CN107277733A - 碳纤维球顶及其制造方法 - Google Patents

碳纤维球顶及其制造方法 Download PDF

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Publication number
CN107277733A
CN107277733A CN201710237833.3A CN201710237833A CN107277733A CN 107277733 A CN107277733 A CN 107277733A CN 201710237833 A CN201710237833 A CN 201710237833A CN 107277733 A CN107277733 A CN 107277733A
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China
Prior art keywords
carbon fiber
top dome
carbon
fiber top
prepreg
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Granted
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CN201710237833.3A
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CN107277733B (zh
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狄勋
赵彬
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AAC Technologies Pte Ltd
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AAC Technologies Pte Ltd
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Priority to CN201710237833.3A priority Critical patent/CN107277733B/zh
Priority to US15/646,777 priority patent/US20180302719A1/en
Publication of CN107277733A publication Critical patent/CN107277733A/zh
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  • Medicinal Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Multimedia (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Diaphragms For Electromechanical Transducers (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

本发明涉及一种碳纤维球顶，所述碳纤维球顶包括至少两层碳纤维预浸料；其中，所述至少两层碳纤维预浸料包括至少两种碳纤维材料。本发明还涉及一种碳纤维球顶的制造方法，包括如下步骤，利用预浸树脂预浸至少两种碳纤维材料；将所述预浸后的所述至少两种碳纤维材料相互贴合。本发明中的碳纤维球顶结构通过将碳纤维预浸料替换所述铝箔，提高了强度，同时降低了厚度，使得声音品质得到提升，通过预浸料的固化过程，使得碳纤维材料紧密贴合，形成一体结构，从而避免了层间已分离的现象，防水效果更好，保证了使用寿命。

Description

碳纤维球顶及其制造方法
【技术领域】
本发明涉及电声器械领域，具体涉及一种碳纤维球顶结构及一种碳纤维球顶的制造方法。
【背景技术】
球顶形扬声器是指利用球顶形振膜直接辐射声波的扬声器。属于电动式扬声器，振膜是一个半球形膜片，用振膜折环直接支撑音圈而没有定心支片，特点是高频响应好，指向性宽及失真较小。振膜的球顶部常用铝箔与发泡材料复合制成，随着电子行业的发展，电声系统需要不断的提升性能与可靠性，对球顶的要求也越来越高，现有的铝箔与发泡材料复合的球顶已经不能满足使用需求，常会出现铝箔碎裂、铝箔与发泡材料分层、材料强度不足等问题。另一方面，由于铝箔材质较软，作为产品直观可观察的部分，容易出现污染、划伤等现象，带来不美观的问题，且由于发泡材料受力容易发生形变，受力之后恢复性能差，无法承受压力，且容易吸水，使得铝箔与发泡材料之间容易产生分层的现象发生，同时为了达到振动强度和保证力学性能，球顶中采用的发泡材料和铝箔的组合层厚度较大。
【发明内容】
本发明针为了解决现有技术中球顶结构力学性能差、不美观、容易破碎、材料易分层、厚度大、容易吸水的问题中至少一个，提供了一种力学性能、声学性能优异、美观、层与层之间结合紧密、不会吸水的碳纤维球顶，所述碳纤维球顶包括至少两层碳纤维预浸料；其中，所述至少两层碳纤维预浸料包括至少两种碳纤维材料。
作为一种改进，所述碳纤维球顶厚度为40～250um。
作为一种改进，所述碳纤维球顶的厚度为80～150um。
作为一种改进，相邻层的碳纤维预浸料之间的纤维夹角范围为0～90度。
作为一种改进，相邻层的碳纤维预浸料的厚度比例范围为1：20～1:1。
作为一种改进，所述碳纤维预浸料包括碳纤维材料和预浸树脂，所述碳纤维材料的拉伸模量大于200Gpa。
作为一种改进，所述预浸树脂包括环氧树脂、聚醚醚酮、聚酰亚胺、聚苯硫醚、聚对苯撑苯并二噁唑、聚对苯二甲酰对苯二胺中的一种或多种。
作为一种改进，所述至少两种材料的碳纤维材料包括M系列碳纤维和T系列碳纤维。
作为一种改进，所述碳纤维球顶包括M55碳纤维和位于所述M55碳纤维上下端面上的T300碳纤维。
作为一种改进，所述M55碳纤维的厚度为80um，所述T300碳纤维厚度为10um。
本发明另一方面还提供了一种制造上述碳纤维球顶的制造方法，包括如下步骤，利用预浸树脂预浸至少两种碳纤维材料；将所述预浸后的所述至少两种碳纤维材料相互贴合。
本发明的有益效果是：通过将碳纤维预浸料替换所述铝箔，同时采用了不同的材质方式，提高了强度，同时降低了厚度，使得球顶表面平整，整体外观好，使得声音品质得到提升，通过预浸料的固化过程，使得碳纤维紧密贴合，从而避免了层间易分离的现象，防水性能得到提升，保证了使用寿命。
【附图说明】
图1是本发明碳纤维球顶实施例结构示意图；
图2是本发明碳纤维球顶采用三层层结构的实施例结构示意图；
图3是本发明碳纤维球顶采用四层结构的实施例结构示意图；
图4是本发明碳纤维球顶采用三层结构的另一实施例结构示意图；
图5是本发明碳纤维球顶另一实施例结构示意图；
图6是本发明碳纤维球顶制造方法的流程示意图；
【具体实施方式】
下面结合图1至图6对本发明作详细描述。
现有的球顶结构中采用了发泡材料和铝箔进行复合，来制备球顶结构，由于发泡材料和铝箔为两种不同的材质，层与层之间贴合不紧密，也会造成分层的情况产生，从而造成防水效果不好，容易吸水的情况发生，另，不同的属性材料具有不同的声音特性也会造成声音性能的损失，在制备不同材质组成的球顶结构时，制备方法也较复杂。
本发明为了克服现有技术中球顶结构易碎、易分层、强度不足、美观差、厚度大、防水效果差的问题，提供了一种利用碳纤维材料所制备出的球顶结构，采用碳纤维材料替换现有的铝箔和发泡材料，使得制备方法简单，易于掌控，且由于都是采用碳纤维材料，从而避免了由于材质不同带来的分层现象，同时利用复合后的碳纤维材料，能够提供足够强度，满足使用需求，厚度上也可相对发泡材料与铝箔的组合减薄了很多，具体地，本发明实施例提供了一种碳纤维球顶，所述碳纤维球顶包括至少两层碳纤维预浸料；其中，所述至少两层碳纤维预浸料中的碳纤维材料包括了至少两种碳纤维材料。本发明采用至少两层碳纤维预浸料进行复合从而形成都是采用碳纤维材料制备而出的球顶，保证了层与层之间紧密贴合，同时由于碳纤维承受力能力大，保证了碳纤维球顶的强度，预浸料中的预浸树脂在复合过程中固化，进一步提高强度的同时，也保证了碳纤维预浸料复合后表面光洁、美观。
本发明进一步地在所述至少两层碳纤维预浸料中采用了至少两种种类型号的碳纤维材料，避免了由于采用单一碳纤维材质带来的问题，如都采用M系列的碳纤维，这时，由于碳纤维丝较粗，间距较大，表面粗糙，使得复合后的材料表面粗糙，影响了力学和声学性能；而如果都使用T碳纤维又会造成强度不够的问题发生，连接力较弱，本发明实施例采用了两种材质的碳纤维，能够保证具有高强度的同时，还具有贴合紧密一体化，防水效果好，外观平整，声学振动性能好的优点，既保证了强度，又保证了韧度。需要说明的是T系列和M系列是日本东丽公司的碳纤维型号，属于行业标准，本领域技术人员可以轻松获取这两种系列的碳纤维材料。
本发明采用碳纤维材料来制备球顶，材料比强度大，在提供相同强度的情况下可减小球顶厚度，材料耐挤压，可以和音膜一体成形，材料为实体，不会吸水，防水效果更好。碳纤维层与层之间粘接效果好，不易分层。
具体地，参见图1，本发明实施例中碳纤维球顶100，包括第一碳纤维层110和设置在所述第一碳纤维层110上的第二碳纤维层120，第一碳纤维层中110和第二碳纤维层120中含有碳纤维预浸料，第一碳纤维层110中碳纤维预浸料和所述第二碳纤维层120中的碳纤维预浸料中的碳纤维不同，如，第一碳纤维层110中碳纤维预浸料采用T系列碳纤维的预浸料，如T300、T400、T700等；第二碳纤维层120中的碳纤维预浸料采用M系列碳纤维的预浸料，如M30、M35、M40、M45、M50、M55等，或者相反亦可，通过高温高压处理使得第一碳纤维层110中的预浸树脂和第二碳纤维层120中预浸树脂固化形成一体复合层，既保证了材料的强度，又保证了材料的韧度，保证了振动性能，同时T系列的碳纤维表面光滑，减少了振动噪音，提供了较高的声学品质。
本发明实施例中的碳纤维球顶不仅可以包括两层碳纤维层，也可包括两层以上的碳纤维层，如三层碳纤维层、四层碳纤维层、五层碳纤维层或者更过层，但是需要保证，多层碳纤维层中的碳纤维预浸料采用了至少两种材质的碳纤维料，如，同时包括T系列的碳纤维料和M系列的碳纤维料，具体碳纤维料材质型号可根据产品需要进行设置。本发明实施例中的碳纤维球顶采用了多层碳纤维预浸料进行复合，能够提供较好的力学强度，同时厚度也较薄，具有复合性能，即能保证强度，又能保证振动韧度，本发明实施例中的碳纤维球顶的厚度在40～250um之间，既保证了强度，也保证了制造的方便性；同时本发明的实施例中的碳纤维球顶在保证了力学强度之外，还能提供较高的声学品质，由于采用的是同一种材质属性制备的球顶，保证了发声的纯度，特别是当碳纤维球顶的厚度在80～150um时，能够保证了具有较好的频率特性，能够覆盖更高的发声范围。
如图2所示，为具有三层碳纤维复合层的球顶，图3为具有四层碳纤维复合层的球顶结构；图2中的碳纤维球顶200可采用三种种类型号的碳纤维，比如最上层采用T系列碳纤维预浸料210，如T500碳纤维，中间的用M系列碳纤维浸料220，如M55碳纤维，最下面用T系列碳纤维预浸230，如T300碳纤维，复合成一体材料，具有高强度，同时不易破碎。图3中的碳纤维球顶结构300可采用四种种类型号的碳纤维，最上层采用T300碳纤维预浸料310，中间采用M35和M55碳纤维预浸料320、330，最下层采用T400碳纤维预浸料340，其中中间两层M系列的碳纤维保证了球顶结构的韧性，保证了球顶结构在长期振动的寿命，防止破碎的情况发生，进一步还可采用单向带，设置纤维分布方向垂直，保证了各个方向受力均衡，通过高温高压处理复合后，形成一体结构，强度高，不易破碎，同时外层的T系列的碳纤维强度高，保证了整体强度，同时T系列碳纤维预浸料固化后形成光洁外观，减少了振动时产生的噪音。
本发明实施例中球顶结构采用多层的碳纤维，可采用单向带、编织布、或者更多向的编织的碳纤维布，各层之间纤维方向形成一定角度，保证了各个方向的承受力能力，层与层之间夹角设置成0度～90度，如，相邻层设置成30度，45度，60度等。
本发明实施例球顶结构的复合层中层与层之间使用不同材料，更有利于满足产品需求，如单纯的M55系列的碳纤维，很难制作100um外观平整的碳纤维球顶。如图4所示，本发明实施例提供了一种具有三层碳纤维复合层的碳纤维球顶400，包括位于中间的M55碳纤维预浸料410，两面使用T300碳纤维编织布预浸料420、430，所述M55碳纤维预浸料410厚度为80um,碳纤维编织布预浸料420、430的厚度为10um，这样，80um的M55碳纤维的保证了振动弹性，保证了恢复性能，又因表层的T300碳纤维的存在使外观平整。本发明实施例中的碳纤维球球顶结构中的碳纤维层的厚度可以相同，也可以不同，相邻层厚度之比可设置在1：20～1：1之间。
本发明中的碳纤维预浸料包括了碳纤维材料和预浸树脂包括碳纤维材料和预浸树脂，所述碳纤维预浸料可以在纤维延伸方向，即纤维方向能够承受较大受力，在纤维方向垂直的方向上能够承受较弱受力，但通过与树脂固化后大大增强承受力的能力，具体地，所述预浸树脂包括：环氧树脂、聚醚醚酮(PEEK)、聚酰亚胺(PI)、聚苯硫醚(PPS)、聚对苯撑苯并二噁唑(PBO)、聚对苯二甲酰对苯二胺(芳纶1414)中的一种或多种；所述碳纤维材料的拉伸模量大于200Gpa，所述碳纤维材料由片状石墨微晶等有机纤维沿纤维轴向方向堆砌而成，经碳化及石墨化处理而得到的微晶石墨材料。碳纤维“外柔内刚”，质量比金属铝轻，但强度却高于钢铁，并且具有耐腐蚀、高模量的特性，实践中，可以采用包括东丽的T系列T300以上、M系列所有，以及相同强度级别的其他系列和其他供应商的材料。使得本发明的球顶结构力学性能得到很大提升，同时重量减轻，厚度变薄，通过紧密贴合使得防水效果更好。
制造时，仅需将碳纤维预浸料相互贴合即可，由于碳纤维预浸料上自带粘性，不需额外的粘接剂即能实现粘接，粘接之后通过高温高压处理，使得所述碳纤维预浸料中的预浸树脂固化，进一步地提升了粘接的强度，贴合更加紧密，同时保证了固化后的碳纤维单向带预浸料强度进一步提升，保证了球顶结构的受力强度，固化后的树脂进一步提升了所述球顶结构的高频性能。同时采用了碳纤维后，使得球顶结构的厚度整体减小，提供了振动性能保证了声音品质，同时节省了产品空间。另，由于碳纤维预浸料中的树脂固化后能够使得球顶结构的表面光滑，且由于固化后的树脂强度硬不易产生刮痕，使得所述碳纤维球顶结构更加美观。
本发明中的球顶可为平板状，也可设置有半球形结构，具体地，为了进一步提升高频性能，还可将所述碳纤维球顶结构设置成具有半球形的结构，如图5所示，本发明的一些实施例提供了一种碳纤维球顶500，包括M55碳纤维预浸料510，位于碳纤维单向带预浸料510两侧的T300碳纤维预浸料540，通过将M55碳纤维预浸料510与所述T300碳纤维预浸料高温高压复合形成球顶结构，所述球顶结构包括凸包结构520，和平板结构530，所述平板结构设置在所述凸包结构的四周。
在形成好本发明的碳纤维球顶后，经过切割形成需要的形状，如采用激光切割、切边模冲切、模切机模切等技术切割成型，再与音膜粘合，如采用背胶、打胶等方式形成振动组件，最后装配成扬声器。
本发明另一方面，为了制造上述实施例中的力学性能、声学性能优异，制作外观精美的碳纤维球顶，提供了一种制作方法，此制造方法工艺简单、可靠，所制得的球顶性能优异。具体地，如图6所示，本发明的实施例提供了一种碳纤维球顶的制造方法，包括如下步骤：包括如下步骤，M101利用预浸树脂预浸至少两种碳纤维材料形成碳纤维预浸料；M102将所述预浸后的碳纤维材料相互贴合，由于预浸后的碳纤维材料具有粘性，不需额外的粘胶即可进行贴合，操作简便；M103再经过高温高压处理即可将所述碳纤维带紧密贴合，工艺简单、可靠。所述预浸树脂包括：环氧树脂、聚醚醚酮(PEEK)、聚酰亚胺(PI)、聚苯硫醚(PPS)、聚对苯撑苯并二噁唑(PBO)、聚对苯二甲酰对苯二胺(芳纶1414)中的一种或多种。
本发明中的球顶制造方法仅通过简单粘贴即能形成复合层，再通过高温高压进行强化，获得力学性能、声学性能优异，不易分层的球顶结构，同时能够保证美观，防水效果更好，本实施例中的方法简单、易操作，对设备的要求低，具有广泛的使用前景。
以上所述的仅是本发明的实施方式，在此应当指出，对于本领域的普通技术人员来说，在不脱离本发明创造构思的前提下，还可以做出改进，但这些均属于本发明的保护范围。

Claims (11)

1.一种碳纤维球顶，其特征在于，所述碳纤维球顶包括至少两层碳纤维预浸料；其中，所述至少两层碳纤维预浸料包括至少两种碳纤维材料。
2.如权利要求1所述的碳纤维球顶，其特征在于，所述碳纤维球顶的厚度为40～250um。
3.如权利要求2所述的碳纤维球顶，其特征在于，所述碳纤维球顶的厚度为80～150um。
4.如权利要求1所述的碳纤维球顶，其特征在于，相邻层的碳纤维预浸料之间的纤维夹角范围为0～90度。
5.如权利要求1所述的碳纤维球顶，其特征在于，相邻层的碳纤维预浸料的厚度比例范围为1：20～1:1。
6.如权利要求1所述的碳纤维球顶，其特征在于，所述碳纤维预浸料包括碳纤维材料和预浸树脂，所述碳纤维材料的拉伸模量大于200Gpa。
7.如权利要求6所述的碳纤维球顶，其特征在于，所述预浸树脂包括环氧树脂、聚醚醚酮、聚酰亚胺、聚苯硫醚、聚对苯撑苯并二噁唑、聚对苯二甲酰对苯二胺中的一种或多种。
8.如权利要求1所述的碳纤维球顶，其特征在于，所述至少两种材料的碳纤维材料包括M系列碳纤维和T系列碳纤维。
9.如权利要求8所述的碳纤维球顶，其特征在于，所述碳纤维球顶包括M55碳纤维和位于所述M55碳纤维上下端面上的T300碳纤维。
10.如权利要求9所述的碳纤维球顶，其特征在于，所述M55碳纤维的厚度为80um，所述T300碳纤维厚度为10um。
11.一种制造如权利要求1～10任一所述的碳纤维球顶的制造方法，其特征在于，包括如下步骤，利用预浸树脂预浸至少两种碳纤维材料；将所述预浸后的所述至少两种碳纤维材料相互贴合。
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