CN102833968A - 立体工件制作方法 - Google Patents

立体工件制作方法 Download PDF

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CN102833968A
CN102833968A CN2012101487133A CN201210148713A CN102833968A CN 102833968 A CN102833968 A CN 102833968A CN 2012101487133 A CN2012101487133 A CN 2012101487133A CN 201210148713 A CN201210148713 A CN 201210148713A CN 102833968 A CN102833968 A CN 102833968A
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interlayer
fiber
sheet material
manufacture method
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吴荣钦
林伯安
黄寒青
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Compal Electronics Inc
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
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    • 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
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

一种立体工件制作方法。通过结合一具延展性板材、一夹层及一纤维预浸片形成一三明治结构，其中夹层位于具延展性板材与纤维预浸片之间。在立体成型三明治结构以后，固化纤维预浸片，以使三明治结构成为一立体工件。

Description

立体工件制作方法
技术领域
本发明是有关于一种立体工件制作方法，且特别是有关于一种采用复合材料（composite material）来制作立体工件的方法。
背景技术
受惠于半导体组件与显示技术的进步，电子产品不断朝向小型化、多功能化且携带方便的方向发展，常见的可携式电子产品包括笔记型计算机（notebook computer）、平板计算机（tablet computer）及行动电话（mobilephone）等。
为了减轻可携式电子产品的机壳重量及提高机壳的结构强度，目前采用了纤维与金属的复合材料（composite material）来制作机壳。在以纤维与金属的复合材料来制作机壳的过程中，将平面状的金属板立体成型为立体金属工件，接着立体金属工件的表面上覆盖纤维预浸片（fiber prepreg）并固化纤维预浸片。
发明内容
本发明提出一种方法，用以制作立体工件。
本发明提出一种立体工件制作方法。通过结合一具延展性板材、一夹层及一纤维预浸片形成一三明治结构，其中夹层位于具延展性板材与纤维预浸片之间。在立体成型三明治结构以后，固化纤维预浸片，以使三明治结构成为一立体工件。
基于上述，本发明先将具延展性板材、夹层及纤维预浸片结合以形成三明治结构，再立体成型三明治结构并固化纤维预浸片以形成立体工件。
为让本发明的上述特征和优点能更明显易懂，下文特举实施例，并配合所附图式作详细说明如下。
附图说明
图1A至图1C绘示本发明的一实施例的一种立体工件制作方法。
图2为图1A的区域2的放大图。
图3绘示图1A的多个三明治结构所形成的卷带。
符号说明
100：三明治结构        110：具延展性板材
115：胶层              120：夹层
125：胶层              130：纤维预浸片
200：立体工件
具体实施方式
图1A至图1C绘示本发明的一实施例的一种立体工件制作方法，而图2为图1A的区域2的放大图。请先参考图1A及图2，通过结合一具延展性板材110、一夹层（core layer）120及一纤维预浸片（fiber prepreg）130形成一三明治结构100，其中夹层120位于具延展性板材110与纤维预浸片130之间且具延展性板材可为一金属板（metal plate）或是包含金属的延性材料。随着产品设计的不同，夹层120可为多层材料层或是单一一层材料层所形成的夹层。此外，为了配合产品的外观或是强度的要求，夹层120可为一均匀厚度夹层或是一不均匀厚度的夹层。具延展性板材110同样可为均匀厚度或是不均匀厚度的具延展性板材。纤维预浸片130同样可为均匀厚度或是不均匀厚度的纤维预浸片。
在结合具延展性板材110、夹层120及纤维预浸片130的步骤中，可将夹层120黏合至具延展性板材110，接着将纤维预浸片130黏合至夹层120，但本发明不限于此。
在结合具延展性板材110及夹层120的步骤中，可通过一胶层115来黏合具延展性板材110及夹层120。胶层115可通过在具延展性板材110或夹层120上涂布胶材来形成。
在结合夹层120及纤维预浸片130的步骤中，可通过一胶层125来黏合夹层120及纤维预浸片130。胶层125可通过在夹层120或预浸纤维片130上涂布胶材来形成。在另外一个实施例中，夹层120与预浸纤维片130可通过预浸纤维片130表面的预浸液体作为接口而结合，并不需要额外的胶层，其中预浸纤维片130表面的预浸液体包含环氧树脂。此外，若夹层120具有开口，则制作三明治结构的程序可不需要通过其它的胶层125。当夹层120具有开口时，可先将夹层120与预浸纤维片通过预浸纤维片130表面的预浸液体结合。预浸液体将可透过夹层120的开口而分布至夹层120的另一面。接下来当具延展性板材110与夹层120结合时，仅需透过预浸液体即可于夹层120结合而形成三明治结构而不需额外的胶层。
在本实施例中，当具延展性板材110采用金属板时，则金属板可为镀锡钢板（SPTE）、铝板（Aluminum plate）或不锈钢板（SUS plate）。夹层120为的材质可为塑料（plastic）、植物纤维、碳纤维、玻璃纤维、或石墨（graphite）。纤维预浸片130是将纤维布含浸树脂（resin）所形成。纤维预浸片130所采用的纤维可为碳纤维（carbon fiber）、植物纤维、或玻璃纤维（glass fiber）。
请参考图1B，在完成图1A的三明治结构100以后，将三明治结构100立体成型（three-dimensionally shaped）。在本实施例中，可以冲压（pressing）的方式立体成型三明治结构100。
请参考图1C，在立体成型三明治结构100以后，固化纤维预浸片130，以使三明治结构100成为一立体工件200（例如电子装置的机壳）。固化纤维预浸片130是固化纤维预浸片130的半固化树脂部分。在本实施例中，可以热固化（thermosetting）方式固化纤维预浸片130。
当以冲压（pressing）的方式立体成型图1B的三明治结构100时，可接着通过将热能经由冲压用的模具传导至纤维预浸片130来固化纤维预浸片130。随着制程设计的不同，当立体成型的三明治结构100形成后也可另外置入加热设备中进行加热的程序以固化预浸纤维片130。
值得注意的是，在图1A的形成三明治结构100的步骤中，一般是将具延展性板材110、夹层120、以及纤维预浸片130先行裁切后再开始进行组立的程序。随着制程设计的不同。多个三明治结构100也可先形成为卷带状，如图3所示，且在图1B的立体成型三明治结构100的步骤中，将卷带状的三明治结构100切割并展开以立体成型。
综上所述，本发明先将具延展性板材、夹层及纤维预浸片结合以形成三明治结构，再立体成型三明治结构并固化纤维预浸片以形成立体工件。此外，本发明可在生产前期结合卷带式制程来提高生产效率。
虽然本发明已以实施例揭露如上，然其并非用以限定本发明，任何所属技术领域中具有通常知识者，在不脱离本发明的精神和范围内，当可作些许的更动与润饰，故本发明的保护范围当根据权利要求所界定的内容为准。

Claims (14)

1.一种立体工件制作方法，其特征在于，包括：
结合一具延展性板材、一夹层及一纤维预浸片形成一三明治结构，其中该夹层位于该具延展性板材与该纤维预浸片之间；
立体成型该三明治结构；以及，
加热该立体三明治结构以固化该纤维预浸片。
2.如权利要求1所述的立体工件制作方法，其特征在于，在形成该三明治结构的步骤中，将该三明治结构形成为卷带状，且在立体成型该三明治结构的步骤中，将卷带状的该三明治结构展开以立体成型。
3.如权利要求1所述的立体工件制作方法，其特征在于，在结合该具延展性板材、该夹层及该纤维预浸片的步骤中，将该夹层黏合至该具延展性板材，接着将纤维预浸片黏合至该夹层，其中在结合该具延展性板材及该夹层的步骤中，通过一胶层来黏合该具延展性板材及该夹层。
4.如权利要求1所述的立体工件制作方法，其特征在于，在结合该具延展性板材、该夹层及该纤维预浸片的步骤中，将该夹层黏合至该纤维预浸片，接着将具延展性板材黏合至该夹层。
5.如权利要求4所述的立体工件制作方法，其特征在于，该夹层包含多数个开口且纤维预浸片与夹层之间及夹层与具延展性板材之间可通过纤维预浸片的预浸液体结合。
6.如权利要求1所述的立体工件制作方法，其特征在于，在立体成型该三明治结构的步骤中，以冲压的方式立体成型该三明治结构。
7.如权利要求1所述的立体工件制作方法，其特征在于，在固化该纤维预浸片的步骤中，以热固化方式固化该纤维预浸片。
8.如权利要求7所述的立体工件制作方法，其特征在于，热固化该纤维预浸片的制程系可以加热立体成型该三明治结构制程中所使用的模具来达成。
9.如权利要求1所述的立体工件制作方法，其特征在于，该具延展性板材为一金属板或是一包含金属的延性板材，其中金属板为镀锡钢板、铝板或不锈钢板。
10.如权利要求1所述的立体工件制作方法，其特征在于，该夹层的材质为塑料、碳纤维、植物纤维、玻璃纤维、或石墨。 
11.如权利要求1所述的立体工件制作方法，其特征在于，该纤维预浸片的纤维为碳纤维、植物纤维、或玻璃纤维。
12.如权利要求1所述的立体工件制作方法，其特征在于，该夹层为多层材料层所形成的不均匀厚度的夹层或单一层材料层所形成的不均匀厚度的夹层。
13.如权利要求1所述的立体工件制作方法，其特征在于，该具延展性板材为不均匀厚度的具延展性板材。
14.如权利要求1项所述的立体工件制作方法，其特征在于，该纤维预浸片为不均匀厚度的纤维预浸片。 
CN2012101487133A 2011-06-14 2012-05-14 立体工件制作方法 Pending CN102833968A (zh)

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TW201249651A (en) 2012-12-16
US20120318444A1 (en) 2012-12-20
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