壳体 100
纤维层 110
如下具体实施方式将结合上述附图进一步说明本发明。
具体实施方式
请参阅图1及图2，本发明较佳实施例具有编织纹路壳体的制造方法包括以下步骤：
步骤S10，提供未固化的编织纤维预浸布10。该编织纤维预浸布10是由编织纤维布含浸树脂形成。编织纤维预浸布10中含浸的树脂为透明或半透明的热固性树脂，如环氧树脂。该编织纤维布为选自碳纤维、玻璃纤维、克维拉（Kevler）纤维材料及混编（Hybrid）纤维中的一种编织而成。本实施例优选为碳纤维或玻璃纤维。该编织纤维布表面形成有交错的立体编织纹路。
步骤S20，于一透明或半透明的热塑性塑料薄膜30的一表面上涂覆一热固性胶粘剂层20。该热固性胶粘剂层20为带有环氧基团的胶粘剂。本实施例中，该热固性胶粘剂层20为液体状的环氧树脂胶水。该热塑性塑料薄膜30为聚碳酸酯(Polycarbonate，PC)薄膜。
步骤S30，将所述编织纤维预浸布10与热塑性塑料薄膜30具有热固性胶粘剂层20的表面贴合，得到一组合体40。贴合后，确保该组合体40内无气泡、凸起、褶皱等。
步骤S40，将该组合体40放入预先设计好形状的模具60中进行热压，使组合体40成型所需的三维形状，由此获得一预制件50。该热压过程中，模具60加热至100℃-250℃，同时通过模具60对组合体40施加10kg/cm2-180kg/cm2的压力。所述热压过程持续时间大约为20-60分钟。冷却后，编织纤维预浸布10中的树脂以及热固性胶粘剂层20硬化，使组合体40获得固定的三维形状。当所述编织纤维预浸布10中含浸的树脂为环氧树脂时，根据环氧树脂的固化温度，热压过程中设置模具60的温度为170℃。
步骤S50，对预制件50进行裁切，以去除多余边料，由此得到具有所需三维外形以及具有立体编织纹路外观的壳体100。
可以理解，所述步骤S10与步骤S20的先后顺序可以交换。
请参阅图3，由上述方法制得的壳体100包括一纤维层110及通过一热固性胶粘剂层20粘合于该纤维层110表面的热塑性塑料薄膜30。
该纤维层110由固化的含浸有树脂的编织纤维布（即编织纤维预浸布）形成。所述树脂为透明或半透明，其可为热固性树脂，如环氧树脂。本实施例选用透明的环氧树脂。该编织纤维布为选自碳纤维、玻璃纤维、克维拉（Kevler）纤维材料及混编（Hybrid）纤维中的一种编织而成。本实施例优选为碳纤维或玻璃纤维。该编织纤维布表面形成有交错的立体编织纹路。
该热固性胶粘剂层20带有环氧基团的粘合剂。为了使所述纤维层110的立体编织纹路可视，该热固性胶粘剂层20具有较高的透明度。
该热塑性塑料薄膜30为透明或半透明状，其可为聚碳酸酯薄膜。热塑性塑料薄膜30的厚度大约为0.2mm。
所述编织纤维布的立体编织纹路透过热塑性塑料薄膜30，使壳体100表面具有立体编织纹路的装饰效果。
上述具有编织纹路壳体的制造方法通过于编织纤维预浸布10的表面粘合一热塑性塑料薄膜30，再通过热压成型及裁切余料后获得具有编织纹路外观的壳体100。由于热塑性塑料薄膜30覆盖于编织纤维预浸布10的表面，使壳体100具有平整光滑的表面，避免了编织纤维预浸布10直接形成壳体外表面时会产生坑洞而使壳体表面凹凸不平的缺陷。

Claims (9)

1.一种具有编织纹路壳体的制造方法，包括如下步骤：
提供未固化的编织纤维预浸布，该编织纤维预浸布是由编织纤维布含浸树脂形成；
于一透明或半透明的热塑性塑料薄膜的一表面涂覆一热固性胶粘剂涂层；
将该编织纤维预浸布与热塑性塑料薄膜具有热固性胶粘剂层的表面贴合，得到一组合体；
将该组合体放入模具中进行热压，使该组合体成型所需的三维形状，由此获得一预制件；
对预制件进行裁切，以去除余料而得到具有所需三维外形的壳体。
2.如权利要求1所述的具有编织纹路壳体的制造方法，其特征在于：热压过程中，所述模具的温度为100℃-250℃，模具对该组合体施加的压力为10kg/cm2-180kg/cm2。
3.如权利要求1所述的具有编织纹路壳体的制造方法，其特征在于：所述编织纤维预浸布的编织纤维布为选自碳纤维、玻璃纤维、克维拉纤维材料及混编纤维中的一种编织而成。
4.如权利要求1所述的具有编织纹路壳体的制造方法，其特征在于：所述编织纤维预浸布中的树脂为透明或半透明的热固性树脂。
5.如权利要求1所述的具有编织纹路壳体的制造方法，其特征在于：所述热塑性塑料薄膜为聚碳酸酯薄膜。
6.一种具有编织纹路的壳体，其包括一纤维层，其特征在于：该纤维层由固化的含浸有树脂的编织纤维布形成，该壳体还包括一热塑性塑料薄膜，该热塑性塑料薄膜通过一热固性胶粘剂层粘合于该纤维层的表面。
7.如权利要求6所述的具有编织纹路的壳体，其特征在于：所述编织纤维预浸布的编织纤维布为选自碳纤维、玻璃纤维、克维拉纤维材料及混编纤维中的一种编织而成。
8.如权利要求6所述的具有编织纹路的壳体，其特征在于：所述编织纤维预浸布中的树脂为透明或半透明的热固性树脂。
9.如权利要求6所述的具有编织纹路的壳体，其特征在于：所述热塑性塑料薄膜为聚碳酸酯薄膜。
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