CN107696628B - 异材质层叠复合材料及其制品 - Google Patents

异材质层叠复合材料及其制品 Download PDF

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CN107696628B
CN107696628B CN201610648428.6A CN201610648428A CN107696628B CN 107696628 B CN107696628 B CN 107696628B CN 201610648428 A CN201610648428 A CN 201610648428A CN 107696628 B CN107696628 B CN 107696628B
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CN107696628A (zh
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马水源
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Pufeng New Technology Materials Co Ltd
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Abstract

本发明公开了一种异材质层叠复合材料，依次包括一第一层构造、一中心基板及一第二层构造，该第一层构造为一第一编织纤维层、一金属层和一第一塑胶层中至少一种；该中心基板为一热塑性塑胶板；该第二层构造包括一第二编织纤维层与一第二塑胶层，或包括一第二编织纤维层与一无纺布层；该第一层构造与该第二层构造的编织纤维层以一胶层与该中心基板连接；该第一层构造与该第二层构造之间的机械强度差值小于20％；该中心基板为主要结构填充、支撑层，材料选用多变，不同材质可调整结构强度、刚性与耐冲击性，相对均为编织层的编织塑胶板材加工成本低、热塑工艺简单，具市场竞争力。

Description

异材质层叠复合材料及其制品
技术领域
本发明涉及一种复合材料，尤其涉及一种异材质相互层叠的复合材料。
背景技术
目前行李箱制造业以硬壳类的行李箱为主要发展趋势，硬壳行李箱主要可分为塑胶材质或金属材质两种，由于塑胶或金属可加工成为特殊形状或外型，且塑胶或金属材质相对于布类等软质材质的行李箱拥有高强度、耐久性及防水性等特质，深受消费者喜爱。
塑胶材质的硬壳行李箱，又大致可分为传统式塑胶板或是复合塑胶板等，以单层或是多层板材形式层叠后压板塑型，塑胶板或是复合塑胶板材虽价格低廉，但结构强度不佳，往往耐不住强烈的撞击，相当容易破裂。
为了改善前述塑胶板强度不足的缺点，继而发展出以塑胶条或是塑胶纤维编织而成的多层编织塑胶板材或复合编织塑胶板材，虽然编织结构相对前述塑胶板材具有较佳的结构强度，但多层编织塑胶板材的材料、生产、加工、人力成本高，且热塑工艺困难，很容易产生纤维断裂或错位、成型后于弯折处易出现皱折，花纹无法连续，多层编织塑胶板材使热塑深度受限等问题，导致目前以多层编织塑胶板材所制造的行李箱单价高昂，无法普及。
金属材质的硬壳行李箱，除了金属材料价格高、多层叠合后的重量非常重的缺点外，无法以车缝工艺生产行李箱以免除昂贵的热压模具生产成本，且受外力冲击后外型无法自行回弹恢复形状进而需要回厂送修等，均是金属材质难以克服的问题。
发明内容
为了解决目前塑胶或金属硬壳行李箱在生产制造上，若要增加结构强度却导致成本增加，或是欲降低成本却又牺牲结构强度因而材料选用受到限制等种种问题，本发明提供一种异材质层叠复合材料，其依次包括一第一层构造、一中心基板及一第二层构造，其中：该第一层构造为一第一编织纤维层、一金属层和一第一塑胶层中至少一种；该中心基板为一热塑性塑胶板；该第二层构造包括一第二编织纤维层与一第二塑胶层，或包括一第二编织纤维层与一无纺布层；该第一层构造与该第二层构造中的该第一编织纤维层和第二编织纤维层分别通过一胶层与该中心基板连接；以及该第一层构造与该第二层构造之间的机械强度差值小于20％。
其中，该中心基板的厚度为0.2～3.0mm；该第一编织纤维层或该第二编织纤维层或该无纺布层的厚度为0.2mm～0.5mm；该塑胶层的厚度为0.05～0.15mm；以及该金属层的厚度为0.1～0.5mm。
其中，该中心基板的材质包括聚对苯二甲酸乙二醇酯、聚丙烯、聚乙烯、尼龙、聚碳酸酯或聚甲基丙烯酸甲酯；该第一编织纤维层或该第二编织纤维层的材质包括聚乙烯纤维、聚丙烯纤维、碳纤维、玻璃纤维、克维拉纤维、尼龙纤维或天然纤维；该第一塑胶层或第二塑胶层的材质包括聚丙烯、尼龙、聚氨酯、热塑性聚氨酯、聚对苯二甲酸乙二醇酯、Surlyn塑胶、Pebox塑胶、聚碳酸酯或聚甲基丙烯酸甲酯；该金属层的材质包括铝、镁铝合金、不锈钢、铜、镀铬铜或钛合金；以及该胶层的材质包括共聚烯烃类、共聚酰胺类、共聚酯类、热塑性聚氨酯类、聚烯烃类、聚酰胺类、环氧树脂类或聚酯类胶体。
其中，该胶层渗入该第一编织纤维层和第二编织纤维层的纤维中，渗入的所述胶层分别占该第一编织纤维层、第二编织纤维层的体积三分之一至二分之一。
其中，该无纺布层的部分纤维勾绕或缠绕于该第二编织纤维层的部分纤维中。
其中，该第一层构造的该第一塑胶层表面有一热升华或印刷的文字或图案。
本发明进一步提供一种行李箱外壳、溜冰鞋鞋面与护具，其用前述的异材质层叠复合材料所制成。
由上述说明可知，本发明有以下的优点：
1.本发明通过热塑性塑胶材质的中心基板，作为异材质层叠复合材料的主要结构填充层以及支撑层，以解决现有技术的塑胶板结构强度不佳与耐不住强烈撞击缺点；本发明的该中心基板材料选用多变化，可利用不同材质的板材来调整所需要的结构强度、刚性与耐冲击特性，且该中心基板不为编织的结构，厚度可任意调整，相对于既有均为编织层的多层编织塑胶板材材料与加工成本更低、热塑工艺较为简单，更具备市场竞争力。
2.由于本发明的第一层构造与第二层构造机械强度相近的因素，后续加工成型时不容易产生纤维断裂、错位、弯折处产生皱折或是花纹无法连续的问题，且本发明的编织纤维层相对于具有同样厚度或强度的既有多层编织塑胶板材少，热塑深度较不易受影响。
3.本发明利用金属材质作为最外层并迭合中心基板与编织纤维层所得的金属异材质层叠复合材料，该中心基板可作为整体复合材料的支撑层与填充层，该编织纤维层也可提供良好的刚性与强度，使得本发明金属复合材料相对于既有金属迭板材不仅整体刚性与结构强度更佳优异外，还可达到重量减轻的效果。举例而言，铝金属的比重为2.7g/cm3，以1mm厚度的铝板而言，每平方公尺的面积就会产生2700g的重量，然而，本发明中的金属异材质层叠复合材料，可利用0.2mm厚度的铝板搭配0.8mm的纤维编织层与中心基板，以同样1mm的厚度下，本发明每平方公尺面积的重量仅1400g，可减轻近一半的重量，并且保持结构强度、刚性与耐冲击性不减。
且进一步地，该编织纤维层、该中心基板受到撞击后具有自行回弹并恢复原本构型的能力，可改善既有技术的金属材质硬壳行李箱受外力冲击后外型无法自行回弹恢复形状进而需要回厂送修的缺点。
4.本发明的编织纤维层可依据用途选用不同纤维材质、颜色、图案与编织方法，同时达到美观与增加整体异材质层叠复合材料的结构强度与刚性的效果。该编织纤维层具有高比表面积，通过胶水/胶膜与压合制程即可容易地与其他异材质相互粘合与接着。
5.本发明是以编织纤维层、塑胶中心基板或金属等各种不同材料层叠复合而得，通过塑胶与金属间的不同材质以及编织材与板材间的不同结构加以相互复合，达到调控成品的外观、样式、厚度、刚性与结构强度的效果，材料、结构强度的调整弹性高。
6.该编织纤维层可使本发明不需通过热压模具加工成型，而可利用车缝技术直接形成立体形状，例如行李箱外壳、提包等，免除昂贵的热压模具生产成本，成型制造的工艺更多元，且本发明遭受外力撞击而产生内凹缺陷时，该中心基板与该编织纤维层可让本发明自行回弹与恢复原本塑型形状的效果，改善既有金属行李箱无法自行回复形状而需要送回原厂修理的问题。
附图说明
图1为本发明第一较佳实施例的异材质层叠复合材料的层状构造示意图；
图2中a～d为本发明第一较佳实施例的异材质层叠复合材料的剖面示意图；
图3为本发明第二较佳实施例的异材质层叠复合材料的剖面示意图；
图4为本发明第三较佳实施例的异材质层叠复合材料的层状构造示意图。
附图标记说明：
10 异材质层叠复合材料
11 中心基板
13 第一层构造
15 第二层构造
131 第一编织纤维层
151 第二编织纤维层
132 第一塑胶层
152 第二塑胶层
153 无纺布层
A 胶层
具体实施方式
请参考图1，本发明第一较佳实施例的异材质层叠复合材料10包括依次层叠的一第一层构造13、一中心基板11及一第二层构造15，该第一层构造13、该第二层构造15与该中心基板11之间分别设有一胶层A用以相互粘着。
其中，本实施例的该第一层构造13是由一第一编织纤维层131与一第一塑胶层132迭合所形成，该第一编织纤维层131除了可提供异材质层叠复合材料10拥有编织纹路的外观外，编织的结构相对一般塑胶板具有更好、更优异的结构强度。本实施例的该第一编织纤维层131厚度较佳为0.2mm～0.5mm，该第一编织纤维层131的材质不限定，可以由聚乙烯纤维(Polyethylene,PE)、聚丙烯纤维(Polypropylene,PP)、聚对苯二甲酸乙二醇酯(Polyethylene Terephthalate,PET,简称聚酯)、碳纤维、玻璃纤维、克维拉纤维、尼龙纤维(Nylon)、天然纤维(Natural fiber)等材质所编织而成。
该第一塑胶层132披覆于该第一编织纤维层131表面，可作为该第一编织纤维层131的保护层或是提供亮面的质感；更进一步地，可于该第一塑胶层132表面运用热升华或印刷的方式加以装饰文字或图案。本实施例的该第一塑胶层132厚度较佳介于0.05～0.15mm，该第一编织纤维层131与该第一塑胶层132之间也可以该胶层A相互粘着，该第一塑胶层132的材质可以是聚丙烯(Polypropylene,PP)、尼龙(Nylon)、聚氨酯(Polyurethane,PU)、热塑性聚氨酯(Thermoplastic Urethane,TPU)、聚对苯二甲酸乙二醇酯(Polyethylene Terephthalate,PET,简称聚酯)、
Figure BDA0001073632290000051
塑胶(商品名)或
Figure BDA0001073632290000052
塑胶(商品名)、聚碳酸酯(Polycarbonate,PC)或聚甲基丙烯酸甲酯(Polymethylmethacrylate,PMMA)所形成的塑胶膜。
该第二层构造15与该第一层构造13同样以一第二编织纤维层151与一第二塑胶层152迭合，且该第二编织纤维层151与该第二塑胶层152之间也可设有该胶层A以相互粘着，该第二编织纤维层151与该第二塑胶层152的材质种类与前述该第一编织纤维层131与该第一塑胶层132相同。
该中心基板11是本发明的主要技术特征之一，其夹置于该第一层构造13与该第二层构造15之间，可提供该异材质层叠复合材料10的整体复合结构填充、支撑，增加总体结构强度的功用；该中心基板11相对于均以纤维织布迭合而成的既有多层编织塑胶板具备成本更低的优势。本发明该中心基板11较佳是选用热塑性塑胶，除了具有热可塑加工特性外，也具有良好的回收性，厚度介于0.2～5.0mm，材质包括聚对苯二甲酸乙二醇酯(PolyethyleneTerephthalate,PET,简称聚酯)、聚丙烯(Polypropylene,PP)、聚乙烯(Polyethylene,PE)、尼龙(Nylon)、聚碳酸酯(Polycarbonate,PC)或聚甲基丙烯酸甲酯(Polymethylmethacrylate,PMMA)。
本实施例的该第一层构造13与该第二层构造15是以该第一编织纤维层131、第二编织纤维层151与该中心基板11相互粘着，而粘着使用的该胶层A材质依据粘着介面材质的不同，包括共聚烯烃类、共聚酰胺类、共聚酯类或热塑性聚氨酯类粘着胶体。
该胶体A主要以透明的胶水或胶膜的方式施于各层之间，其材质的选择是以接着相同或近似特性的材料为依据，例如当该第一编织纤维层131的材质为聚乙烯纤维，该中心基板11的材质为聚乙烯塑胶板时，该胶体A则可选择对聚乙烯纤维与聚乙烯塑胶板具有相容性的共聚烯烃类胶体，可达到良好的粘贴、接着效果。
为了使该异材质层叠复合材料10的整体复合结构，以该中心基板11为中心，两侧粘合的该第一层构造13与该第二层构造15应力达到平衡或降低；较佳地，该第一层构造13与该第二层构造15之间的机械物性(Compressive Strength)或强度差值介于0～20％之间可称为平衡。所谓的机械强度至少包括抗弯折强度、抗张强度与抗冲击强度等机械强度参数；当该第一层构造13与该第二层构造15之间的应力相同或相近时，可以减少后续加工成型可能会产生里层翘曲、脱层、纹路压缩等问题，而使该第一层构造13与该第二层构造15达到应力平衡的方法可以通过各层材质选择、厚度大小或是编织纤维层的丹数(Denier,或称丹或丹尼数)调整。
该第一层构造13与该第二层构造15以该中心基板11为中心，达到应力平衡的例子，除了该第一层构造13与该第二层构造15的各层选择相同材质、厚度的材料外，若要使用不同材质、厚度的材料相互搭配时，可例如该第一层构造13选择1100丹、厚度为0.2mm的该第一编织纤维层131与厚度为0.1mm的该第一塑胶层132，该第二层构造15则可对应选择900～1300丹、厚度为0.2mm～0.5mm的该第二编织纤维层151与厚度为0.05～0.15mm的该第一塑胶层132，此时该中心基板11两侧的该第一层构造13与该第二层构造15的机械强度可达平衡，使热压后的该异材质层叠复合材料10平整、无翘曲或皱折。
本实施例的该第一编织纤维层131、第二编织纤维层151与该胶层A之间，可进一步以半含浸的状态结合，所谓的半含浸是指该胶层A渗入或含浸于该第一编织纤维层131、第二编织纤维层151的局部纤维中，达到占该第一编织纤维层131、第二编织纤维层151的体积约三分之一至二分之一，但另一侧的该131第一编织纤维层131、第二编织纤维层151表面未有该胶层A透出或仅有少量透出。而达到半含浸的实施方法，可以是该第一纤维编织层131、第二编织纤维层151与该胶层A相互迭合后，调控该胶层A的厚度或体积小于该第一纤维编织层131、第二编织纤维层151；热压时，由调整热压参数，相对少量的该胶层A仅渗透或含浸至该第一纤维编织层131、第二编织纤维层151的局部，不超出或仅极少量透出其另一侧表面，以保持异材质层叠复合材料表面的干净，无胶水或胶体外露的情形。
本发明第一较佳实施例中该第一层构造11与该第二层构造13，除了前述是以该第一编织纤维层131、第二编织纤维层151分别与该第一塑胶层132、第二塑胶层152的搭配外，请参考图2中a～d，在该第一编织纤维层131与该第二编织纤维层151两个达到应力平衡的前提下，该第一编织纤维层131也可以仅为该131第一编织纤维层131(如图2a与图2c)或该第一塑胶层132(如图2b与图2d)与该中心基板11粘着，该第二层构造则可单纯仅为该第二编织纤维层152(如图2c与图2d)与该中心基板11粘着，于此不限定。
请参考图3，本发明第二较佳实施例与前述第一较佳实施例基本上相同，差异在于将该第二层构造13中该第一塑胶层132以一无纺布层153取代，该无纺布层153以针扎方式将该无纺布层153的局部纤维与该第一编织纤维层131的局部纤维相互勾绕固定，而此时该无纺布层153与该第一编织纤维层131之间可选择性地施用该胶层A。
请参考图4，本发明第三较佳实施例的异材质层叠复合材料10，其层叠结构与前述第一、第二实施例相同，以一第一层构造13、一中心基板11及一第二层构造15依次层叠形成，各层之间以一胶层A相互粘贴结合，而本实施例与前述第一、第二实施例的差异是在于该第一层构造13是金属材质的薄片/板层，且厚度介于0.1～0.5mm之间。
该第一层构造13的材质包括铝、镁铝合金、不锈钢、铜、镀铬铜或钛合金；该第二层构造15是一第一编织纤维层131，材质包括碳纤维(Carbon Fiber)、玻璃纤维(GlassFiber)、克维拉纤维(Kevlar Fiber)、聚酯纤维(Polyester Fiber)、尼龙纤维(NylonFiber)或天然纤维(Natural Fiber)；而该中心基板11是热塑性塑胶板，材质包括聚对苯二甲酸乙二醇酯(Polyethylene Terephthalate,PET,简称聚酯)、聚丙烯(Polypropylene,PP)、聚乙烯(Polyethylene,PE)、尼龙(Nylon)、聚碳酸酯(Polycarbonate,PC)或聚甲基丙烯酸甲酯(Polymethylmethacrylate,PMMA)。
由于本实施例的该第一层构造13为金属材质，其与塑胶材质的该中心基板11不为相容性材料，故两者之间粘着所使用的该胶层A较佳使用聚烯烃类、聚酰胺类、聚酯类胶体，可达到较佳的粘着效果。而该第二层构造15与该中心基板11之间所使用的该胶层A，除了同样可用前述的聚烯烃类、聚酰胺类、聚酯类的材质外，也可与上述实施例1使用相同的共聚烯烃类、共聚酰胺类、共聚酯类或热塑性聚氨酯类粘着胶体，同样具有良好的接着效能。
为了达到本实施例金属材质的该第一层构造13与塑胶或天然纤维材质该第二层构造15之间的应力平衡，以该中心基板11为中心，当该第一层构造13为0.2mm的薄铝板时，该第二层构造15可选择1300～1800丹、厚度介于0.2～0.5mm之间的编织纤维层，可达到该中心基板11两侧的机械强度应力平衡，使热压后的该异材质层叠复合材料10平整、无翘曲或皱折。
本发明前述各实施例的制造方法，较佳是将各层相互堆迭后，依照所选用的各层材料与各层厚度设定热压参数，再将层叠材料送入设定温度为50℃的热压台，立即加热到设定的温度，温度范围为150～178℃，压力范围为14～20kg/cm2，并持温3～6分钟后，立即将热压台降温到50℃，再取出成品。
而在应用方面，本发明的异材质复合版材可广泛应用于各种领域的产品，例如行李箱外壳、护具、溜冰鞋、冰刀鞋、笔记型电脑外壳等。
上述仅为本发明的较佳实施例而已，并非用以限定本发明主张的权利范围，凡其它未脱离本发明所揭示的精神所完成的等效改变或修饰，均应包括在本发明的主张范围内。

Claims (9)

1.一种异材质层叠复合材料，其特征在于，其依次包括一第一层构造、一中心基板及一第二层构造，其中：
所述第一层构造为一第一编织纤维层、一金属层和一第一塑胶层中至少一种；
所述中心基板为一热塑性塑胶板，所述中心基板的材质包括聚对苯二甲酸乙二醇酯、聚丙烯、聚乙烯、尼龙、聚碳酸酯或聚甲基丙烯酸甲酯；
所述第二层构造包括一第二编织纤维层与一第二塑胶层，或包括一第二编织纤维层与一无纺布层；
所述第一层构造与所述第二层构造中的所述第一编织纤维层和所述第二编织纤维层分别通过一胶层与所述中心基板连接；
所述胶层的材质包括共聚烯烃类、共聚酰胺类、共聚酯类、热塑性聚氨酯类、聚烯烃类、聚酰胺类、环氧树脂类或聚酯类胶体；以及
所述第一层构造与所述第二层构造之间的机械强度差值小于20%。
2.如权利要求1所述的异材质层叠复合材料，其特征在于，
所述中心基板的厚度为0.2~3.0mm；
所述第一编织纤维层或所述第二编织纤维层或所述无纺布层的厚度为0.2mm~0.5mm；
所述第一塑胶层或所述第二塑胶层的厚度为0.05~0.15mm；以及
所述金属层的厚度为0.1～0.5mm。
3.如权利要求1或2所述的异材质层叠复合材料，其特征在于，
所述第一编织纤维层或所述第二编织纤维层的材质包括聚乙烯纤维、聚丙烯纤维、聚对苯二甲酸乙二醇酯纤维、碳纤维、玻璃纤维、克维拉纤维、尼龙纤维或天然纤维；
所述第一塑胶层或所述第二塑胶层的材质包括聚丙烯、尼龙、聚氨酯、聚对苯二甲酸乙二醇酯、Surlyn塑胶、聚碳酸酯或聚甲基丙烯酸甲酯；以及
所述金属层的材质包括铝、镁铝合金、不锈钢、铜、镀铬铜或钛合金。
4.如权利要求1或2所述的异材质层叠复合材料，其特征在于，所述胶层渗入所述第一编织纤维层和所述第二编织纤维层中，渗入的所述胶层分别占所述第一编织纤维层、所述第二编织纤维层的体积的三分之一至二分之一。
5.如权利要求1或2所述的异材质层叠复合材料，其特征在于，所述无纺布层的部分纤维勾绕或缠绕于所述第二编织纤维层的部分纤维中。
6.如权利要求1所述的异材质层叠复合材料，其特征在于，所述第一层构造的所述第一塑胶层表面有一热升华或印刷的文字或图案。
7.一种行李箱外壳，其特征在于，其用权利要求1至6任一所述的异材质层叠复合材料所制成。
8.一种溜冰鞋鞋面，其特征在于，其用权利要求1至6任一所述的异材质层叠复合材料所制成。
9.一种护具，其特征在于，其用权利要求1至6任一所述的异材质层叠复合材料所制成。
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CN110432618A (zh) * 2019-09-11 2019-11-12 平湖相伴宝产业互联网有限公司 箱体
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