CN103238382A - 用于提供具有电磁干扰屏蔽的增强复合材料的方法和设备 - Google Patents

用于提供具有电磁干扰屏蔽的增强复合材料的方法和设备 Download PDF

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CN103238382A
CN103238382A CN2011800582473A CN201180058247A CN103238382A CN 103238382 A CN103238382 A CN 103238382A CN 2011800582473 A CN2011800582473 A CN 2011800582473A CN 201180058247 A CN201180058247 A CN 201180058247A CN 103238382 A CN103238382 A CN 103238382A
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furnace charge
extrusion machine
fusion furnace
product
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E·J·温策尔
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Inteva Products LLC
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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
    • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
    • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
    • B29C31/08—Feeding of the material to be moulded, e.g. into a mould cavity of preforms to be moulded, e.g. tablets, fibre reinforced preforms, extruded ribbons, tubes or profiles; Manipulating means specially adapted for feeding preforms, e.g. supports conveyors
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58—Component parts, details or accessories; Auxiliary operations
    • B29B7/60—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/88—Adding charges, i.e. additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/88—Adding charges, i.e. additives
    • B29B7/90—Fillers or reinforcements, e.g. fibres
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
    • B29C48/2886—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
    • B29C48/385—Plasticisers, homogenisers or feeders comprising two or more stages using two or more serially arranged screws in separate barrels
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
    • B29C48/402—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders the screws having intermeshing parts
    • 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
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0073—Shielding materials
    • H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
    • H05K9/0083—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising electro-conductive non-fibrous particles embedded in an electrically insulating supporting structure, e.g. powder, flakes, whiskers
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K9/00—Screening of apparatus or components against electric or magnetic fields
    • H05K9/0073—Shielding materials
    • H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
    • H05K9/009—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/34—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices
    • B29B7/38—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary
    • B29B7/46—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft
    • B29B7/48—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft with intermeshing devices, e.g. screws

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  • Engineering & Computer Science (AREA)
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  • Physics & Mathematics (AREA)
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  • Robotics (AREA)
  • Composite Materials (AREA)
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Abstract

一种形成具有电磁干扰屏蔽的产品的方法，所述方法包括以下步骤：将第一聚合物插入第一复合挤压机内，其中第一复合挤压机提供第一熔融炉料；将第一熔融炉料插入第二复合挤压机内，其中第二复合挤压机将多个导电纤维引入到第一熔融炉料中以及其中第二复合挤压机提供包括第一熔融炉料和多个导电纤维的第二熔融炉料；将第二熔融炉料放置在压缩模的至少一个口模上；以及围绕第二熔融炉料闭合压缩模以形成产品。

Description

用于提供具有电磁干扰屏蔽的增强复合材料的方法和设备
相关申请的交叉引用
本申请要求于2010年10月6日提交的美国临时专利申请No.61/390410的权利，其内容通过引用包含于此。
技术领域
本发明的示例性实施例总的涉及具有特定特征的复合材料及其制造方法。更进一步地，本发明的示例性实施例也总的涉及纤维增强的热塑性聚合物结构部件的制造，以及更特别地涉及用于热塑性聚合物结构部件的线上（in-line）复合、放置、压缩成型的设备和方法。
背景技术
典型的电磁干扰（EMI）屏蔽外壳由金属或高度填充的聚合物复合材料组成。需要导电介质来屏蔽外壳的内容物以及外壳周围的部件从而不受杂散电磁场影响。常见的金属外壳包括钢铁和铝。聚合物复合材料通常是含有不锈钢纤维、碳纤维和/或镀镍的碳纤维的注塑的热塑性塑料。
可以通过弯曲和焊接金属薄板或者铸造铝并且浸渍粘合剂以密封任何孔隙来形成金属外壳。形成的金属板外壳在轮廓和特征方面通常受到限制。
因此，希望提供一种具有EMI屏蔽的复合物，以及用于提供这种复合物的设备。更进一步也希望提供由具有EMI屏蔽的复合物形成的部件。此外还期望通过挤压成型工艺形成该部件。
发明内容
根据示例性实施例提供一种使用可替换成型技术以及导电纳米尺寸的填料技术从聚合物复合材料制造电外壳的方法。
根据本发明的示例性实施例，形成具有电磁干扰屏蔽的产品的方法包括以下步骤：将第一聚合物插入第一复合挤压机中，其中第一复合挤压机提供第一熔融炉料；将第一熔融炉料插入第二复合挤压机中，其中第二复合挤压机将多个导电纤维导入第一熔融炉料中以及其中第二复合挤压机提供包括第一熔融炉料以及多个导电纤维的第二熔融炉料；将第二熔融炉料放置在压缩模的至少一个模具上或输送机上以随后传输到压缩模的模具上；以及围绕第二熔融炉料闭合压缩模以形成产品。
在另一个示例性实施例中，提供挤压成型组件，该组件具有：第一聚合物复合挤压机；第二聚合物复合挤压机，其配置为接收来自第一聚合物复合挤压机的熔融炉料；以及用于提供多个纤维到第二聚合物复合挤压机中的组件，其中所述组件以及第二聚合物复合挤压机提供具有导电性质的纤维增强的熔融炉料。
本发明的上述的和其他的特征和优点将被本领域技术人员从下面的详细描述、附图、以及所附的权利要求中领会和理解。
附图说明
现在将仅以示例的方式参考附图描述本发明的实施例，其中：
图1是根据本发明的示例性实施例的挤压成型（ECM）仓室的示意图；以及
图2示出根据本发明的示例性实施例的一种形成具有EMI屏蔽的产品的非限制性的方法。
具体实施方式
提供用于生产具有EMI屏蔽的纤维增强的模制结构部件的线上复合和挤压成型设备。该设备允许用于形成第一聚合物熔融体，将所述第一聚合物熔融体供给到第二挤压机，第二挤压机将聚合物熔融体与至少一个增强纤维复合以形成纤维增强的聚合复合物，将纤维增强的聚合物复合物放置在压缩模上，并且模制其中的增强结构部件。
参考下面的美国专利No.6648402、No.6558146、No.6508967和No.6497775，其中每个的内容通过引用包含于此。
图1示出了根据本发明的示例性实施例的挤压成型（ECM）仓室10的示例性实施例。ECM是一种开放的模制工艺，且该特征允许使用特定的处理技术以在相同的工具或模腔之内组合不同的聚合物材料和/或插入物。ECM仓室10生产出熔融炉料12，熔融炉料12通过机器人或其它等价装置16最终提供给位于垂直压缩压力机15内的压缩模14。压缩模中将有阴半部18和阳半部20，其中每一个都包括接触表面22。阴半部和阳半部优选是形状相互配合的。压缩模也可以是通常用于将聚合物模制成期望的形状和形式的传统模具。
在一个实施例中，复合挤压机24、26可移动地布置于3轴工作台（未示出）上，以使得熔融炉料能直接放置在接触面上、或替代地机器人相对于固定的模具可以移动以将熔融炉料从熔融体接收输送机（未示出）传输。
ECM组件10还包括第一聚合物复合挤压机24，其将熔融炉料进给至第二纤维/聚合物混合挤压机26。每个挤压机都是双螺杆挤压机，具有主体、入口端和具有口模的出口端。螺杆旋转以混合和朝向挤压机出口端移动聚合物熔融体。
第一复合挤压机24的聚合物熔融体由聚合物材料28形成，通过包括使用漏斗30（聚合物材料被进给至其中）的任意技术将聚合物材料28引入到第一挤压机中。通常，聚合物材料是塑料颗粒的形式。更进一步地且作为一种替代，添加剂32可以被添加到漏斗30。在一个实施例中，该添加剂包括偶联剂、热稳定剂、着色剂、再研磨材料、和其它填料，以增强其机械性能。可替换地，添加剂可能被包含在颗粒28的聚合物材料中，或可替换地聚合物材料可不加任何添加剂而应用并且第二挤压放置复合装置包括该添加剂。再进一步地且在一个实施例中，添加剂或添加剂中的至少一些是导电的或具有导电特性以使得由聚合物材料形成的产品将一体形成有EMI屏蔽能力。这样的导电添加剂的非限制性示例从由玻璃、碳、不锈钢、导电的纳米尺寸的填料技术、纳米线、它们的等价物以及组合组成的组中选择。更进一步地，上述添加剂可以以纤维配置提供。
第二复合挤压机26还具有入口端和出口端。出口端还包括用于纤维增强的熔融炉料的形成/成形的放置口模头30。
第二复合挤压机还包括纤维进给设备33。纤维进给设备提供将连续纤维引入到第二复合挤压机的手段，且包括一个纤维供给卷筒或多个纤维供给卷筒34，每个纤维供给卷筒在其附近都包含预定的张力下的至少一个纤维缠绕。所述至少一个纤维可以是玻璃、碳、不锈钢等。更进一步地且在一个实施例中，纤维或纤维中的至少一些是导电的或具有导电特性，以使得由聚合物材料形成的产品将一体形成有EMI屏蔽能力。这样的导电纤维的非限制性的示例可以从上述由玻璃、碳、不锈钢、导电的纳米尺寸的填料技术、纳米线、它们的等价物以及组合组成的组中选择。
将纤维进给至第二复合挤压机的可替换手段包括但并不限于用于将不连续（切碎的）的纤维进给至挤压机的进料喉口（feedthroat）的重量损耗（loss-in-weight）给料器，以及用于切断和进给不能在挤压机的机筒内被轻易切碎的连续纤维的线上纤维切碎设备。可替换地，纤维被配置为在挤压机的机筒的螺杆内被切碎。
纤维被引入到第二复合挤压机中以提供所形成产品的所需的增强应用以及EMI屏蔽能力。
第二复合挤压机还包括切断组件，切断组件具有切割构件和致动器，其中致动器的启动导致切割构件的运动来将熔融体切割成在传送带（未示出）上的炉料12，从而机器人或其他等价装置16可以捡起熔融炉料且将其放置在压缩模的两半中的一个上。之后，压缩模形成由具有EMI屏蔽特性的复合材料构造的产品40。由于产品40由模制工艺形成，所以其可以在具有EMI屏蔽特性的同时具有几乎任何配置。一个非限制性的产品40的配置是车辆的仪表板或内部部分。
每个挤压机将包括加热元件，加热元件伴随剪切和压力来塑炼聚合物复合材料熔融体，熔融体最终包括布置到压缩模14的口模上的熔融炉料。加热元件（未示出）结合通过挤压机的螺杆的旋转而引入的剪切热来形成聚合物熔融体。另外，在得到的复合物中的增强纤维和/或导电纤维的百分比可以通过控制由纤维进给设备所提供的纤维的数量而改变。因此，增强纤维和/或导电纤维的百分比可以通过增加或减少与聚合物熔融体复合的增强纤维的量来改变。增强纤维/填料可以同时以不同的百分比添加到其中一个或两个复合挤压机，来提供具有优化的机械性能和最低成本的聚合物复合材料。
使用具有线上材料复合（ECM w/ILC或LFT-D-ILC压缩）工艺技术的挤压成型，使得能够生产定制配方的复合材料，并且同时提供了较高的性能/成本比，所述复合材料符合所需求的EMI屏蔽、机械性能和阻燃性。
这样，提供了用于提供形成有EMI屏蔽能力的产品的方法和设备，其中导电添加剂被提供到第一挤压机或第二挤压机、或可替换地被提供到第一和第二挤压机、或其任意组合，以使得得到的包括导电材料的熔融炉料和由其形成的产品具有EMI屏蔽特性。
图2示出根据本发明的示例性实施例的至少一种形成有电磁干扰屏蔽的产品的非限制性的方法。在第一步骤50中，第一聚合物被插入第一复合挤压机内，其中所述第一复合挤压机提供第一熔融炉料。在第二步骤52中，第一熔融炉料被挤压进入第二复合挤压机，其中所述第二复合挤压机在步骤54中将多个导电纤维引入到第一熔融炉料中，且其中所述第二复合挤压机在步骤56提供包括第一熔融炉料和多个导电纤维的第二熔融炉料。此后，在步骤58，第二熔融炉料被放置在压缩模的至少一个口模上。在步骤60中，压缩模围绕第二熔融炉料闭合以形成产品，因为导电产品引入到熔融炉料中，所以产品具有EMI屏蔽能力。在可替换实施例中且如上文所述，导电添加剂在步骤50中添加，或在步骤50中添加的添加剂中的至少一些是导电性的，或具有导电特性，从而使由此聚合物材料形成的产品将一体形成有EMI屏蔽能力。这些导电添加剂可以被步骤54中添加的多个导电纤维代替，或是除步骤54中添加的多个导电纤维之外的导电添加剂。
虽然参考示例性实施例描述了本发明，但本领域技术人员应当理解，在不脱离本发明的范围的情况下，可以对其中的元件做出各种改变并且可以将其中的元件替换为其他等价物。此外，在不脱离本发明的实质范围的情况下，依照本发明的教导可以做出许多修改以适应特定的情况或材料。因此，本发明并不局限于实施本发明的最佳方式所公开的具体实施例，而是包括落入所附权利要求的范围内的所有实施例。

Claims (19)

1.一种形成具有电磁干扰屏蔽的产品的方法，包括：
将第一聚合物插入第一复合挤压机中，其中所述第一复合挤压机提供第一熔融炉料；
将所述第一熔融炉料挤压至第二复合挤压机中，其中所述第二复合挤压机将多个导电纤维引入到所述第一熔融炉料中，以及其中所述第二复合挤压机提供包括所述第一熔融炉料和所述多个导电纤维的第二熔融炉料；
将所述第二熔融炉料放置在压缩模的至少一个口模上；以及
围绕所述第二熔融炉料闭合所述压缩模，以形成所述产品。
2.根据权利要求1所述的方法，其中多个添加剂也被插入到所述第一复合挤压机中。
3.根据权利要求2所述的方法，其中所述多个添加剂和所述第一聚合物被插入所述第一复合挤压机的漏斗中。
4.根据权利要求2所述的方法，其中所述多个添加剂的至少一些具有向产品提供一体的电磁干扰屏蔽的导电特性。
5.根据权利要求4所述的方法，其中具有导电特性的多个添加剂从由玻璃、碳、不锈钢及其组合组成的组中选择。
6.根据权利要求5所述的方法，其中内部部件是车辆的仪表板。
7.根据权利要求1所述的方法，其中内部部件是车辆的仪表板。
8.根据权利要求1所述的方法，其中所述多个导电纤维从由玻璃、碳、不锈钢及其组合组成的组中选择。
9.根据权利要求8所述的方法，其中多个添加剂也被插入到所述第一复合挤压机中，以及其中所述多个添加剂的至少一些具有给所述产品提供一体的电磁干扰屏蔽的导电特性，以及其中具有导电特性的多个添加剂从由玻璃、碳、不锈钢及其组合组成的组中选择。
10.根据权利要求9所述的方法，其中所述产品是车辆的仪表板。
11.根据权利要求1所述的方法，其中所述多个导电纤维向所述产品提供一体的电磁干扰屏蔽，以及所述导电纤维从由玻璃、碳、不锈钢及其组合组成的组中选择，以及所述多个导电纤维还为所述产品提供了结构性增强。
12.一种挤压成型仓室，包括：
第一聚合物复合挤压机；
第二聚合物挤压机，被配置为接收来自所述第一聚合物复合挤压机的熔融炉料；以及
纤维进给设备，用于将多个纤维提供至所述第二聚合物复合挤压机，其中所述第一聚合物复合挤压机和所述第二复合物挤压机提供具有导电性质的纤维增强的熔融炉料。
13.根据权利要求12所述的挤压成型仓室，还包括：
被配置为接收所述纤维增强的熔融炉料的压缩模。
14.根据权利要求12所述的挤压成型仓室，其中多个添加剂也被插入到所述第一复合挤压机中。
15.根据权利要求14所述的挤压成型仓室，其中所述多个添加剂的至少一些具有向产品提供一体的电磁干扰屏蔽的导电特性。
16.根据权利要求15所述的挤压成型仓室，其中具有导电特性的多个添加剂从由玻璃、碳、不锈钢及其组合组成的组中选择。
17.根据权利要求12所述的挤压成型仓室，其中所述多个纤维的至少一些从由玻璃、碳、不锈钢及其组合组成的组中选择，以及导电纤维向产品提供一体的电磁干扰屏蔽。
18.根据权利要求17所述的挤压成型仓室，还包括：被配置为接收所述纤维增强的熔融炉料的压缩模，其中，所述压缩模被配置为限定用作车辆的内部部件的产品。
19.根据权利要求18所述的挤压成型仓室，其中所述内部部件是车辆的仪表板。
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US20120091615A1 (en) 2012-04-19
JP2017052280A (ja) 2017-03-16
WO2012048097A2 (en) 2012-04-12
EP2625942A2 (en) 2013-08-14
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