CN102833969B - 立体工件 - Google Patents

立体工件 Download PDF

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CN102833969B
CN102833969B CN201210156730.1A CN201210156730A CN102833969B CN 102833969 B CN102833969 B CN 102833969B CN 201210156730 A CN201210156730 A CN 201210156730A CN 102833969 B CN102833969 B CN 102833969B
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interlayer
sheet material
buckled zone
tool ductility
flat region
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CN102833969A (zh
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吴荣钦
林伯安
凌国南
黄寒青
庄万历
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Compal Electronics Inc
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    • 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
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of pure plastics material, e.g. foam layers
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/028—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • 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
    • 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
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    • B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
    • B29C70/222—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure the structure being shaped to form a three dimensional configuration
    • 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
    • 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
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F1/00—Details not covered by groups G06F3/00 - G06F13/00 and G06F21/00
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    • G06F1/1633—Constructional details or arrangements of portable computers not specific to the type of enclosures covered by groups G06F1/1615 - G06F1/1626
    • 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
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • 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
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B29K2705/02—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1043—Subsequent to assembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
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    • Y10T428/24331—Composite web or sheet including nonapertured component

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Abstract

一种立体工件，包括一第一具延展性板材、一第二具延展性板材及一夹层。夹层位于第一具延展性板材与第二具延展性板材之间。第一具延展性板材、第二具延展性板材及夹层结合在一起并具有立体形状。第一具延展性板材具有一板材平坦区及一板材弯曲区。夹层具有一夹层平坦区及一夹层弯曲区。夹层平坦区重叠于板材平坦区，且夹层弯曲区重叠于板材弯曲区。

Description

立体工件
技术领域
本发明是有关于一种立体工件，且特别是有关于一种应用复合材料(composite material)的立体工件。
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，采用了复合材料来制作机壳。目前采用复合材料的机壳包含两金属板及一夹层(corelayer)，其中夹层位于两金属板之间，并分别与两金属板结合。
为了减少机壳的重量，夹层具有多个开口，而这些开口布满夹层的整面。然而，在立体成型后的机壳会因为夹层在机壳弯曲处的这些开口而产生外观上不平滑的缺陷。
发明内容
本发明关于一种立体工件，用以保持其弯曲处在外观上的平滑度。
本发明提出一种立体工件，其包括一第一具延展性板材、一第二具延展性板材及一夹层。夹层位于第一具延展性板材与第二具延展性板材之间。第一具延展性板材、第二具延展性板材及夹层结合在一起并具有立体形状。第一具延展性板材具有一平坦区及一弯曲区。夹层具有一夹层平坦区及一夹层弯曲区。夹层平坦区重叠于板材平坦区，且夹层弯曲区重叠于板材弯曲区。
基于上述，本发明通过在夹层的夹层平坦区上形成开口来减少立体工件的重量，并通过夹层的夹层弯曲区来确保第一具延展性板材呈现出平滑的外观。
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，并配合附图作详细说明如下。
附图说明
图1为本发明的一实施例的一种立体工件在立体成型前的分解图。
图2A为图1的立体工件在立体成型前的局部剖面立体图。
图2B为图2A的立体工件在立体成型前的局部剖面分解图。
图3A为图2A的立体工件于立体成型后的局部剖面立体图。
图3B为图3A的立体工件在立体成型后的局部剖面分解图。
图4为本发明的另一实施例的夹层的立体图。
图5为本发明的另一实施例的夹层分为两独立构件的分解图。
符号说明
100：立体工件                     110：第一具延展性板材
112：板材平坦区                   114：板材弯曲区
120：第二具延展性板材             130、130a：夹层
132：夹层平坦区                   134：夹层弯曲区
136：开口                         138：开口
142：胶层                         144：胶层
230：夹层                         230a：构件
230b：构件                        232：夹层平坦区
234：夹层弯曲区
具体实施方式
图1为本发明的一实施例的一种立体工件在立体成型前的分解图。请参考图1，本实施例的立体工件100包括一第一具延展性板材110、一第二具延展性板材120及一夹层130。夹层130位于第一具延展性板材110与第二具延展性板材120之间。第一具延展性板材110、第二具延展性板材120及夹层130结合在一起而形成类似三明治状的结构。在本实施例中，第一具延展性板材110可经由一胶层142与夹层130相互黏合，而第二具延展性板材120可经由另一胶层144与夹层130相互黏合。
在本实施例中，第一具延展性板材110与第二具延展性板材120可为金属板(metal plate)、包含金属的延性材料、或是预浸纤维片。预浸纤维片的材质可为植物纤维、玻璃纤维、或是碳纤维。当第一具延展性板材110及第二具延展性板材120为金属板时，则金属板为不锈钢板(SUS plate)、铝板(Aluminum plate)或镀锡钢板(SPTE)。此外，夹层130可为膜层(mylar/film)、纤维编织层(fabric)或预浸纤维片(prepreg)，其中膜层可为塑料膜层，而纤维编织层或预浸纤维片的材质可为植物纤维、玻璃纤维、或是碳纤维。
随着产品设计的不同，夹层130可为多层材料层或是单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130可为一均匀厚度夹层或是一不均匀厚度的夹层。第一具延展性板材110及第二具延展性板材120同样可为均匀厚度或是不均匀厚度的具延展性板材。当所采用的夹层130为预浸纤维片时，则第一具延展性板材110与第二具延展性板材120可直接通过预浸纤维片上的预浸液体与预浸纤维片结合而不需要透过胶层。
图2A为图1的立体工件在立体成型前的局部剖面立体图，且图2B为图2A的立体工件在立体成型前的局部剖面分解图。请参考图2A及图2B，第一具延展性板材110及第二具延展性板材120均具有一板材平坦区112及一板材弯曲区114，而板材弯曲区114将于立体成型(three-dimensionally shaped)时(如图2A至图3A)受到弯曲。此外，夹层130具有一夹层平坦区132及一夹层弯曲区134。为了减轻立体工件成型后的重量，夹层130的夹层平坦区132通常具有多数个开口136，且这些开口呈现圆孔状排列。夹层130的夹层平坦区132重叠于第一具延展性板材110的板材平坦区112，而夹层弯曲区134重叠于板材弯曲区114。在本实施例中，夹层130的夹层弯曲区134可为一实体区而不包含任何开口。
图3A为图2A的立体工件于立体成型后的局部剖面立体图，且图3B为图3A的立体工件在立体成型后的局部剖面分解图。请参考图3A及图3B，当第一具延展性板材110、第二具延展性板材120及夹层130结合在一起并受力成为立体工件100时，第一具延展性板材110、第二具延展性板材120及夹层130的夹层弯曲区134会发生弯曲的形变并维持第一具延展性板材110的一平滑表面，即维持第一具延展性板材110的外观平滑。
当第一具延展性板材110、第二具延展性板材120及夹层130已立体成型时，夹层平坦区132重叠于板材平坦区112，并通过在夹层平坦区132上形成这些开口136来减少夹层130的重量。此外，夹层弯曲区134重叠于板材弯曲区114，并通过夹层弯曲区134的设计来确保第一具延展性板材110的板材弯曲区114呈现出平滑的外观，特别是棱线的部位。
在本实施例中，依照实际需求，当板材弯曲区114围绕板材平坦区112时，夹层弯曲区134可对应围绕夹层平坦区132。随着产品设计的不同，夹层弯曲区134于弯曲后形成一弯角(半径为R)，而夹层130在夹层弯曲区134的宽度w(见图2B)通常会大于此弯角所对应的圆周长(即2πR)，以确保弯曲后的工件维持表面平滑的样态。
图4为本发明的另一实施例的夹层的立体图。请参考图4，夹层130a类似于图1的夹层130，但夹层130a除了具有在夹层平坦区132的开口136以外，还更具有在夹层弯曲区134的多个开口138。换言之，夹层130a具有多个开口136及138，这些开口的一部分(即这些开口136)分布于夹层平坦区132，且这些开口的另一部分(即这些开口138)分布于夹层弯曲区134。
在本实施例中，夹层130a上的夹层弯曲区134的开口率小于夹层平坦区132的开口率，以使弯曲后的板材弯曲区(如图3A或图3B的标号114)具有平滑的外观。然而，随着产品设计的不同，夹层130a的夹层平坦区132上的开口的分布密度可大于或小于夹层弯曲区134上的开口的分布密度，且夹层平坦区132上的开口的孔径尺寸可大于或小于夹层弯曲区134上的开口的孔径尺寸。
图5为本发明的另一实施例的夹层分为两独立构件的分解图。请参考图5，除了图1的夹层130为单一构件以外，本实施例的夹层230包括两个结构各自独立的构件230a及230b，这些构件230a及230b在结构上各自独立，且这些构件230a及230b分别构成夹层平坦区232及夹层弯曲区234。在本实施例中，依照实际需求，夹层弯曲区234可围绕夹层平坦区232。随着产品设计的不同，构件230b可包含夹层弯曲区234及部分夹层平坦区232，但是这并不限制本发明的范围。
综上所述，本发明能通过在夹层的夹层平坦区上形成开口来减少立体工件的重量，并能通过夹层的夹层弯曲区的开口率小于夹层平坦区的开口率来确保第一具延展性板材呈现出平滑的外观。
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 (18)

1.一种立体工件，其特征在于，包括：
一第一具延展性板材；
一第二具延展性板材；以及
一夹层，位于该第一具延展性板材与该第二具延展性板材之间且具有一夹层平坦区及一夹层弯曲区，其中该夹层弯曲区的开口率小于该夹层平坦区的开口率，且当该第一具延展性板材、该第二具延展性板材及该夹层结合在一起并受力成为该立体工件时，该第一具延展性板材、该第二具延展性板材、及该夹层的该夹层弯曲区会发生弯曲的形变并维持该第一具延展性板材的一平滑表面。
2.如权利要求1所述的立体工件，其特征在于，该第一具延展性板材具有一板材平坦区与一板材弯曲区，其中该板材平坦区重叠于该夹层平坦区且该板材弯曲区重叠于该夹层弯曲区。
3.如权利要求1所述的立体工件，其特征在于，该夹层弯曲区为一实体区。
4.如权利要求1所述的立体工件，其特征在于，该夹层弯曲区围绕该夹层平坦区。
5.如权利要求1所述的立体工件，其特征在于，该夹层具有多个开口，该些开口的一部分分布于该夹层平坦区，且该些开口的另一部分分布于该夹层弯曲区。
6.如权利要求5所述的立体工件，其特征在于，该夹层弯曲区上的开口的分布密度小于或大于该夹层平坦区上的开口的分布密度。
7.如权利要求5所述的立体工件，其特征在于，该夹层弯曲区上的开口的孔径尺寸小于或大于该夹层平坦区上的开口的孔径尺寸。
8.如权利要求1所述的立体工件，其特征在于，该夹层包括两构件，该些构件在结构上各自独立，且该些构件分别构成该夹层平坦区及该夹层弯曲区。
9.如权利要求1所述的立体工件，其特征在于，该第一具延展性板材与该第二具延展性板材通过胶层与该夹层相互黏合。
10.如权利要求1所述的立体工件，其特征在于，该第一具延展性板材与该第二具延展性板材的材质为金属板、包含金属的延性材料、或是预浸纤维片。
11.如权利要求10所述的立体工件，其特征在于，该预浸纤维片的材质为植物纤维、玻璃纤维、或是碳纤维。
12.如权利要求10所述的立体工件，其特征在于，该金属板的材质为不锈钢板、铝板或镀锡钢板。
13.如权利要求1所述的立体工件，其特征在于，该夹层为膜层、纤维编织层、或预浸纤维片。
14.如权利要求13所述的立体工件，其特征在于，该膜层为塑料膜层。
15.如权利要求13所述的立体工件，其特征在于，该纤维编织层或该预浸纤维片的材质为植物纤维、玻璃纤维、或是碳纤维。
16.如权利要求1所述的立体工件，其特征在于，该夹层弯曲区于弯曲后形成一弯角，且该夹层弯曲区的宽度大于该弯角所对应的圆周长。
17.如权利要求1所述的立体工件，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。
18.如权利要求1所述的立体工件，其特征在于，该第一具延展性板材及第二具延展性板材为不均匀厚度的具延展性板材。
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