CN103003052B - 薄壁平顶模制零件，尤其是用于移动电子器件的壳体零件 - Google Patents

薄壁平顶模制零件，尤其是用于移动电子器件的壳体零件 Download PDF

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CN103003052B
CN103003052B CN201180021824.1A CN201180021824A CN103003052B CN 103003052 B CN103003052 B CN 103003052B CN 201180021824 A CN201180021824 A CN 201180021824A CN 103003052 B CN103003052 B CN 103003052B
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M.奥佩尔曼
A.施密特
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Oechsler AG
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Abstract

呈现出已经达到了减小借助于注塑模制产生的且装备有装饰层的壳体零件的壁厚的技术极限。为了仍然进一步(甚至显著地)减小合成的壁厚，建议改变初始材料，该初始材料为在一侧上装备有装饰层(11)的纤维复合材料(13)，壳体零件在深拉工艺中由该初始材料形成。即使施加较厚的装饰层(11)，装饰层(11)的外表面(17)出于手感的原因而有较高的凸纹，合成的壁厚保持仍远低于可借助于注入模制产生的壳体零件的壁厚。如果纤维复合材料(13)用作用于定形的零件的深拉初始材料，装饰材料在纤维复合材料的表面(16)上直接地发泡或喷射，则可实现壁厚的甚至进一步的减小。

Description

薄壁平顶模制零件，尤其是用于移动电子器件的壳体零件
技术领域
本发明涉及薄壁平顶模制零件，尤其是用于移动电子器件的壳体零件。
背景技术
从EP1157799A1中获知的手机，其后封壳由塑料膜构成为基础层，皮革或其它“未来的”装饰层已经施加到该基础层上。该复合材料为加热成形的，且最后在注入模具中用塑料反注入（back-injected）来使复合材料在机械上稳定，这仅导致了相对较低机械稳定性的厚壁的封壳作为生产设备上的大量开支的回报。
然而，市场需要比以往更平的移动器件如音乐储存装置、微型计算机或网络访问装置和类似的消费性电子装置，且尤其还在手机外壳中需要。三维壳体零件的高度如电池盖的高度也相应地缩小。这通常在注塑模具中由热塑性材料产生为很多面板。出于涉及注入模制技术的原因，且由于关于针对壳体的机械稳定性的抗弯刚度和抗扭刚度的最低要求，故不可随意简单地减小此类单独地装卸的相对较大面积的壳体零件的壁厚。目前，对于热塑性模制零件，大约1.5毫米的壁厚被认为是最小值。然而，如果出于视觉或手感原因而将装饰层(例如，仿皮革纹理的塑料膜)施加到注入模制壳体零件的外表面上，然后所述塑料膜通常还用完全透明的热塑性保护层覆盖以覆盖边缘，则合成的璧厚通常以大约0.4毫米至大约1.9毫米增大。对于较高品质的消费性产品的此类市场设计的要求与实现薄壁塑料模制零件的注入模制相关努力直接相反。
发明内容
鉴于此类情形，本发明潜在的技术问题在于，不论装饰涂层怎样，都将以上类型的模制零件仍全部制作成薄壁的。
这不可使用如上文所述的EP1157799中提出的为了机械稳定性而反注入的基础膜实现。
如果根据DE102004053131A1，平纤维复合材料半成品在其压缩模制的过程中连结到装饰层上，优选利用插入的保护膜，例如以产生机动车辆仪表板，则也不可实现所期望的极薄且仅为平顶的模制零件。例如，如果半成品由分别为三分之一(按重量计)的热塑性长纤维、天然材料长纤维(如，亚麻)和短纤维木材成分(例如，木粉形式)构成，则该半成品旨在显示出良好的加热成形性质。纤维缠绕，以形成非织造结构，在通过针刺形成之前附加地强化非织造结构。在形成期间，塑料纤维熔合，以便一方面连结木粉中的天然纤维，而另一方面以便熔合在装饰层上。因此，塑料纤维不会以纤维复合材料的方式有助于模制零件的机械承压能力。缠绕在一起、然后针刺且最后在木粉中熔合在一起的亚麻纤维的此类非织造织物明显不会导致用于极薄且仍机械上稳定的塑料模制零件的初始材料的优化。
US2003/0240235A1涉及在热塑性纤维复合材料的内核上产生限定的区，该区用作用于翻折移动的铰链，尤其是用于气囊从机动车辆仪表板展开。为此，在对内核的压力和加热下，从表面(可选地在相对表面上也适合)压出柔性且高度可延伸的材料层，且然后以此方式装备的内核设有完全包绕的装饰层，其可包括热塑性材料或织造织物。最大限度的薄壁设计在这里不相关，且也不可由此实现。
另一方面，通过主权利要求中指出的基本特征来解决上文概括的问题。根据主要权利要求，尤其是由热塑性材料注入模制成的模制零件不再是在随后设有装饰层，而是该模制零件在其由以夹层形式与塑料基质层合的多褶层纤维复合材料加热成形为薄支承件的同时设有此类装饰物。
此类纤维复合材料在市场上以板形式或片形式出售，尤其用于制造机动车辆车身零件，如保险杠和备用轮胎盘。由于纤维复合材料的良好机械性质，尤其是其高抗弯刚度和抗扭刚度，故对于其它方面相等的定形，纤维复合材料仅需要大约注入模制壁厚的三分之一的厚度。该纤维复合材料装备有衬膜，衬膜用于施加用于装饰层的粘合带。即使在将装饰层这样施加到两个夹层表面中的其中一个上，由坯料加热成形的合成形成的零件也具有比相当的但还未装饰的注入模制件更小的壁厚。
这是由于为纤维加强的基础结构的形式的纤维复合材料通常测量的厚度仅为大约0.5毫米，且因此，为了手感清楚的外形，可设有例如0.4毫米的相对较厚的装饰层，加上分别0.1毫米厚的粘合带和衬膜。这导致1.1毫米下的具有明显地改善手感性质的总厚度，这较好地比上述类型的涂布的注入模制零件薄30%，这结合至少相同的机械性质实现，例如，机械性质关于相等几何形状的合成模制零件的抗弯刚度和抗扭刚度。例如，由此类初始材料制成的形成零件为具有在手感方面吸引人的装饰表面(例如，皮革或人造革的)的薄壁技术的稳定壳体零件。
为了简化描述，将仅论述纤维复合材料的纤维加强的织造织物，但对于本发明的目的，这些可同样良好地为单褶层或多褶层，且采取针织物、无纬织物、纤维束(粗纱)、毡和类似的垫的形式。使用的纤维结构大体上以限定的方式定向，且与热固定基质或优选为与热塑性基质层合以产生夹层型纤维复合材料。
尤其是在提高机械要求的情况下，这将在其自身中明显的是使用碳纤维用于加强织造织物。这些不仅特别坚固，而且它们的织造结构在形成的零件中也在自身中提供了令人满意的感觉和高品质的外观。然而，由于碳的导电性质和合成的屏蔽行为，例如，此类形成零件不可用在无线电天线并入其中的器件中，例如手机。在同样极坚固的凯夫拉(Kevlar)或芳香族聚酰胺纤维的情况下，这个缺点不会出现，但例如，由于需要此类纤维用于防护头盔和防弹背心，故很难以消费性货物的合理价格买到此类织物。因此，出于实用的目的，通常仅可使用具有常规玻璃纤维织造织物的合层，这些合层也提供非常好的机械强度水平，尤其在多褶层的形式中。
即使在涂布有装饰层之后，且在呈现出至少相当的机械性质的同时，这里使用的根据本发明的该初始材料因而比通过常规注入模制产生的仍未涂布的模制零件更薄。具体而言，装饰层粘性地连结到层合的织物的两个外表面中的其中一个上，但例如，也可取决于材料配对将装饰层焊接到层合的织物的两个外表面中的其中一个上。取决于设备要求，装饰层可为真皮，或具有所期望的表面纹理的塑料膜，或实际的纺织品层，或甚至薄木材层或金属层。
为了进一步减小壁厚，甚至可构想出的是，将纤维复合材料的加强织物反常地不与两侧上的塑料基质都层合，而是在良好彻底润湿的织物结构的情况下与仅一侧上的塑料基质层合，于是装饰层将如上文所述那样直接地施加到由基质材料穿透的织物上与基质相对的不平表面上。然而，此类非对称结构将导致强度的损失，且将必须解决与大量制造相关的复杂性，因为大致仅层合在一侧上的织造织物可在加热成形期间变弯(“双金属效应”)。此外，对于有效地连结到仅一侧上的该织物，关键是保持装饰层足够稳定。
为了实现形成的零件的总厚度中的仍可察觉到进一步减小，因此根据本发明形成的规定，在没有粘合条形式的联接剂和其衬膜的情况下，用于通过压制或发泡将装饰层直接地熔合到对称层合纤维复合材料的两个表面上。这引起在形成的零件的厚度上进一步减小大约0.2mm，由于将装饰层附加整体结合到纤维复合材料中而可能具有甚至更好的机械性质。
在引入到加热成形模具中之前或之后，将层合的且然后在一侧上装饰性地涂布的纤维复合材料的坯料加热至容纳纤维织物的基质的玻璃过渡温度或玻璃软化温度，且然后在模具中直接地加热成形来产生壳体零件或类似形成的零件，然后获得已装备有所期望的手感或视觉的外表面的壳体零件或类似形成的零件，而不需要抛光。
附图说明
附图中的单个图示出了根据本发明的初始材料的总体略图，初始材料用于较平但机械上稳定的具有装饰层的塑料形成的零件的加热成形。
具体实施方式
在该示例性实施例中，与相对较厚的装饰层11(例如，0.4mm的人造革)层合的机械上稳定的支承件12由纤维复合材料13层合成，这里为一层且类似亚麻的纤维复合材料13的玻璃纤维织造织物14在各个情况下已经在两侧上以常规方式与热塑性基质15层合。为了实现具有坚固纹理外形(因此，其在手感方面也尤其非常令人满意)的外表面17，层合在该支承件12的一个表面16上的通常0.5mm厚的装饰层11因而可如绘出那样例如具有与支承件12完全相同的厚度。在该示例性实施例中，装饰层11不是粘性地直接连结到支承件12的其中一个表面16上，而是改为使用粘合带19，利用插入的衬膜18(通常分别为0.1mm厚)施加到支承件12上。
对于加热成形的整个初始材料，也对于由其加热成形的壳体或类似形成的零件(未示出)的壁厚，这导致了仍仅为约一毫米的壁厚。
由于将显现出已经达到了由注塑模制产生且设有装饰层的平顶壳体(如，用于移动器件的电池盖)的关于减小壁厚的技术极限，故为了实现仍然显著的合成壁厚的进一步减小，本发明已经变为板形式或片形式的初始材料，其包括在一侧上设有装饰层11的纤维复合材料13，壳体零件通过加热成形而由该初始材料形成。即使出于手感的原因施加具有重度纹理外表面17的厚装饰层11，形成的零件的合成壁厚也将远小于通过注入模制产生的壳体零件的壁厚。如果纤维复合材料13用作用于形成的零件的加热成形初始材料，装饰材料已经直接地在初始材料的表面16上发泡或喷涂，则实现了壁厚的甚至更大的减小。

Claims (8)

1.一种薄壁平顶模制零件，用于移动电子器件的壳体零件，所述模制零件包括可加热成形的板形式或片形式的夹层型多褶层纤维复合材料(13)，所述纤维复合材料(13)用作装饰层(11)的支承件(12),其中所述纤维复合材料(13)在其表面中的至少一个表面上与塑料基质(15)层合，将所述装饰层(11)施加到所述纤维复合材料(13)的其中仅一个表面上。
2.根据权利要求1所述的模制零件，其特征在于，所述装饰层(11)粘性地连结、或焊接到所述支承件上。
3.根据权利要求1中所述的模制零件，其特征在于，所述装饰层(11)在所述支承件上发泡或喷涂。
4.根据权利要求1中的一项所述的模制零件，其特征在于，通过使用粘合带(19)在所述纤维复合材料(13)和所述装饰层(11)之间插入衬膜(18)的方式来施加所述装饰层(11)。
5.根据权利要求1中所述的模制零件，其特征在于，所述纤维复合材料(13)的织造织物(14)仅在一侧上与塑料基质(15)层合，以及将所述装饰层(11)施加到由基质材料穿透的所述织造织物(14)的不平表面上，该不平表面与所述塑料基质(15)相对。
6.根据权利要求1所述的模制零件，其特征在于，所述模制零件的装饰层(11)的外表面(17)是粗糙纹理的。
7.根据权利要求1所述的模制零件，其特征在于，真皮、人造革、纺织品、木材或金属作为用于所述装饰层(11)的材料。
8.根据权利要求1所述的模制零件，其特征在于，所述模制零件为移动器件的电池盖。
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