CN112389041A - 一种树脂层压板和金属板的复合体及其制造方法 - Google Patents
一种树脂层压板和金属板的复合体及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种树脂层压板和金属板的复合体及其制造方法,一种树脂层压板和金属板的复合体,其包括:复合平板部,其包括横向接合的金属板和树脂层压板,所述树脂层压板由树脂叠层与金属板对接后热压固化而得,所述树脂叠层包括依次竖向层叠的下表层、芯层及上表层;还包括异形部,其通过对所述复合平板部的金属板加工获得。本发明巧妙地将金属板与树脂叠层先横向接合后热压形成复合平板部,然后再对复合平板部的金属板进行加工成型形成异形部,然后再对金属板进行加工成型形成异形件,即得既有重量轻强度高,同时在需要的部位又可以成型为比较复杂的结构形状的复合板,解决了现有纤维树脂叠层难以成型成结构较复杂的异形件的问题。
Description
技术领域
本发明涉及层压复合板技术领域,特别是涉及了一种树脂层压板和金属板的复合体及其制造方法。
背景技术
由于具有优良的绝缘性、高的力学强度、较低的密度以及可设计性强,纤维树脂层压板被越来越广泛的应用在消费电子产品领域,比如手机和平板电脑后盖、键盘基板、转轴用连接件等。但在具体应用时,有时需要将纤维树脂层压板的局部成型为具有独特外形的异形结构,以满足不同情况下的应用需求。针对热固性纤维层压板主要通过模压成型的工艺形成异形件,但存在以下问题:模具价格昂贵、生产效率比较低、难以成型比较复杂的结构形状,如果使用模压一体成型,则模具的利用率低,成本较高。
发明内容
基于此,有必要针对上述技术问题,提供一种树脂层压板和金属板的复合体及其制造方法。
为了解决上述技术问题,本发明采用了如下所述的技术方案:
一种树脂层压板和金属板的复合体,其包括:复合平板部,其包括横向接合的金属板和树脂层压板,所述树脂层压板由树脂叠层与金属板对接后热压固化而得,所述树脂叠层包括依次竖向层叠的下表层、芯层及上表层;还包括异形部,其通过对所述复合平板部的金属板加工获得。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述金属板与所述树脂叠层之间对接接合面设置有插接结构。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述插接结构为相匹配的凸型部和凹型部。可以理解的是,所述凸型部可以设置在所述金属板,也可以设置在所述树脂叠层,对应地,所述凹型部可以设置在所述树脂叠层,也可以设置在所述金属板。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述凸型部是对接前在所述金属板端部加工成型的;所述凹型部为所述芯层与上表层和下表层竖向层叠时错位内凹形成的。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述芯层、上表层和下表层均为浸渍有树脂的纤维预浸料或树脂半固化片。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述芯层为低密度芯板;所述上表层和下表层为浸渍有树脂的纤维预浸料或树脂半固化片。所述低密度芯板优选但不限定为填充空心玻璃微珠的合成泡沫、PEI泡沫、蜂窝板或者其他低密度材料。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述浸渍有树脂的纤维预浸料或树脂半固化片中的树脂选自环氧树脂、乙烯基酯树脂、不饱和聚酯树脂、MMA树脂、丙烯酸树脂、聚氨酯树脂和三聚氰胺树脂种的任一种热固性树脂。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述金属板为铝、铝合金、钢、不锈钢、钛、钛合金、镁或镁合金,但不局限于此。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述纤维预浸料的纤维包括选自碳纤维、玻璃纤维、芳族聚酰胺纤维、聚酯纤维、尼龙纤维、聚芳酯纤维、聚乙烯醇纤维或苯并唑纤维的至少一种。
作为本发明提供的所述的树脂层压板和金属板的复合体的一种优选实施方式,所述凸型部横向上从内端至外端的厚度逐渐增厚,以增强凸型部和凹型部之间的咬合强度。
一种树脂层压板和金属板的复合体的制造方法,其特征在于,所述方法为方法一或方法二,其中,
所述方法一包括以下步骤:
提供金属板,将所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层、芯层及上表层依次竖向层叠形成树脂叠层;层叠时,所述芯层与上表层和下表层错位内凹形成凹型部;
将所述凸型部对接入所述凹型部形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部;
将热压固化后的复合平板部的金属板加工成异形部,获得复合体;
所述方法二包括以下步骤:
提供金属板,将所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层置于热压固化模具中;
将所述金属板置于热压固化模具中,所述金属板的凸型部下端搭接在所述下表层的端部上;
在所述下表层上层叠芯层,其端部抵接到所述凸型部的端部;
在所述芯层上层叠上表层,其端部下端搭接在所述金属板的凸型部的上端,形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部;
将热压固化后的复合平板部的金属板加工成异形部,获得复合体。
作为本发明提供的所述的树脂层压板和金属板的复合体的制造方法的一种优选实施方式,对接前,使用偶联剂溶液对所述金属板与所述树脂叠层的对接接合面进行处理,以增强金属板与树脂叠层的结合力。偶联剂溶液处理一般是使用偶联剂溶液浸渍或涂覆金属表面,待金属表面的偶联剂溶液干燥后即可使用,可自然风干也可以使用烘箱烘干,目的是使金属表面披覆一层或多层偶联剂分子(偶联剂分子的另一端可以与热固性树脂发生化学键结合,可以将偶联剂理解成金属与树脂间的化学连接桥)。
与现有技术相比,本发明有以下有益效果:
本发明巧妙地将金属板与树脂叠层先横向接合后热压形成复合平板部,然后再对复合平板部的金属板进行加工成型形成异形部(即异形件),即获得一种既有重量轻强度高,同时在需要的部位又可以成型为比较复杂的结构形状的复合体,解决了现有纤维树脂叠层难以成型成结构较复杂的异形件的问题;本发明无需改动热压模具,采用常规的平板式热压模具即可,共用性强,利用率高,解决了现有纤维树脂叠层一体成型不同异形件时需要开发多款配套模具、成本较高以及利用率低的问题。
附图说明
图1为本发明复合体中金属板对接前的结构示意图;
图2为本发明复合体中树脂叠层对接前的结构示意图;
图3为本发明复合体中复合平板部的金属板异形加工前的结构示意图;
图4为本发明复合体中复合平板部的金属板被加工成C型异形部的结构示意图;
图5为本发明复合体中复合平板部的金属板被加工成U型异形部的结构示意图;
图6为本发明复合体中复合平板部的金属板被加工成螺旋型异形部的结构示意图;
图7为本发明复合体制造方法一中各步骤对应的结构示意图;
图8为本发明复合体的一种实施状态的立体图;
图9为本发明复合体中金属板对接前的另一结构示意图;
图10为本发明复合体的另一实施状态的结构示意图。
具体实施方式
为了解决如背景技术所描述的技术问题,本发明人将金属板与纤维预浸料或树脂半固化片进行竖向层叠,以通过金属板的延展特性、易加工特性增强纤维树脂叠层的异形加工,但存在如下问题:缺乏薄壁性和设计自由度、整体质量较重欠缺轻质化。本发明人进一步优化,先将金属板加工成异形件,然后再与树脂板复合,由于金属板是异形件,树脂板是平板件,两者复合过程比较困难,复合制造效率低,还需要开发配套的新热压模具,且复合过程难免对已加工好的异形件造成一定的影响,特别是需要多个异形件与树脂板复合的,复合难度更大,不良率更高。本发明人经过大量的试验,提出了本发明的树脂层压板和金属板的复合体及其制造方法。
具体地,
一种树脂层压板和金属板的复合体,其包括:复合平板部,其包括横向接合的金属板和树脂层压板,所述树脂层压板由树脂叠层与金属板对接后热压固化而得,所述树脂叠层包括依次竖向层叠的下表层、芯层及上表层;还包括异形部,其通过对所述复合平板部的金属板加工获得。
一种树脂层压板和金属板的复合体的制造方法,所述方法为方法一或方法二,其中,
所述方法一包括以下步骤:
提供金属板,将所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层、芯层及上表层依次竖向层叠形成树脂叠层;层叠时,所述芯层与上表层和下表层错位内凹形成凹型部;
将所述凸型部对接入所述凹型部形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部;
将热压固化后的复合平板部的金属板加工成异形部,获得复合体;
所述方法二包括以下步骤:
提供金属板,将所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层置于热压固化模具中;
将所述金属板置于热压固化模具中,所述金属板的凸型部下端搭接在所述下表层的端部上;
在所述下表层上层叠芯层,其端部抵接到所述凸型部的端部;
在所述芯层上层叠上表层,其端部下端搭接在所述金属板的凸型部的上端,形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部;
将热压固化后的复合平板部的金属板加工成异形部,获得复合体。
本发明巧妙地将金属板与树脂叠层先横向接合后热压固化形成复合平板部,然后再对复合平板部的金属板进行加工成型形成异形部,即获得一种既有重量轻强度高,同时在需要的部位又可以成型为比较复杂的结构形状的复合板,解决了现有纤维树脂层压板难以成型成结构较复杂的异形件的问题;本发明无需改动热压模具,采用常规的平板式热压模具即可,共用性强,利用率高,解决了现有纤维树脂叠层一体成型不同异形件时需要开发多款配套模具、成本较高以及利用率低的问题;也解决了竖向层叠层压金属板与树脂板形成的复合板缺乏薄壁性和设计自由度、整体质量较重欠缺轻质化的问题。本发明可将金属板横向接合在树脂叠层的任意侧端部,可以是一侧端、两侧端、三侧端或者四侧端,设计自由度强,也不需要重新开发热压模具,解决了先将金属板加工成异形件,然后再与树脂板复合所存在的复合困难、复合制造效率低、良率低(特别是多边异形件),且需要重新开发热压模具的问题。
为了使本技术领域的人员更好地理解本发明方案,下面将对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分的实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都应当属于本发明保护的范围。
实施例1
本实施例提供了一种树脂层压板12和金属板11的复合体1,其包括:
复合平板部10,其包括横向接合的金属板11和树脂层压板12,所述树脂层压板12由树脂叠层与金属板11对接后热压固化而得(如图3所示),所述树脂叠层包括依次竖向层叠的下表层121、芯层122及上表层123;还包括异形部112,其通过对所述复合平板部10的金属板11加工获得。
在本实施例中,对接前在所述金属板11端部加工成型形成凸型部111,如图1所示;所述芯层122与上表层123和下表层121竖向层叠时错位内凹形成凹型部124,如图2所示。可以理解的是,凸型部111的厚度与芯层122的厚度相适配,其中芯层122可以是一层片状基材,也可以是多层片状基材。同理的,所述上表层123和下表层121都可以是一层片状基材,也可以是多层片状基材。
在本实施例中,下表层121、芯层122及上表层123均为浸渍有环氧树脂的碳纤维预浸料,即片状基材均为浸渍有环氧树脂的碳纤维预浸料。
在本实施例中,所述金属板11为铝板。
为了提升复合板1的整体美观性,优选地,上表层123与所述金属板11上侧面平齐;下表层121与所述金属板11的下侧面平齐。
请参考图7、8,上述复合树脂叠层12和金属板11的复合板1的制造方法,其包括以下步骤:
提供一金属板11,将所述金属板11待对接的端部加工成凸型部111;
提供下表层121、芯层122及上表层123,将下表层121、芯层122及上表层123依次竖向层叠形成树脂叠层;层叠时,所述芯层122与上表层123和下表层121错位内凹形成凹型部124;
将所述凸型部111对接入所述凹型部124形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部10;其中,热压固化是在高温高压及真空条件下进行热压固化,温度为130~200℃,压力为40~180psi,真空条件的真空度为20~60torr;
将热压固化后的复合平板部10的金属板11加工成异形部112,获得复合体1。
其中所述异形部112结构可以根据实际需要自由设计,如C型(如图4所示)、U型(如图5所示)、S型、类O型或螺旋型(如图6所示)等等。
实施例2
本实施例与实施例1不同之处在于:所述芯层122为低密度芯材,以进一步满足轻质化要求。
其中,所述低密度芯材优选但不限定空心玻璃微珠填充的环氧树脂半固化片等等。
实施例3
本实施例与实施例1不同之处在于:下表层121、芯层122及上表层123均为浸渍有乙烯基酯树脂的玻璃纤维预浸料。所述金属板11为不锈钢板。
实施例4
本实施例与实施例1不同之处在于:下表层121、芯层122及上表层123均为浸渍有聚氨酯树脂的尼龙纤维预浸料。所述金属板11为镁合金板。
实施例5
本实施例与实施例1不同之处在于:对接前,先对所述凸型部111与凹型部124的对接接合面进行偶联剂溶液处理,以增强连接强度。
实施例6
本实施例与实施例1不同之处在于:对接前,先对所述凸型部111进行表面处理,以获得粗糙表面,增强连接强度。
实施例7
本实施例与实施例1不同之处在于:所述凸型部111横向上从内端至外端的厚度逐渐增厚,以增强凸型部111和凹型部124之间的咬合强度,如图9所示。
实施例8
本实施例与实施例1不同之处在于:下表层121、芯层122及上表层123均为MMA树脂半固化片。所述金属板11为镁板。
实施例9
请参考图10,本实施例提供了一种复合树脂叠层12和金属板11的复合板1,其包括:
复合平板部10,其包括一树脂层压板12及分别与所述树脂层压板12两端部横向接合的两金属板11;所述树脂层压板12由树脂叠层与金属板11对接后热压固化而得(如图3所示),所述树脂叠层包括依次竖向层叠的下表层121、芯层122及上表层123;还包括异形部112,其通过对所述复合平板部10的两金属板11加工获得。
在本实施例中,对接前在所述金属板11端部加工成型形成凸型部111;所述芯层122与上表层123和下表层121竖向层叠时错位内凹形成凹型部124。可以理解的是,凸型部111的厚度与芯层122的厚度相适配,其中芯层122可以是一层片状基材,也可以是多层片状基材。同理的,所述上表层123和下表层121都可以是一层片状基材,也可以是多层片状基材。
在本实施例中,下表层121、芯层122及上表层123均为浸渍有丙烯酸树脂的聚酯纤维预浸料。
在本实施例中,所述金属板11为钢板。
为了提升复合板1的整体美观性,优选地,上表层123的上侧面、下表层121的下侧面分别与所述金属板11上侧面的下侧面平齐。
上述树脂层压板和金属板的复合体的制造方法,其包括以下步骤:
提供两金属板,将每一所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层置于热压固化模具中;
将两所述金属板置于热压固化模具中,每一所述金属板的凸型部下端搭接在所述下表层的端部上;
在所述下表层上层叠芯层,其端部抵接到所述凸型部的端部;
在所述芯层上层叠上表层,其端部下端搭接在所述金属板的凸型部的上端,形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部10;其中,热压固化是在高温高压及真空条件下进行热压固化,温度为130~200℃,压力为40~180psi,真空条件的真空度为20~60torr;
将热压固化后的复合平板部10的两金属板加工成异形部,获得复合体。其中所述异形部112结构可以根据实际需要自由设计,如C型、U型、S型、类O型或螺旋型等等。
实施例10
本实施例与实施例9不同之处在于:金属板为3个,每一金属板端部均加工有凸型部,对应的,所述树脂叠层三侧端部形成三个凹型部,以将3个金属板的凸型部对接入所述树脂叠层的三个凹型部,即一树脂叠层横向接合三个金属板。
实施例11
本实施例与实施例9不同之处在于:树脂叠层为2个,则2个树脂叠层和2个金属板间隔横向接合,即一金属板、一树脂叠层、一金属板和一树脂叠层依次横向接合。对应的,位于内侧的芯层和金属板的两端部均要形成凹型部和凸型部。
异形件加工时,可对两金属板进行加工成异形部,以设计出所需的结构更复杂的异形构件。
对比例1
该对比例与实施例1不同之处在于:树脂叠层为2层,即上表层和下表层;所述金属板与树脂叠层的插接结构为L型结构,即所述金属板端部加工为台阶,所述上表层和下表层层叠时错位形成倒台阶,对接时倒台阶搭接在台阶上,然后热压固化形成复合平板部。
但对比例1获得的复合体相比实施例1的复合体的接合强度较差,而且容易存在金属板加工过程中出现接合区域撕裂或翘起的问题,不良率较高。
显然,以上所描述的实施例仅仅是本申请一部分实施例,而不是全部的实施例。本申请可以以许多不同的形式来实现,相反地,提供这些实施例的目的是使对本申请的公开内容的理解更加透彻全面。尽管参照前述实施例对本申请进行了详细的说明,对于本领域的技术人员来而言,其依然可以对前述各具体实施方式所记载的技术方案进行修改,或者对其中部分技术特征进行等效替换。凡是利用本申请说明书内容所做的等效结构,直接或间接运用在其他相关的技术领域,均同理在本申请专利保护范围之内。
Claims (10)
1.一种树脂层压板和金属板的复合体,其特征在于,其包括:复合平板部,其包括横向接合的金属板和树脂层压板,所述树脂层压板由树脂叠层与金属板对接后热压固化而得,所述树脂叠层包括依次竖向层叠的下表层、芯层及上表层;还包括异形部,其通过对所述复合平板部的金属板加工获得。
2.根据权利要求1所述的树脂层压板和金属板的复合体,其特征在于,所述金属板与所述树脂叠层之间对接接合面设置有插接结构。
3.根据权利要求2所述的树脂层压板和金属板的复合体,其特征在于,所述插接结构为相匹配的凸型部和凹型部。
4.根据权利要求3所述的树脂层压板和金属板的复合体,其特征在于,所述凸型部是对接前在所述金属板端部加工成型的;所述凹型部为所述芯层与上表层和下表层竖向层叠时错位内凹形成的。
5.根据权利要求3或4所述的树脂层压板和金属板的复合体,其特征在于,所述凸型部横向上从内端至外端的厚度逐渐增厚。
6.根据权利要求1所述的树脂层压板和金属板的复合体,其特征在于,所述芯层、上表层和下表层均为浸渍有树脂的纤维预浸料或树脂半固化片。
7.根据权利要求1所述的树脂层压板和金属板的复合体,其特征在于,所述芯层为低密度芯板;所述上表层和下表层为浸渍有树脂的纤维预浸料或树脂半固化片。
8.根据权利要求6或7所述的树脂层压板和金属板的复合体,其特征在于,所述纤维预浸料的纤维包括选自碳纤维、玻璃纤维、芳族聚酰胺纤维、聚酯纤维、尼龙纤维、聚芳酯纤维、聚乙烯醇纤维、玄武岩纤维、芳纶纤维或苯并唑纤维的至少一种。
9.一种树脂层压板和金属板的复合体的制造方法,其特征在于,所述方法为方法一或方法二,其中,
所述方法一包括以下步骤:
提供金属板,将所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层、芯层及上表层依次竖向层叠形成树脂叠层;层叠时,所述芯层与上表层和下表层错位内凹形成凹型部;
将所述凸型部对接入所述凹型部形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部;
将热压固化后的复合平板部的金属板加工成异形部,获得复合体;
所述方法二包括以下步骤:
提供金属板,将所述金属板待对接的端部加工成凸型部;
提供下表层、芯层及上表层,将下表层置于热压固化模具中;
将所述金属板置于热压固化模具中,所述金属板的凸型部下端搭接在所述下表层的端部上;
在所述下表层上层叠芯层,其端部抵接到所述凸型部的端部;
在所述芯层上层叠上表层,其端部下端搭接在所述金属板的凸型部的上端,形成待热压复合板;
将待热压复合板进行热压固化形成复合平板部;
将热压固化后的复合平板部的金属板加工成异形部,获得复合体。
10.根据权利要求9所述的树脂层压板和金属板的复合体的制造方法,其特征在于,对接前,使用偶联剂溶液对所述金属板与所述树脂叠层的对接接合面进行处理。
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