CN103896516A - 石材外壳及其制造方法 - Google Patents

石材外壳及其制造方法 Download PDF

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CN103896516A
CN103896516A CN201210590270.3A CN201210590270A CN103896516A CN 103896516 A CN103896516 A CN 103896516A CN 201210590270 A CN201210590270 A CN 201210590270A CN 103896516 A CN103896516 A CN 103896516A
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王仁博
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Shenzhen Futaihong Precision Industry Co Ltd
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Abstract

本发明提供一种石材外壳，该石材外壳的材质为铁丸石，该铁丸石的主要成分为石英、粘土矿及含铁钙聚合体，所述粘土矿中含有Zn元素、Al2O3、CaO、MgO、Ba2O3、SiO2及TiO2，所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4，该石材外壳采用铁丸石粉末为原料以注塑成型的方式制成。本发明还提供一种石材外壳的制造方法。

Description

石材外壳及其制造方法
技术领域
本发明涉及一种石材外壳及其制造方法。
背景技术
现有的电子产品壳体的材质主要为金属、塑料及玻璃。但，由于金属壳体易于被腐蚀性介质腐蚀，使金属壳体表面的装饰性膜层发生脱落，严重影响其外观；塑料基体的抗老化性能较差；而玻璃壳体易碎且难以形成复杂的三维结构。此外，上述三种材质的壳体均不具有如玉石般温润、细腻的手感。
发明内容
有鉴于此，提供一种具有良好的抗老化性、耐腐蚀性及硬度的石材外壳。
另，还提供一种上述石材外壳的制造方法。
一种石材外壳，该石材外壳的材质为铁丸石，该铁丸石的主要成分为石英、粘土矿及含铁钙聚合体，所述粘土矿中含有Zn元素、Al2O3、CaO、MgO、Ba2O3、SiO2及TiO2，所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4，该石材外壳采用铁丸石粉末为原料以注塑成型的方式制成。
一种石材外壳的制造方法，其包括如下步骤：
提供一铁丸石粉末，该铁丸石粉末的主要成分为石英、粘土矿及含铁钙聚合体，所述粘土矿中含有Zn元素、Al2O3、CaO、MgO、Ba2O3、SiO2及TiO2，所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4；
将铁丸石粉末、胶粘剂及增塑剂混合，经混料机造料制得注塑料，该胶粘剂为聚乙烯及聚丙烯的混合物，增塑剂为邻苯二甲酸二丁酯；
采用所述注塑料进行注塑成型，成型一坯体；
对所述坯体进行脱脂处理；
对坯体进行烧结处理，制得石材外壳。
本发明采用铁丸石粉末为原料经注塑成型制造所述石材外壳，使所述石材外壳具有温润、细腻的手感，同时具有良好的耐腐蚀性及抗老化性能。
具体实施方式
本发明一较佳实施例的石材外壳可以是手机、PDA、笔记本电脑、MP3、MP4、GPS导航仪、蓝牙耳机、数码相机及音箱等产品的外壳。
该石材外壳的材质为铁丸石。该铁丸石的主要成分为石英(SiO2)、粘土矿及含铁钙聚合体。此外，铁丸石还含有少量的碳化物、氧化镍及氧化铅等杂质。该铁丸石中，石英的质量百分含量为51~62%、粘土矿的质量百分含量为27~34%、含铁钙聚合体的质量百分含量为8~10%、及所述杂质的质量百分含量为3~5%。所述粘土矿为高岭石﹑蒙脱石﹑方解石、云母及伊利石等。该粘土矿中含有Zn元素及Al2O3、CaO、MgO、Ba2O3、SiO2、TiO2等氧化物。所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4。
本发明一较佳实施例的石材外壳的制造方法，主要包括如下步骤：
（1）提供铁丸石粉末。
所述铁丸石粉末的粒径为0.4~0.1mm。该铁丸石的主要成分为石英(SiO2)、粘土矿及含铁钙聚合体。此外，铁丸石还含有少量的碳化物、氧化镍及氧化铅等杂质。该铁丸石中，石英的质量百分含量为51~62%、粘土矿的质量百分含量为27~34%、含铁钙聚合体的质量百分含量为8~10%、及所述杂质的质量百分含量为3~5%。所述粘土矿为高岭石﹑蒙脱石﹑方解石、云母及伊利石等。该粘土矿中含有Zn元素及Al2O3、CaO、MgO、Ba2O3、SiO2、TiO2等氧化物。所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4。
（2）制造注塑料。
将铁丸石粉末、胶粘剂及增塑剂以（42~47）:（35~50）:(3~8)的体积比配制并置于混料机内，之后在140~180℃的温度下混合60~150min，制得注塑料。该胶粘剂为聚乙烯（PE）及聚丙烯（PP）的混合物。增塑剂为邻苯二甲酸二丁酯（DBP）。所述注塑料为柱状体，长为4~7mm，直径为2~3mm。
（3）采用所述注塑料进行注塑成型，成型一坯体。
所述注塑成型的压力为120~180MPa，注射温度为150~170℃，模具温度为40~60℃；之后，进行保压处理形成一坯体，保压压力为200~300MPa，保压时间为20~50min。
（4）对所述坯体进行脱脂处理。
将所述坯体置于一脱脂炉中，将脱脂炉内的温度以25~37℃/h的升温速率由室温升至150℃；再以3.8~6.3℃/h的升温速率升至400℃；之后，以6.6~10℃/h的升温速率升至500℃；最后，以29.2~50℃/h的升温速率升至850℃。所述脱脂处理用以脱除坯体中的增塑剂及粘结剂。脱脂处理后，将所述坯体自然冷却至室温。
（5）对坯体进行烧结处理。
将脱脂后的坯体置于一烧结炉中，将烧结炉内的温度经梯度升温至1250℃，具体操作及工艺参数如下：先以4~6℃/min的升温速率由室温升至600℃；再以2~4℃/min的升温速率升至800℃；最后，以0.8~1.2℃/min的升温速率升至1250℃，并在该温度下保温时间为90~150min。之后，再对所述坯体进行降温处理，具体操作及工艺参数如下：先以3.7~5℃/min的降温速率将烧结炉内的温度降至800℃，再以3.7~5℃/min的降温速率将烧结炉内的温度降至室温。
（6）采用CNC铣削或激光切割处理，将坯体加工成预定尺寸的石材壳体。
（7）对石材壳体研磨或抛光处理。
所述研磨或抛光处理用以提高石材壳体表面的平整度。
（8）清洗所述石材壳体。
所述清洗处理包括如下步骤：先采用pH值为5的弱酸溶液清洗5~15分钟，去除坯体表面的碱性杂质；再采用pH值为9的弱碱溶液清洗5~15分钟，去除坯体表面的酸性杂质；之后，采用10wt%的乙醇或丙酮清洗5~15分钟，去除坯体表面的有机杂质，纯水清洗5分钟；最后，将坯体置于60~80℃温度下干燥40~80min。本实施例中，所述弱酸溶液为盐酸溶液，所述碱性溶液为氢氧化钠溶液。
本发明采用铁丸石粉末为原料经注塑成型制造所述石材外壳，使所述石材外壳具有温润、细腻的手感，同时具有良好的耐腐蚀性及抗老化性能。另外，采用该铁丸石粉末添加胶粘剂及增塑剂进行注塑成型该石材外壳，相较于现有单纯的机械磨削制程，效率高，成本低，且较容易获得三维结构的石材外壳。

Claims (10)

1.一种石材外壳，其特征在于：该石材外壳的材质为铁丸石，该铁丸石的主要成分为石英、粘土矿及含铁钙聚合体，所述粘土矿中含有Zn元素、Al2O3、CaO、MgO、Ba2O3、SiO2及TiO2，所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4，该石材外壳采用铁丸石粉末为原料以注塑成型的方式制成。
2.如权利要求1所述的石材外壳，其特征在于：该铁丸石中，石英的质量百分含量为51~62%、粘土矿的质量百分含量为27~34%、含铁钙聚合体的质量百分含量为8~10%。
3.如权利要求1所述的石材外壳，其特征在于：该粘土矿为高岭石﹑蒙脱石﹑方解石、云母及伊利石。
4.一种石材外壳的制造方法，其包括如下步骤：
提供一铁丸石粉末，该铁丸石粉末的主要成分为石英、粘土矿及含铁钙聚合体，所述粘土矿中含有Zn元素、Al2O3、CaO、MgO、Ba2O3、SiO2及TiO2，所述含铁钙聚合体中含有Fe2O3、Fe4O3、CaCO3及CaSiO4；
将铁丸石粉末、胶粘剂及增塑剂混合，经混料机造料制得注塑料，该胶粘剂为聚乙烯及聚丙烯的混合物，增塑剂为邻苯二甲酸二丁酯；
采用所述注塑料进行注塑成型，成型一坯体；
对所述坯体进行脱脂处理；
对坯体进行烧结处理，制得石材外壳。
5.如权利要求4所述的石材外壳的制造方法，其特征在于：所述脱脂处理的方法为：先将脱脂炉内的温度以25~37℃/h的升温速率由室温升至150℃；再以3.8~6.3℃/h的升温速率升至400℃；之后，以6.6~10℃/h的升温速率升至500℃；最后，以29.2~50℃/h的升温速率升至850℃。
6.如权利要求4所述的石材外壳的制造方法，其特征在于：该烧结处理包括如下步骤：先将坯体置于一烧结炉中；再将该烧结炉内的温度升温至1250℃；之后，对该烧结炉进行降温处理。
7.如权利要求6所述的石材外壳的制造方法，其特征在于：该烧结过程中通过如下方法将烧结炉内的升温至1250℃：先以4~6℃/min的升温速率由室温升至600℃；再以2~4℃/min的升温速率升至800℃；最后，以0.8~1.2℃/min的升温速率升至1250℃，并在该温度下保温时间为90~150min。
8.如权利要求6所述的石材外壳的制造方法，其特征在于：所述降温处理的方法为：先以3.7~5℃/min的降温速率将烧结炉内的温度降至800℃，再以3.7~5℃/min的降温速率将烧结炉内的温度降至室温。
9.如权利要求4所述的石材外壳的制造方法，其特征在于：采用所述注塑料进行注塑成型的压力为120~180MPa，注射温度为150~170℃，模具温度为40~60℃。
10.如权利要求4所述的石材外壳的制造方法，其特征在于：注塑料通过如下方法制得：将铁丸石粉末、胶粘剂及增塑剂以（42~47）:（35~50）:(3~8)的体积比置于混料机内，并在140~180℃的温度下混合60~150min。
CN201210590270.3A 2012-12-29 2012-12-29 石材外壳及其制造方法 Pending CN103896516A (zh)

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CN201210590270.3A CN103896516A (zh) 2012-12-29 2012-12-29 石材外壳及其制造方法
TW102103189A TW201433237A (zh) 2012-12-29 2013-01-28 石材外殼及其製造方法
US13/930,306 US20140184039A1 (en) 2012-12-29 2013-06-28 Device housing and method for manufacturing the same

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