CN102582084A - 热塑性弹性体射包碳纤维预浸材的制造方法及其产品 - Google Patents
热塑性弹性体射包碳纤维预浸材的制造方法及其产品 Download PDFInfo
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Abstract
一种热塑性弹性体射包碳纤维预浸材的制造方法及其产品,该热塑性弹性体射包碳纤维预浸材的制造方法包含一热压成型步骤,及一射包成型步骤。该热压成型步骤是将一热塑性介质与一碳纤维预浸材热压成型为一半成品;该射包成型步骤是将一液态热塑性弹性体射包于该半成品的热塑性介质上,使该半成品成为一热塑性弹性体射包碳纤维预浸材的产品。利用热压成型使碳纤维预浸材与热塑性介质的官能基间产生化学键结而有效地结合,而该热塑性介质则能提供热塑性弹性体一良好的同构型高分子结合接口,进而与热塑性弹性体产生化学键结以提升结合力。
Description
技术领域
本发明涉及一种种射包成型方法及其产品,特别是涉及一种热塑性弹性体射包碳纤维预浸材的制造方法及其产品。
背景技术
所谓的射包成型(over-molding)是指将高分子材料射出包覆于一半成品上,生活中常见的螺丝起子、安全剪刀,及儿童餐具…等随处可见射包成型的小型成品。随着3C产业的蓬勃发展,近年来有愈来愈多的业者将射包成型应用在3C产品的制作上,例如:记忆卡、电子组件的接头…等。甚至连笔记本电脑外壳都可采用射包成型。
然而,众所周知,异质材料间的结合力较差,因此,射包成型的成品在应用上常会因结合力不足而相互分离进而损坏,为了克服异质材料射包成型时结合力不足的问题,相关业者多会利用机械投锚理论(mechanical & anchor theory),通过研磨、喷砂、蚀刻…等表面处理的方式增加半成品的表面粗糙度,借以增加高分子材料在射包时与半成品的接触面积,进而提升高分子材料在射包成型时与半成品间的摩擦力。
但是,异质材料间的结合力较差,其主要原因是因为异质材料的化学键结不同,导致高分子材料与半成品间的结合力不足,而利用表面处理方式增加高分子材料在射包时与半成品的接触面积,只是增加高分子材料与半成品间的摩擦力,并无法根本克服异质材料间因化学键结不同所导致结合力不足的问题。
发明内容
本发明的目的在于提供一种能有效提升结合力的热塑性弹性体射包碳纤维预浸材的制造方法。
本发明热塑性弹性体射包碳纤维预浸材的制造方法,包含一个热压成型步骤,及一个射包成型步骤。
该热压成型步骤将一个热塑性介质与一个碳纤维预浸材在一预成型温度热压成型为一个半成品,该预成型温度会使该热塑性介质产生热变形但是不会熔化。
该射包成型步骤将一个热塑性弹性体(Thermoplastic Elastomer,TPE)加热熔化成液态,并射包于该半成品的热塑性介质上,使该半成品成为一个热塑性弹性体射包碳纤维预浸材的产品。
本发明的目的及解决其技术问题还可采用于下技术措施进一步实现。
较佳地,所述热塑性弹性体射包碳纤维预浸材的制造方法,其中该热压成型步骤中的热塑性介质是选自:聚对苯二甲酸乙二酯或热塑性聚胺基甲酸酯。
较佳地,所述热塑性弹性体射包碳纤维预浸材的制造方法,其中该热压成型步骤中的碳纤维预浸材是预浸环氧树脂,且在该预成型温度下,该碳纤维预浸材中的环氧树脂会液化渗出而与软化的热塑性介质相互接合而成为该半成品。
较佳地,所述热塑性弹性体射包碳纤维预浸材的制造方法,其中该热压成型步骤的预成型温度是介于130℃~150℃间。
较佳地,所述热塑性弹性体射包碳纤维预浸材的制造方法,其中该射包成型步骤是将热塑性弹性体加热至170℃熔化成液态后,再射出至该半成品的热塑性介质上。
本发明的另一目的,在于提供一种由上述制造方法所制成热塑性弹性体射包碳纤维预浸材的产品。
本发明热塑性弹性体射包碳纤维预浸材的产品,包含一个碳纤维预浸层、一个与该碳纤维预浸层热压成型的热塑性介质层,及一个射包成型于该热塑性介质层上的热塑性弹性体层。
较佳地,所述热塑性弹性体射包碳纤维预浸材的产品,其中该碳纤维预浸层是预浸环氧树脂的碳纤维预浸材。
较佳地,所述热塑性弹性体射包碳纤维预浸材的产品,其中该热塑性介质层是选自聚对苯二甲酸乙二酯或热塑性聚胺基甲酸酯。
本发明的有益效果在于:利用热压成型使碳纤维预浸材的官能基(Function group)能与热塑性介质的官能基间产生化学键结(架桥反应)而有效地结合,且该热塑性介质还能提供后续射包热塑性弹性体时一良好的同构型高分子结合接口,而与热塑性弹性体产生化学键结而紧密接合以提升结合力。
附图说明
图1是一流程图,说明本发明热塑性弹性体射包碳纤维预浸材的制造方法的较佳实施例;
图2是一示意图,辅助说明图1;
图3是一剖视示意图,说明本发明热塑性弹性体射包碳纤维预浸材的产品的较佳实施例。
具体实施方式
下面结合附图及实施例对本发明进行详细说明。
参阅图1、2,本发明热塑性弹性体射包碳纤维预浸材的制造方法的较佳实施包含一热压成型步骤11,及一射包成型步骤12。
该热压成型步骤11是将一热塑性介质21与一碳纤维预浸材22在一预成型温度热压成型为一半成品23,该预成型温度会使该热塑性介质21产生热变形但是不会熔化。而该热塑性介质21则能够是聚对苯二甲酸乙二酯(Polyethylene Terephthalate,PET)或热塑性聚胺基甲酸酯(Thermoplastic Polyurethane,TPU)。
于本较佳实施例中,该碳纤维预浸材22是预浸环氧树脂(Epoxy),而该热塑性介质21则是聚对苯二甲酸乙二酯(PET),且该预成型温度是对应该热塑性介质21而介于130℃~150℃间。
热压成型时碳纤维预浸材22中的环氧树脂会液化渗出,而且由于该热塑性介质21在该预成型温度下,只会产生热变形(软化)但是不会熔化,因此,所渗出的环氧树脂的官能基能与该热塑性介质21的官能基间产生化学键结(架桥反应),而使该热塑性介质21能紧密地与该碳纤维预浸材22相结合成为该半成品23。
在此要特别说明的是,由于该热塑性介质21在该预成型温度下,只会产生热变形但是不会熔化,因此,该热塑性介质21还能够当成热压成型时该碳纤维预浸材22的脱模介质,而不需再于模具内预先涂抹离型剂,且不需再于事后进行清除离型剂的作业,所以能简化碳纤维预浸材22的热压成型制程,而能有效缩短热压成型所需的时间,加快生产速度以提升产能。
该射包成型步骤12是将该半成品23设置于一模具200中,且利用一射出机201将一热塑性弹性体24加热至170℃熔化成液态后,而射包位在该模具200中的半成品23的热塑性介质21上。
由于该热塑性弹性体24与该热塑性介质21同为高分子材料,因此,该热塑性介质21还能提供射包热塑性弹性体24时一良好的同构型高分子结合接口,进而利用该热塑性弹性体24的冷却凝固反应,以及该热塑性弹性体24与该热塑性介质21分子间的化学键结而紧密结合以提升结合力,使该半成品23成为一如图3所示的热塑性弹性体射包碳纤维预浸材的产品3。
在此要特别说明的是,虽然该射出机201是将该热塑性弹性体24加热至170℃而熔化成液态,但是,射出成型时,液态的热塑性弹性体24的温度会迅速传向模具200,因此,当液态的热塑性弹性体24射包至该热塑性介质21时,也不会造成该热塑性介质21熔化。
参阅图3,该产品3包含一碳纤维预浸层31、一与该碳纤维预浸层31热压成型的热塑性介质层32,及一射包于该热塑性介质层32上的热塑性弹性体层33,由于该产品3是由上述制造方法所制成,因此,该碳纤维预浸层31、热塑性介质层32,及热塑性弹性体层33间是利用化学键结的方式相互结合,具有较佳的结合力,而能有效克服现有异质材料射包时结合力不足的问题。
综上所述,本发明热塑性弹性体射包碳纤维预浸材的制造方法及其产品,利用热压成型使碳纤维预浸材22的官能基能与热塑性介质21的官能基间产生化学键结而有效地结合,且该热塑性介质还能提供后续射包热塑性弹性体24时一良好的同构型高分子结合接口,进而利用该热塑性弹性体24的冷却凝固反应,以及该热塑性弹性体24与该热塑性介质21分子间的化学键结而紧密结合以提升结合力。
Claims (8)
1.一种热塑性弹性体射包碳纤维预浸材的制造方法,其特征在于:该制造方法包含一个热压成型步骤,及一个射包成型步骤,该热压成型步骤是将一个热塑性介质与一个碳纤维预浸材在一个预成型温度热压成型为一个半成品,该预成型温度会使该热塑性介质产生热变形但是不会熔化,该射包成型步骤是将一个热塑性弹性体加热熔化成液态,并射包于该半成品的热塑性介质上,使该半成品成为一个热塑性弹性体射包碳纤维预浸材的产品。
2.根据权利要求1所述热塑性弹性体射包碳纤维预浸材的制造方法,其特征在于:该热压成型步骤中的热塑性介质是选自聚对苯二甲酸乙二酯或热塑性聚胺基甲酸酯。
3.根据权利要求2所述热塑性弹性体射包碳纤维预浸材的制造方法,其特征在于:该热压成型步骤中的碳纤维预浸材是预浸环氧树脂,且在该预成型温度下,该碳纤维预浸材中的环氧树脂会液化渗出而与软化的热塑性介质相互接合而成为该半成品。
4.根据权利要求3所述热塑性弹性体射包碳纤维预浸材的制造方法,其特征在于:该热压成型步骤的预成型温度是介于130℃~150℃间。
5.根据权利要求3所述热塑性弹性体射包碳纤维预浸材的制造方法,其特征在于:该射包成型步骤是将热塑性弹性体加热至170℃熔化成液态后,再射出至该半成品的热塑性介质上。
6.一种根据权利要求1所述制造方法所制成热塑性弹性体射包碳纤维预浸材的产品,其特征在于:该产品包含一个碳纤维预浸层、一个与该碳纤维预浸层热压成型的热塑性介质层,以及一个射包于该热塑性介质层上的热塑性弹性体层。
7.根据权利要求6所述热塑性弹性体射包碳纤维预浸材的产品,其特征在于:该碳纤维预浸层是预浸环氧树脂的碳纤维预浸材。
8.根据权利要求6所述热塑性弹性体射包碳纤维预浸材的产品,其特征在于:该热塑性介质层是选自聚对苯二甲酸乙二酯或热塑性聚胺基甲酸酯。
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CN111788055A (zh) * | 2018-03-05 | 2020-10-16 | 科思创德国股份有限公司 | 热塑性复合材料制品及其制造方法和用途 |
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GB201504498D0 (en) * | 2015-03-17 | 2015-04-29 | Penso Holdings Ltd | Method and apparatus for production of carbon fibre components |
DE102015211377A1 (de) * | 2015-06-19 | 2016-12-22 | Ako - Kunststoffe Alfred Kolb Gmbh | Verfahren zur Herstellung eines faserverstärkten Kunststoffbauteils und faserverstärktes Kunststoffbauteil |
US20170217056A1 (en) * | 2016-01-29 | 2017-08-03 | Dell Products L.P. | Carbon Fiber Information Handling System Housing and Process for Manufacture |
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WO2019023326A2 (en) | 2017-07-27 | 2019-01-31 | Ossur Iceland Ehf | ASSEMBLY COMPRISING MUTUALLY LATCHED COMPONENTS |
CN113001944B (zh) * | 2021-02-09 | 2023-09-08 | 东莞市欧比迪精密五金有限公司 | 热塑性碳纤维制品成型工艺 |
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