CN109270992A - 板状构件、包含板状构件的壳体及其制作方法 - Google Patents

板状构件、包含板状构件的壳体及其制作方法 Download PDF

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CN109270992A
CN109270992A CN201810763180.7A CN201810763180A CN109270992A CN 109270992 A CN109270992 A CN 109270992A CN 201810763180 A CN201810763180 A CN 201810763180A CN 109270992 A CN109270992 A CN 109270992A
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layer
surface layer
shell
tabular component
perforations
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黄寒青
林伯安
吴荣钦
凌国南
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Compal Electronics Inc
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Abstract

本发明提供一种壳体，包括板状构件及树脂构件。板状构件具有底面，并包括第一表层、第二表层及芯层。第一表层具有多个第一贯孔配置于第一表层的至少一边缘。第一表层及第二表层是相对设置于芯层的两侧。树脂构件包覆板状构件的边缘及底面，且具有延伸部。延伸部通过多个第一贯孔延伸至第一表层及第二表层之间并邻接芯层。本发明另提供一种壳体的制作方法。

Description

板状构件、包含板状构件的壳体及其制作方法
技术领域
本发明是有关于一种壳体，且特别是有关于一种由板状构件组成的壳体及其制作方法。
背景技术
在各种电子装置中，计算机已经是人类生活中不可缺少的重要产品。随着技术的进展，计算机的功能和速度也不断加强，而从早期体积庞大的大型机械，发展到桌上型计算机和笔记型计算机。
以市场趋势而言，笔记型计算机的两个重点需求在于体积的减少和重量的减轻。除了计算机中的微电子组件之外，计算机机壳材料的选择也是发展重点。现有技术的笔记型计算机采用塑料机壳，尽管价格低廉，但在为了减少体积和重量而薄型化后，强度明显不足。因此，开始发展出其它的材料，例如采用玻璃纤维、碳纤维或复合材料等较新颖的材料来制作机壳。然而，对于复合材料所制的机壳而言，其在强度及重量之间的平衡仍有改善的空间。
发明内容
本发明提供一种壳体，能提升机械性质强度与达到轻量化的效果。
本发明提供一种壳体的制作方法，能制作出具有上述优点的壳体。
本发明所提供的壳体包括板状构件及树脂构件。板状构件具有底面，并包括第一表层、第二表层及芯层。第一表层具有多个第一贯孔配置于第一表层的至少一边缘。第一表层与第二表层是相对设置于芯层的两侧。树脂构件包覆板状构件的边缘及底面，且具有延伸部。延伸部通过多个第一贯孔延伸至第一表层及第二表层之间并邻接芯层。
在本发明的一实施例中，上述的板状构件的至少一边缘具有至少一凹部与至少一凸部交错设置。
在本发明的一实施例中，上述的第一表层及第二表层的材料分别为碳纤维、玻璃纤维、人造纤维、天然纤维、金属、合金、塑料或其组合。
在本发明的一实施例中，上述的芯层的材料为高分子发泡材料。
在本发明的一实施例中，上述的板状构件更包括第一粘合层及第二粘合层。第一表层更具有面对芯层的第一表面。第二表层具有面对芯层的第二表面。第一粘合层配置于第一表面上，第二粘合层配置于第二表面上，芯层夹设于第一粘合层与第二粘合层之间。第一粘合层具有对应于多个第一贯孔的多个第二贯孔，延伸部更延伸至多个第二贯孔。
在本发明的一实施例中，上述的第一贯孔的最大孔径大于芯层的厚度。
在本发明的一实施例中，上述的芯层的厚度为0.1毫米(mm)～1毫米(mm)。
本发明所提供的壳体的板状构件的制作方法包括：提供一板状构件，其中板状构件具有底面并包括第一表层、第二表层以及芯层，第一表层与第二表层是相对设置于芯层的两侧，第一表层具有多个第一贯孔配置于第一表层的至少一边缘。将板状构件置于一成型模具中，将填料注入并固化以形成树脂构件，其中树脂构件包覆板状构件的边缘及底面，且具有延伸部，延伸部通过多个第一贯孔延伸至第一表层及第二表层之间并邻接芯层。
在本发明的一实施例中，上述的板状构件的至少一边缘具有至少一凹部与至少一凸部交错设置。
在本发明的一实施例中，上述的板状构件更包括第一粘合层以及第二粘合层，第一表层通过第一粘合层粘接于芯层，第二表层通过第二粘合层粘接于芯层。
在本发明的一实施例中，更包括将第一表层、第二表层、第一粘合层、第二粘合层及芯层的层叠结构进行热压合。
在本发明的一实施例中，上述的第一粘合层具有对应于多个第一贯孔的多个第二贯孔，延伸部更延伸至多个第二贯孔。
在本发明的一实施例中，上述的第一贯孔的最大孔径大于芯层的厚度。
在本发明的一实施例中，上述的芯层的厚度为0.1毫米(mm)～1毫米(mm)。
在本发明的一实施例中，上述的成型模具具有多个凹陷部，多个凹陷部对应于第一表层的多个第一贯孔。
本发明实施例的壳体包括板状构件及树脂构件，板状构件的第一表层因具有多个第一贯孔配置于第一表层的至少一边缘，使得填料注入第一表层与第二表层之间时，可以分流到多个第一贯孔，减少填料挤压芯层的程度，减轻板状构件以及壳体的重量，藉此达到轻量化的效果，此外，分流到多个第一贯孔的填料固化后所形成的树脂构件延伸部也可加强树脂构件及第一表层的结合能力，进而提升壳体的机械性质强度。本发明实施例的壳体的制作方法因使用上述的板状构件，因此能制作出具有上述优点的壳体。
有关本发明的其它功效及实施例的详细内容，配合附图说明如下。
附图说明
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请中记载的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其它的附图。
图1是本发明一实施例的壳体的仰视图；
图2是图1的壳体沿AA’剖面线的剖视图；
图3是本发明一实施例的板状构件的示意图；
图4是本发明一实施例的壳体的制造方法的流程示意图；
图5是图3的板状构件沿BB’剖面线的剖视图；
图6是本发明一实施例的板状构件放置于成型模具的剖视图。
符号说明
10：壳体 100、100a：板状构件
1001：底面 101：树脂构件
1011：延伸部 110：第一表层
111：第一贯孔 112：第一表面
113：凹部 114：凸部
120：第二表层 121：第二表面
130、130a：芯层 131a：第三贯孔
150：第一粘合层 151：第二贯孔
160：第二粘合层 200：成型模具
201：凹陷部 S101、S102：步骤
D：深度 R：孔径
T：厚度
具体实施方式
在本文中，由“一数值至另一数值”表示的范围，是一种避免在说明书中一一列举该范围中的所有数值的概要性表示方式。因此，记载了某一特定数值范围，等同于公开了该数值范围内的任意数值以及由该数值范围内的任意数值界定出的较小数值范围，如同在说明书中明文写出该任意数值和该较小数值范围一样。例如，记载“尺寸为10mm～100mm”的范围，就等同于公开了“尺寸为20mm～50mm”的范围，无论说明书中是否列举其它数值。
图1是本发明一实施例的壳体的仰视图。图2是图1的壳体沿AA’剖面线的剖视图。图3是本发明一实施例的板状构件的示意图。请参考图1至图3，本实施例的壳体10包括板状构件100及树脂构件101，具有多个表面，其中至少一表面是由板状构件100及树脂构件101所构成。板状构件100例如可为复合材料，具有底面1001，并包括第一表层110、第二表层120及芯层130。第一表层110具有多个第一贯孔111配置于第一表层110的至少一边缘。第二表层120与第一表层110是相对设置于芯层130的两侧。树脂构件101包覆板状构件100的边缘及底面1001，具有延伸部1011，其中延伸部1011通过多个第一贯孔111延伸至第一表层110及第二表层120之间并邻接芯层130。
上述的第一表层110及第二表层120的材料例如分别可为碳纤维、玻璃纤维、人造纤维、天然纤维、金属、合金、塑料或其组合等，但不以此为限。在其它实施例中也可使用不同的纤维化材料，以提升板状构件100的机械性质强度。
上述的芯层130的材料可为高分子发泡材料，例如可为聚碳酸酯(polycarbonate，PC)、聚对苯二甲酸乙二醇酯(polyethylene terephthalate，PET)、聚甲基丙烯酸甲酯(polymethyl methacrylate，PMMA)、聚乙烯(polyethylene，PE)、丙烯腈-丁二烯-苯乙烯树脂(acrylonitrile-butadiene-styrene，ABS)、聚酰胺(polyamide，PA)、聚丙烯(polypropylene，PP)、聚苯乙烯(polystyrene，PS)等，但不以此为限，也可以使用其它质量轻的材料。
上述的树脂构件101为将填料朝板状构件100注入，并在填料固化之后形成树脂构件101，填料例如包括塑料或其它充填用的材料。此外，部分填料会注入于第一表层110及第二表层120之间并经由第一贯孔111溢流而出，当填料固化后即为树脂构件101的延伸部1011。以下将详细说明延伸部1011与第一贯孔111的关系。
在壳体10的制作过程中，部分填料从板状构件100的边缘注入，而填料在注入时会挤压芯层130，以芯层130的材料为高分子发泡材料为例，由于其具有微缝隙结构，使得填料在挤压芯层130时两者会形成非均匀的界线，图2中芯层130及延伸部1011的界线仅为示例。当填料过度挤压芯层130时，会增加板状构件100的重量，因此，在第一表层110的至少一边缘设置多个第一贯孔111，可以让从板状构件100边缘注入的填料分流至第一贯孔111，以减少填料过度挤压芯层130的情况，也可使芯层130及延伸部1011的界线较为均匀。
由于第一贯孔111的功能在于使填料分流，因此第一贯孔111仅需设置于会注入填料的边缘处。举例而言，若填料注入于板状构件100的一侧边，则第一贯孔111仅需设置于第一表层对应的同一侧边即可。此外，为了提升第一贯孔111的分流功能，第一贯孔111的最大孔径R大于芯层130的厚度T，使填料注入时可从第一贯孔111流出，而芯层130的厚度T例如为0.1毫米(mm)～1毫米(mm)。
上述的板状构件100的边缘可具有至少一个凹部113与至少一个凸部114交错设置，但不以此为限，在其它实施例中，板状构件100的边缘亦可不具有凹部113与凸部114结构或是具有多个凹部113与多个凸部114交错设置。凹部113与凸部114结构能提升板状构件100与树脂构件101之间的结合能力，进而提升壳体10的机械性质强度。在图3中，板状构件100的所有边缘皆以具有凹部113与凸部114结构，然而依据设计需求的不同，亦可仅有部分边缘具有凹部113与凸部114结构。
本发明实施例的壳体包括板状构件100及树脂构件101，板状构件100的第一表层110因具有多个第一贯孔111，配置于第一表层110的至少一边缘，使得填料注入第一表层110与第二表层120之间时，可以分流到多个第一贯孔111，减少填料挤压芯层130的程度，减轻板状构件110以及壳体10的重量，藉此达到轻量化的效果，此外，分流到多个第一贯孔111的填料固化后所形成的树脂构件101延伸部1011也可加强树脂构件101及第一表层110的结合能力，进而提升壳体10的机械性质强度。
上述的板状构件100更包括第一粘合层150及第二粘合层160。第一粘合层150及第二粘合层160例如可为粘合胶，但不以此为限。第一表层110更具有面对芯层130的第一表面112，第二表层120具有面对芯层130的第二表面121。第一粘合层150配置于第一表面112上，且具有对应于多个第一贯孔111的多个第二贯孔151，当填料注入第一表层110与第二表层120之间时，填料可进一步填充于多个第二贯孔151。第二粘合层160配置于第二表面121上，芯层130夹设于第一粘合层150与第二粘合层160之间。
对于上述的壳体10的制作过程，以下将再详细说明。图4是本发明一实施例的壳体的制造方法流程示意图。图5是图3的板状构件沿BB’剖面线的剖视图。图6是本发明一实施例的板状构件放置于成型模具的剖视图。请参考图4至图6，本实施例的壳体10的制造方法包括以下步骤：步骤S101，提供一板状构件100a，其中板状构件100a具有一底面1001，并包括第一表层110、第二表层120与芯层130a，第一表层110与第二表层120是相对设置于芯层130a的两侧，第一表层110具有多个第一贯孔111配置于第一表层110的至少一边缘。
具体而言，第一表层110例如是通过第一粘合层150而粘接于芯层130a，第二表层120例如是通过第二粘合层160而粘接于芯层130a，以形成层叠结构，再将此层叠结构进行热压合，形成板状构件100a。此外，第一粘合层150具有对应于多个第一贯孔111的多个第二贯孔151。上述的第一贯孔111及第二贯孔151例如以冲压穿孔(punching)的方式形成，且例如可深入至芯层130a，即芯层130a具有对应于第一贯孔111及第二贯孔151的第三贯孔131a，第三贯孔131a的深度D例如小于或等于芯层130a的厚度T。
请续参图4及图6，进行步骤S102：将板状构件100a置于一成型模具中，将填料注入并固化填料以形成树脂构件101，其中树脂构件101包覆板状构件100a的边缘及底面1001，且具有延伸部1011，延伸部1011通过多个第一贯孔111延伸至第一表层110及第二表层120之间并邻接芯层130a。具体而言，步骤S102中是将上述的板状构件100a放入成型模具中以注入填料，成型模具例如可为注塑成型模具或射出成型模具，但不以此为限。如图6所示，本实施例的成型模具200例如具有多个凹陷部201，这些凹陷部201对应于第一表层110的多个第一贯孔111，凹陷部201是做为填料的分流容置空间。
当填料注入第一表层110及第二表层120之间时，会挤压芯层130a(芯层130a经挤压后即成为上述的芯层130，使板状构件100a成为上述的板状构件100)，部分的填料经第二贯孔151及第一贯孔111而分流到成型模具200的凹陷部201，使得填料挤压芯层130a的程度降低，在填料固化形成树脂构件101后(如图2所示)，即可得到具有轻量化效果的壳体10，且于第一贯孔111及第二贯孔151中固化的填料所形成的树脂构件101延伸部1011亦可加强树脂构件101与第一表层110间的结合能力，提升壳体10的机械性质强度。
综上所述，本发明实施例的壳体包括板状构件及树脂构件，板状构件的第一表层因具有多个第一贯孔配置于第一表层的至少一边缘，使得填料注入第一表层与第二表层之间时，可以分流到多个第一贯孔，减少填料挤压芯层的程度，减轻板状构件以及壳体的重量，藉此达到轻量化的效果，此外，分流到多个第一贯孔的填料固化后所形成的树脂构件延伸部也可加强树脂构件及第一表层的结合能力，进而提升壳体的机械性质强度。本发明实施例的壳体的制作方法因使用上述的板状构件，因此能制作出具有上述优点的壳体。
以上所述的实施例及/或实施方式，仅是用以说明实现本发明技术的较佳实施例及/或实施方式，并非对本发明技术的实施方式作任何形式上的限制，任何本领域技术人员，在不脱离本发明内容所公开的技术手段的范围，当可作些许的更动或修改为其它等效的实施例，但仍应视为与本发明实质相同的技术或实施例。

Claims (15)

1.一种壳体，其特征在于，包括：
一板状构件，具有一底面，其中该板状构件包括：
一第一表层，具有多个第一贯孔配置于该第一表层的至少一边缘；
一第二表层；以及
一芯层，其中该第一表层与该第二表层是相对设置于该芯层的两侧；以及一树脂构件，包覆该板状构件的边缘及该底面，且具有一延伸部，该延伸部延伸至该第一表层及该第二表层之间并邻接该芯层，其中该延伸部延伸至该些第一贯孔。
2.如权利要求1所述的壳体，其特征在于，该板状构件的至少一边缘具有至少一凹部与至少一凸部交错设置。
3.如权利要求1所述的壳体，其特征在于，该第一表层及该第二表层的材料分别为碳纤维、玻璃纤维、人造纤维、天然纤维、金属、合金、塑料或其组合。
4.如权利要求1所述的壳体，其特征在于，该芯层的材料为高分子发泡材料。
5.如权利要求1所述的壳体，其特征在于，该板状构件更包括一第一粘合层及一第二粘合层，该第一表层更具有面对该芯层的一第一表面，该第二表层具有面对该芯层的一第二表面，该第一粘合层配置于该第一表面上，该第二粘合层配置于该第二表面上，该芯层夹设于该第一粘合层与该第二粘合层之间，其中该第一粘合层具有对应于该些第一贯孔的多个第二贯孔，该延伸部更延伸至该些第二贯孔。
6.如权利要求1所述的壳体，其特征在于，该些第一贯孔的最大孔径大于该芯层的厚度。
7.如权利要求6所述的壳体，其特征在于，该芯层的厚度为0.1毫米～1毫米。
8.一种壳体的制作方法，其特征在于，包括：
提供一板状构件，其中该板状构件具有一底面并包括一第一表层、一第二表层以及一芯层，该第一表层与该第二表层是相对设置于该芯层的两侧，该第一表层具有多个第一贯孔配置于该第一表层的至少一边缘；
将该板状构件置于一成型模具中，将一填料注入并固化以形成一树脂构件，其中该树脂构件包覆该板状构件的边缘及该底面，且具有一延伸部，该延伸部通过该些第一贯孔延伸至该第一表层及该第二表层之间并邻接该芯层。
9.如权利要求8所述的壳体的制作方法，其特征在于，该板状构件的至少一边缘具有至少一凹部与至少一凸部交错设置。
10.如权利要求8所述的壳体的制作方法，其特征在于，该板状构件更包括一第一粘合层以及一第二粘合层，该第一表层通过该第一粘合层粘接于该芯层，该第二表层通过该第二粘合层粘接于该芯层。
11.如权利要求10所述的壳体的制作方法，其特征在于，更包括将该第一表层、该第二表层、该第一粘合层、该第二粘合层及该芯层的层叠结构进行热压合。
12.如权利要求10所述的壳体的制作方法，其特征在于，该第一粘合层具有对应于该些第一贯孔的多个第二贯孔，该延伸部更延伸至该些第二贯孔。
13.如权利要求8所述的壳体的制作方法，其特征在于，该些第一贯孔的最大孔径大于该芯层的厚度。
14.如权利要求13所述的壳体的制作方法，其特征在于，该芯层的厚度为0.1毫米～1毫米。
15.如权利要求8所述的壳体的制作方法，其特征在于，该成型模具具有多个凹陷部，该些凹陷部是对应于该第一表层的该些第一贯孔。
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