CN112497865A - 一种钢塑板及其制造方法 - Google Patents
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Abstract
本发明提供一种钢塑板及其制造方法,制造方法包括如下步骤:S1:由第一材料形成的第一材料层进行剪切备用;由第二材料形成第二材料层进行剪切备用;由第三材料形成夹层进行剪切备用;S2:第一材料层放置在压合机上;S3:首先在第一材料层上放置一张第一高分子膜,然后夹层放置在第一高分子膜上,最后在夹层上放置一张第二高分子膜;S4:放置定位模块,以将夹层进行位置限位;S5:第二材料层放置在定位模块中;S6:压合机将第二材料层、夹层和第一材料层压合;S7:移走定位模块,形成钢塑板;S8:采用模具把钢塑板的第一材料层的预留部分的端部加工成特定形状。本发明钢塑板兼具背板、中框和前框的背板模组,使得中框前框背板一体化。
Description
技术领域
本发明属于钢塑板的技术领域,尤其涉及一种钢塑板及其制造方法。
背景技术
现有液晶电视显示屏和液晶显示器的背壳大多由三部分组成,前部分为以金属板材冲压成型的背板为承载的模组显示组合件,中间部分为以各种电路板组合的中控集成,外层部分为塑料后盖。显示器件的模组和电路板分别安装在背板的前侧和后侧,塑料面壳将电路板包裹起来,起保护作用。随着液晶显示屏向薄型化发展,为了追求视觉超薄效果,逐渐将原来散乱分布在整个背板背面的中控集成和后盖缩小到底部,只有背板支撑的显示组合件厚度,仍然满足不了消费者对超薄的迫切需要。
现有钢塑板的高强度、轻量化以及超薄的特点很好的切合超薄的需求,所以在大尺寸(65寸及以上)电视背板上得到了大量的应用。
现有钢塑板由2层铁板和位于2层铁板之间的塑胶板压合而成,然后通过分条裁切成规格大小的钢塑板,具备轻量化和高强度的特点符合电视背板的超薄需求,但钢塑板切的中间的塑胶板很难折弯成型,只能用于一般的冲孔和切断加工,使用范围受限制,而且断面可以看到中间的塑胶层,直接暴露不美观,仍需要在钢塑板上黏贴一个铝制的中框,再将屏幕模组安装在中框上,生产制程较长且铝中框价格不菲。
故需要一种超薄、一体化、高强度、轻量化和性价比高的材料。
发明内容
本发明的目的在于提供一种节省材料降低成本和减轻减薄的钢塑板及其制造方法。
本发明提供一种钢塑板的制造方法,包括如下步骤:
S1:由第一材料形成的第一材料层进行剪切备用;由第二材料形成第二材料层进行剪切备用;由第三材料形成夹层进行剪切备用,其中夹层的长度和宽度和第二材料的长度和宽度相同;
S2:第一材料层放置在压合机上;
S3:首先在第一材料层上放置一张与第三材料层相同大小的第一高分子膜,然后夹层放置在第一高分子膜上,最后在夹层上放置一张第二高分子膜,其中第一高分子膜、夹层和第二高分子膜三个材料层对齐并与第一材料层居中后放置在第一材料层上;
S4:放置定位模块,以将夹层进行位置限位;
S5:第二材料层放置在定位模块中;
S6:压合机将第二材料层、夹层和第一材料层压合;
S7:移走定位模块,形成钢塑板;
S8:采用模具把钢塑板的第一材料层的预留部分的端部加工成特定形状。
进一步地,第一材料层的预留部分为第一材料的长度方向延伸超过第二材料层或夹层的部分。
进一步地,第一材料为VCM板材或PCM材料。
进一步地,第二材料为金属材料。
进一步地,第二材料为热镀锌板或电镀锌板或铝板或不锈钢或铜。
进一步地,第一材料层和第二材料层的厚度为0.3-0.5mm。
进一步地,第二材料层上还设有耐指纹涂层,其厚度为5-10um。
进一步地,钢塑板的厚度为1.2-10mm。
本发明还提供一种钢塑板其包括第一材料层、固定在第一材料层上的夹层以及固定在夹层上的第二材料层,第二材料层和夹层的长度和宽度相同,第一材料层的长度和宽度均大于第二材料层的长度和宽度。
采用本发明制造方法形成的钢塑板,钢塑板兼具背板、中框和前框的背板模组,使得中框前框背板一体化,节省材料降低成本,减轻减薄,简化装配流程,整个电视屏结构浑然一体,美观大气。
附图说明
图1是现有液晶显示屏的结构示意图;
图2为本发明钢塑板的俯视图;
图3为图2所示钢塑板在A-A方向的剖视图;
图4为图3所示钢塑板的局部放大图;
图5为本发明钢塑板形成翻边结构的示意图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白,以下结合附图及实施例,对本发明作进一步详细说明。应当理解,此处所描述的具体实施例仅用以解释本发明,并不用于限定本发明。
本发明揭示一种钢塑板的制造方法,如图2至图5所示,包括如下步骤:
S1:由第一材料形成的第一材料层10进行剪切备用,第一材料层10的长度为L1,长度和宽度为H1,厚度为D1;由第二材料形成第二材料层20进行剪切备用,第二材料层20的长度为L2,长度和宽度为H2,厚度为D2,其中L2<L1,H2<H1,D2和D1数值基本相同;由第三材料形成夹层30进行剪切备用,夹层30的长度为L3,长度和宽度为H3,厚度为D3,其中L3=L2,H3=H2,D3>D2,D3>D1;
其中第一材料为VCM板材或PCM材料(相变材料,Phase Change Material,是指温度不变的情况下而改变物质状态并能提供潜热的物质),其中VCM板材是以钢板为基材,在基材的表面滚涂氯乙烯的一种金属彩色层压钢板;第二材料为金属材料,如热镀锌板、电镀锌板、铝板、不锈钢和铜等金属材料;夹层30为PE(指聚乙烯)材料、ABS(丙烯腈bai(A)、丁二烯(B)、苯乙烯(S)三种单体的三du元共聚物)或PC(聚碳酸酯,是一种高分子聚合物)或ABS+PC(ABS成分占多数的合金材料)或PP蜂窝板(由两块较薄的面板,牢固的黏在一层较厚的蜂窝状芯材两面而制成的板材,亦称蜂窝夹层结构,材质主要是PP)等其他轻薄材料。
S2:第一材料层10放置在压合机(图未示)上;
S3:首先在第一材料层10上放置一张与第二材料层20相同大小的第一高分子膜(图未示),然后夹层30放置在第一高分子膜上,最后在夹层30上放置一张第二高分子膜,其中第一高分子膜、夹层30和第二高分子膜三个材料层对齐并与第一材料层10居中后放置在第一材料层10上;
其中高分子膜其实是一种粘接树脂,属于热熔胶黏剂。高分子膜由基体树脂,增黏剂,抗氧剂,增塑剂等几种成分配制而成。
S4:放置定位模块(图未示),以将夹层30进行位置限位,以防止夹层30在第一材料层10上移动位置;
S5:第二材料层20放置在定位模块中;
S6:设定压合机的温度、时间和压力等参数,将第二材料层20、夹层30和第一材料层10压合;
其中,压合机的温度为80-100℃,时间为8-12秒。
S7:移走定位模块,形成钢塑板;
S8:采用模具(图未示)把钢塑板的第一材料层的预留部分的端部加工成翻边结构。
其中,第一材料层10的端部加工形成翻边结构11,在第一材料层10和夹层30之间仍有一定的间隙,这个间隙为模具进行翻边加工进行预留的。
具有翻边结构11的钢塑板称为钢塑背板,钢塑背板用于定位显示面板。
步骤S8的具体方法为:
S81:首先切割钢塑板并形成钢塑背板的展开的形状;然后对钢塑板的第一材料层10进行预卷边处进行预折弯处理并形成待卷折结构(图未示),待卷折结构的高度为0.25-0.35mm(具体为一个料厚)、宽度为0.45-0.55mm;
其中,待卷折结构的作用是为钢塑板进行卷边预切折,保证后钢塑板的卷边工序。这样也可省略切料,直接进行预折。由于钢塑板的第一材料层10的材料为VCM板材或铝材或不锈钢等其他外观材料,第一材料层10进行卷边处理时,材料的公差在±1mm左右,这样会造成预折不到位的风险,所以步骤S1就直接将切料(切料形成未卷边之前的钢塑板所对应的外形结构模具)和预折(形成待卷折结构)一起完成。
S82:钢塑板的第一材料层10进行折弯处理(折弯的角度根据固定显示屏的需要进行,如90度或75度等)并形成折弯结构(图未示),由于第一材料层10的材料是VCM板材或铝材或不锈钢等其他外观材料,在形成折弯结构过程中形成与折弯结构连接的突出结构(图未示,突出结构也就是折弯转角处需要进行侧切处理的结构);
S83:对折弯结构的转角处(即突出结构)进行单独侧切处理,使得折弯转角处的周围材料高度刚好进行卷边结构,不多料,不起皱;
S84:对折弯结构端部由下往上进行卷边或卷圆处理并行卷体结构,卷体结构的端部为待卷折结构。
折弯结构和卷体结构组合翻边结构11。
通过上述四个步骤完成对钢塑板的弯折和卷边(或卷圆)处理后,使得钢塑板变成钢塑背板。
在其他实施例中,翻边结构也可以称为单独折边(即仅第一材料层的一端进行折边)、单独卷边(即第一材料层仅进行卷边处理,也就仅需要上述步骤S81和S84)、卷圆(即第一材料层仅进行卷圆处理,也就仅需要上述步骤S81和S84)和多次折弯(即第一材料层进行多次折弯处理)。
其中第一材料层的预留部分为第一材料层10的长度方向延伸超过第二材料层20或夹层30的部分,其长度为(L1-L2)/2或(L1-L3)/3。
在本实施例中,夹层30的厚度不一定,根据实际需要设定夹层30的厚度,如厚度为1-2mm;第二材料层10和第二材料层20的厚度为0.3-0.5mm;第二材料层20的表面设有耐指纹涂层(图未示),耐指纹涂层的厚度为5-10um,耐指纹涂层具有防耐指纹和防锈作用。
钢塑板的厚度为1.2-5.0mm。
采用本发明制造方法形成的钢塑板,钢塑板兼具背板、中框和前框的背板模组,使得中框前框背板一体化,节省材料降低成本,减轻减薄,简化装配流程,整个电视屏结构浑然一体,美观大气。
以上所述,仅是本发明的较佳实施例而已,并非对本发明作任何形式上的限制,虽然本发明已以较佳实施例揭露如上,然而并非用以限定本发明,任何熟悉本专业的技术人员,在不脱离本发明技术方案范围内,当可利用上述揭示的技术内容做出些许更动或修饰为等同变化的等效实施例,但凡是未脱离本发明技术方案内容,依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰,均仍属于本发明技术方案的范围内。
Claims (10)
1.一种钢塑板的制造方法,其特征在于,包括如下步骤:
S1:由第一材料形成的第一材料层进行剪切备用;由第二材料形成第二材料层进行剪切备用;由第三材料形成夹层进行剪切备用,其中夹层的长度和宽度和第二材料的长度和宽度相同;
S2:第一材料层放置在压合机上;
S3:首先在第一材料层上放置一张与第三材料层相同大小的第一高分子膜,然后夹层放置在第一高分子膜上,最后在夹层上放置一张第二高分子膜,其中第一高分子膜、夹层和第二高分子膜三个材料层对齐并与第一材料层居中后放置在第一材料层上;
S4:放置定位模块,以将夹层进行位置限位;
S5:第二材料层放置在定位模块中;
S6:压合机将第二材料层、夹层和第一材料层压合;
S7:移走定位模块,形成钢塑板;
S8:采用模具把钢塑板的第一材料层的预留部分的端部加工成特定形状。
2.根据权利要求1所述的钢塑板的制造方法,其特征在于,第一材料层的预留部分为第一材料的长度方向延伸超过第二材料层或夹层的部分。
3.根据权利要求1所述的钢塑板的制造方法,其特征在于,第一材料为VCM板材或PCM材料。
4.根据权利要求1所述的钢塑板的制造方法,其特征在于,第二材料为金属材料。
5.根据权利要求4所述的钢塑板的制造方法,其特征在于,第二材料为热镀锌板或电镀锌板或铝板或不锈钢或铜。
6.根据权利要求1所述的钢塑板的制造方法,其特征在于,夹层为PE材料或ABS或PC或ABS+PC或PP蜂窝板。
7.根据权利要求1所述的钢塑板的制造方法,其特征在于,第一材料层和第二材料层的厚度为0.3-0.5mm。
8.根据权利要求1所述的钢塑板的制造方法,其特征在于,第二材料层上还设有耐指纹涂层,其厚度为5-10um。
9.根据权利要求1所述的钢塑板的制造方法,其特征在于,钢塑板的厚度为1.2-10mm。
10.一种钢塑板,由权利要求1-9任一所述的钢塑板的制造方法制造形成的,其特征在于,其包括第一材料层、固定在第一材料层上的夹层以及固定在夹层上的第二材料层,第二材料层和夹层的长度和宽度相同,第一材料层的长度和宽度均大于第二材料层的长度和宽度。
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