CN102085734A - 模内连接装饰复合塑料结构件及其制作方法 - Google Patents

模内连接装饰复合塑料结构件及其制作方法 Download PDF

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CN102085734A
CN102085734A CN 201010530129 CN201010530129A CN102085734A CN 102085734 A CN102085734 A CN 102085734A CN 201010530129 CN201010530129 CN 201010530129 CN 201010530129 A CN201010530129 A CN 201010530129A CN 102085734 A CN102085734 A CN 102085734A
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张�林
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CHENGDU ZHONGJI GUOYE NEW MATERIAL Co Ltd
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32—LAYERED PRODUCTS
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/088—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/095—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C2045/1454—Joining articles or parts of a single article injecting between inserts not being in contact with each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C2045/1486—Details, accessories and auxiliary operations
    • B29C2045/14893—Preventing defects relating to shrinkage of inserts or coating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
    • B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2355/00—Specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of index codes B32B2323/00 - B32B2333/00
    • B32B2355/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles

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Abstract

本发明模内连接装饰复合塑料结构件，包括表面装饰层，与表面装饰层复合的填充粘接层，与填充粘接层复合的塑料结构层。刚性好，生产成本低。本发明模内连接装饰复合塑料结构件的制作方法。生产速度快，成品率高，适用于在模具中完成的能够有效地解决复合体由于塑料层收缩而造成的应力及变形问题。

Description

模内连接装饰复合塑料结构件及其制作方法
技术领域：
本发明涉及一种塑料结构件的复合装饰技术，通过注塑或或挤塑压注工艺就可完成适用于电子电器、汽车内饰件、建材等行业领域的模内连接装饰复合塑料结构件及其制作方法有关。
背景技术：
专利号ZL200610020181.X提供了一种可用普通注塑模具完成的模内装饰塑料件及其制作方法。该专利在实际应用中，不能解决部分结构的变形问题：当产品中塑料结构层部件尺度较大，其尺寸超出表面金属边界范围较多，或塑料层厚度较厚，有较多复杂筋肋结构以及注塑高强度塑料时，以上塑料结构在注塑完成后，塑料会因为由高温流体状态冷却至低温固体状态而产生较大的尺寸收缩。在塑料收缩的过程中，由于金属层材料不会收缩，因而两种材料会产生内应力。
如果塑料收缩应力超过金属层的弯曲强度，则会引起整体部件的弯曲变形，严重时会造成塑料断裂或塑料与金属结合层产生裂缝。
发明内容：
本发明的目的是为了提供一种刚性好，生产成本低的模内连接装饰复合塑料结构件。本发明的另一个目的是为了提供一种生产速度快，成品率高，适用于在模具中完成的能够有效地解决复合体由于塑料层收缩而造成的应力及变形问题的模内连接装饰复合塑料结构件的制作方法。
本发明的目的是这样来实现的：
本发明模内连接装饰复合塑料结构件，包括表面装饰层，与表面装饰层复合的填充粘接层，与填充粘接层复合的塑料结构层。
本发明模内连接装饰复合塑料结构件的制作方法，包括如下步骤：
1)制作表面装饰层，选用或具有表面装饰效果的板材，经过冲裁加工后，用冲压模具进行三维成型形成表面装饰层；
2)选用注塑、挤塑或压注塑料成型加工工艺制作塑料结构层制作塑料结构层；
3)将已成型的表面装饰层放入模具前模型腔内；
4)将已定型的塑料结构层放在模具后模上与模具型腔内的金属装饰层位置对应的位置；
5)将模具合模，然后向模具内注射入填充粘接材料；
6)填充粘接材料在模具内冷却固化形成与表面装饰层和塑料结构层复合的填充粘结层后，开模取出已成形的模内连接装饰复合塑料结构件。
上述的方法中制作塑料结构层时，为使填充粘接层材料与塑料结构层的连接紧密牢固，在塑料结构层部件上制作出锥型孔洞或燕尾槽铆接结构(该孔洞也可作为填充粘接材料的注射入口，或根据产品的结构特点在塑料结构层部件上制作注射入口，通过注射入口向表面装饰与塑料结构层间的间隙注射填充粘结材料、从而形成与表面装饰层和塑料结构层复合的填充粘接层)。
上述的方法中，在模具后模上安装放置塑料结构层准确的定位柱。
上述的方法中，表面装饰层采用贴合有装饰柔性材料的厚度的0.1～1.2mm覆膜金属板或具有表面装饰效果的金属薄板制成。
上述的方法中，塑料结构层采用增强丙烯腈—丁二烯—苯乙烯共聚物，高抗冲聚苯乙烯或透明聚碳酸酯或聚甲基丙烯酸甲酯制成。
本发明模内连接装饰复合塑料结构件中材料选择如下：
(一)、表面装饰层材料的选择：
可根据产品需要选择以下材料：
A.覆膜金属板，即金属板表面的有图案和/或文字的装饰柔性层，金属层的厚度为0.1～1.2mm(金属层厚度主要根据装饰件的尺寸大小来确定，尺寸越大，相应的厚度应越厚)，装饰柔性层由透明塑料薄膜及位于透明塑料薄膜里面上的印刷图案和/或文字装饰层组成。
B.具有表面装饰效果的金属薄板(如拉丝、镜面铝板/不锈钢板等)。
(二)、填充粘接层材料的选择：
填充粘接层的作用是在模具内完成对表面装饰层和塑料结构层的连接，其材料的选择应根据表面装饰层材料的类型来确定.
a.表面装饰层的金属基板无表面涂层，即填充粘接层直接与金属界面进行连接，可选用和金属结合力较强的高分子聚合物材料，如改性聚酰胺树脂或改性聚氨酯聚合物，但不限于这两类聚合物材料。
b.表面装饰层的金属基板已有防锈或改性涂层，则可选择与涂层材料相同极性的高分子聚合物，使填充层能与金属涂层相熔连接。
(三)、塑料结构层材料的选择：
可根据产品的外观及性能要求选择材料进行成型。如对塑料结构层有较高强度要求，可选用增强丙烯腈-丁二烯-苯乙烯共聚物(ABS)，高抗冲聚苯乙烯(HIPS)或其他高强度塑料；如塑料对结构部件有透明度或色彩要求，也可选用相应的透明聚碳酸酯(PC)或聚甲基丙烯酸甲酯(PMMA)进行注塑成型。由于塑料结构件的成型已是较为成熟的工艺，在此不一一列举。
与专利ZL200610020181.X和传统金属塑料连接件及其制作方法相比，本发明模内连接装饰复合结构件及其制作方法具有以下优点：
1.本发明模内连接装饰复合结构件中采用了填充粘接层来连接表面装饰层和塑料结构层，不会产生因塑料的收缩而导致部件弯曲的情况，刚性好，生产成本低。
2.产品可实现各种外观装饰效果与不同材质、性能的塑料结构件的紧密结合，极大的拓展了产品的应用范围。
3.本发明是在注塑或挤塑或压注的过程中同时完成了塑料表面的装饰效果，无需后续进行装饰工序，故工艺简单，节约加工成本和设备投入成本，生产速度快，成品率高。
本发明适用于各种尺寸和各类结构较复杂的装饰复合塑料件，如电子电器产品外观部件，汽车内部装饰件，以及其他领域的复合塑料结构部件。
附图说明：
图1为电视机面框示意图。
图2为图1中的A-A剖面放大图。
具体实施方式：
图1、图2给出了本实施例电视机面框示意图。参见图1、图2，电视机面框由厚度为0.6mm的覆膜冷轧薄钢板层1，填充粘接层2，塑料结构层3组成。塑料结构层3的下直边的尺寸已超出覆膜冷轧薄钢板层外边缘尺寸。
本实施例电视机面框的制作方法步骤如下：
1.选用贴合有装饰柔性材料的覆膜冷轧薄钢板，将上述覆膜冷轧薄钢板经过裁切后，再用冲压模具进行三维成型；
2.根据产品设计要求制作塑料结构层，本实施例选用高透明聚碳酸酯(PC)塑料进行注塑成型。为使填充粘接材料—改性聚酰胺树脂与塑料结构层的连接紧密牢固，在塑料结构层上制作出锥型孔洞，该孔洞同时作为填充粘接材料的注射入口；
3.将三维成型的覆膜冷轧薄钢板放入模具前模型腔内，把注塑成型的高透明聚碳酸酯塑料件放在模具后模上(为放置准确，可在模具后模上安装相应定位柱)；
4.将模具合模，然后向模具内覆膜冷轧薄膜钢板与塑料结构件间注射入填充粘接材料，热熔的填充粘接材料在模具型腔内通过塑料结构件(层)上的锥型孔洞将覆膜冷轧薄钢板和高透明聚碳酸酯塑料件进行融合连接；
5.在填充材料冷却凝固后，便可开模取出有装饰效果的电视机面框复合塑料结构件。
上述各实施例是对本发明的上述内容作进一步的说明，但不应将此理解为本发明上述主题的范围仅限于上述实施例。凡基于上述内容所实现的技术均属于本发明的范围。

Claims (6)

1.模内连接装饰复合塑料结构件，包括表面装饰层，与表面装饰层复合的填充粘接层，与填充粘接层复合的塑料结构层。
2.如权利要求1所述的模内连接装饰复合塑料结构件的制作方法，其特征在于包括如下步骤：
1)制作表面装饰层，选用具有表面装饰效果的板材，经过冲裁加工后，用冲压模具进行三维成型形成表面装饰层；
2)选用注塑、挤塑或压注塑料成型加工工艺制作塑料结构层；
3)将已成型的表面装饰层放入模具前模型腔内；
4)将已定型的塑料结构层放在模具后模上与模具型腔内的金属装饰层位置对应的位置；
5)将模具合模，然后向模具内注射入填充粘接材料；
6)填充粘接材料在模具内冷却固化形成与表面装饰层和塑料结构层复合的填充粘结层后，开模取出已成形的模内连接装饰复合塑料结构件。
3.如权利要求2所述的模内连接装饰复合塑料结构件的制作方法，其特征在于制作塑料结构层时，为使填充粘接层材料与塑料结构层的连接紧密牢固，在塑料结构层部件上制作出锥型孔洞或燕尾槽铆接结构。
4.如权利要求2或3所述的模内连接装饰复合塑料结构件的制作方法，其特征在于在模具后模上安装放置塑料结构层准确的定位柱。
5.如权利要求2或3所述的模内连接装饰复合塑料结构件的制作方法，其特征在于表面装饰层采用贴合有装饰柔性材料的厚度为0.1～1.2mm的覆膜金属板或具有表面装饰效果的金属薄板制成。
6.如权利要求2或3所述的模内连接装饰复合塑料结构件的制作方法，其特征在于塑料结构层采用增强丙烯腈—丁二烯—苯乙烯共聚物或高抗冲聚苯乙烯或透明聚碳酸酯或聚甲基丙烯酸甲酯制成。
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CN108674080A (zh) * 2018-08-23 2018-10-19 厦门岳海进出口有限公司 一种装饰单体及立体装饰物
CN110696274A (zh) * 2019-10-17 2020-01-17 上海瑞尔实业有限公司 以电镀件为嵌件的高光注塑工艺
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CN102602095A (zh) * 2012-03-08 2012-07-25 江阴市信科塑胶五金有限公司 冰箱彩塑覆膜饰条及其制备方法
CN102602095B (zh) * 2012-03-08 2015-09-23 江阴市信科塑胶五金有限公司 冰箱彩塑覆膜饰条及其制备方法
CN107000397A (zh) * 2014-11-19 2017-08-01 日涂汽车涂料有限公司 三维成型品装饰用层积膜、其制造方法以及三维装饰方法
CN105108968A (zh) * 2015-05-19 2015-12-02 上海志承新材料有限公司 防开裂塑框电路制作方法
CN108674080A (zh) * 2018-08-23 2018-10-19 厦门岳海进出口有限公司 一种装饰单体及立体装饰物
CN110696274A (zh) * 2019-10-17 2020-01-17 上海瑞尔实业有限公司 以电镀件为嵌件的高光注塑工艺
CN115157793A (zh) * 2022-04-19 2022-10-11 深圳市天诺通光电科技有限公司 一种装饰复合基材、其制备工艺及应用

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