CN115742261A - Method for forming thermoplastic composite material - Google Patents
Method for forming thermoplastic composite material Download PDFInfo
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- CN115742261A CN115742261A CN202210809575.2A CN202210809575A CN115742261A CN 115742261 A CN115742261 A CN 115742261A CN 202210809575 A CN202210809575 A CN 202210809575A CN 115742261 A CN115742261 A CN 115742261A
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- thermoplastic materials
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Abstract
The invention provides a method for molding a thermoplastic composite material, which is used for solving the problem of overhigh energy consumption of the existing hot press molding process. The method comprises the following steps: laminating a plurality of thermoplastic materials, and covering a flexible film on the laminated thermoplastic materials so as to enable the laminated thermoplastic materials to be positioned in an airtight space; and heating the laminated thermoplastic materials at the temperature of 100-450 ℃ for 10-180 seconds, and exhausting air from the airtight space so that the flexible film applies pressure to the laminated thermoplastic materials.
Description
Technical Field
The invention relates to a method for molding a thermoplastic composite material, in particular to a method for molding a vacuum-molded thermoplastic composite material.
Background
Generally, when a plurality of thermoplastic materials are laminated and molded into an integrated composite material, the laminated thermoplastic materials are placed between a male mold and a female mold, and the male mold and the female mold are pressed against each other to mold the laminated thermoplastic materials. Thus, the contact surfaces of adjacent thermoplastic materials can be fused and jointed, so that a plurality of thermoplastic materials can be hot-pressed to form a composite material.
However, in the hot press molding, the male mold and the female mold must be heated to a predetermined temperature, and the male mold and the female mold have a long time to mold the thermoplastic material. Therefore, the energy consumption of the hot press forming process is too high, and the operation cost is increased.
In view of the above, there is still a need for improvement of the conventional method for forming composite materials.
Disclosure of Invention
In order to solve the above problems, an object of the present invention is to provide a method for molding a thermoplastic composite material, which can reduce the cost of the molding process.
Throughout the present disclosure, directional terms or their similar terms, such as "front", "rear", "left", "right", "top", "bottom", "inner", "outer", "side", etc., are mainly used to refer to the orientation of the drawings, and are only used to assist the description and understanding of the embodiments of the present invention, but not to limit the present invention.
The use of the terms a or an for the elements and components described throughout this disclosure are for convenience only and provide a general sense of the scope of the invention; in the present invention, it is to be understood that the singular includes plural unless it is obvious that it is meant otherwise.
The terms "combined", "combined" and "assembled" as used herein mainly include the forms of the components that can be separated without destroying the components after being connected or the components that can not be separated after being connected, and those skilled in the art can select the components according to the material or assembly requirement of the components to be connected.
The molding method of the thermoplastic composite material comprises the following steps: laminating a plurality of thermoplastic materials, and covering a flexible film on the laminated thermoplastic materials so as to enable the laminated thermoplastic materials to be positioned in an airtight space; and heating the laminated thermoplastic materials at the temperature of 100-450 ℃ for 10-180 seconds, and exhausting air from the airtight space so that the flexible film applies pressure to the laminated thermoplastic materials.
The method for molding a thermoplastic composite material of the present invention may further comprise: laminating a plurality of thermoplastic materials, heating the laminated thermoplastic materials at the temperature of 100-450 ℃ for 10-180 seconds, and covering a flexible film on the laminated thermoplastic materials so as to enable the laminated thermoplastic materials to be positioned in an airtight space; and exhausting the airtight space to enable the flexible film to apply pressure to the plurality of thermoplastic materials which are mutually laminated.
Therefore, in the method for molding a thermoplastic composite material according to the present invention, the soft film is covered on the plurality of thermoplastic materials stacked in the airtight space so that the plurality of thermoplastic materials stacked in the airtight space are positioned, and the plurality of thermoplastic materials stacked in the airtight space are heated so that the contact surfaces of the adjacent thermoplastic materials can be melt-bonded. By exhausting air from the airtight space, the air pressure in the airtight space is reduced, and then the soft film can be closely attached to the plurality of thermoplastic materials which are stacked mutually so as to apply pressure to the plurality of thermoplastic materials which are stacked mutually, and the effect of hot pressing the plurality of thermoplastic materials which are stacked mutually can be achieved through the pressure. Therefore, compared with the existing composite material forming method, the thermoplastic composite material forming method of the invention saves the preheating of the male die and the female die, and can save energy consumption. The temperature rise speed of the thermoplastic materials is higher than that of the mould, and the soft film can quickly apply pressure to the laminated thermoplastic materials by exhausting the airtight space, so that the working time can be saved, and the effect of reducing the production cost can be realized.
The positioning frames can be provided, each positioning frame is provided with at least one grid groove, the grid grooves of the adjacent positioning frames are opposite when the positioning frames are laminated, the thermoplastic materials are positioned in the grid grooves, and the positioning frames are laminated to laminate the thermoplastic materials. Therefore, the method has the effects of quickly and accurately aligning and laminating the thermoplastic materials and facilitating mass molding.
Wherein, the number of the positioning frames is three. Therefore, the method has the effects of quickly and accurately carrying out the alignment lamination of the thermoplastic materials and facilitating the mass forming.
Wherein, the thickness of the positioning frame can be 0.1 mm-0.3 mm. Therefore, each thermoplastic material can be higher than the grid groove, and the soft film can be attached to the thermoplastic material.
The laminated thermoplastic materials can be carried on a platform, the soft film covers the surface of the platform, and the soft film and the surface of the platform form the airtight space together. Therefore, the soft film can be closely attached to the laminated multiple thermoplastic materials so as to apply pressure to the laminated multiple thermoplastic materials.
Wherein, the platform is provided with a heat conduction piece which is provided with a heating source, and a plurality of thermoplastic materials which are overlapped are arranged on the heat conduction piece so as to be heated by the heating source. Thus, the effect of evenly heating the plurality of thermoplastic materials stacked one on another is achieved.
Wherein, a release film is arranged between the heat conduction piece and the laminated thermoplastic materials. Therefore, the thermoplastic material can be conveniently separated from the heat conductor.
The platform is provided with a plurality of air pumping holes which penetrate through the upper surface and the lower surface of the platform, and each air pumping hole pair is positioned in the airtight space. Therefore, the air in the airtight space can be pumped through the plurality of air pumping holes so as to reduce the air pressure in the airtight space.
Wherein, a release film is arranged between the soft film and the laminated thermoplastic materials. Therefore, the flexible membrane has the effect of facilitating the separation of the thermoplastic material and the flexible membrane.
Wherein the airtight space is evacuated at a pressure of about 700 mmHG to about 760 mmHG, so that the flexible film applies pressure to the plurality of thermoplastic materials laminated mutually. Thus, the soft film can generate proper pressure to the plurality of thermoplastic materials which are laminated mutually.
Drawings
FIG. 1: the invention is a schematic diagram of a mold of a preferred embodiment of the molding method of the thermoplastic composite material;
FIG. 2: the invention discloses a first positioning frame and a second positioning frame of a thermoplastic composite material molding method.
Description of the reference numerals
1: thermoplastic material
2: flexible film
3: platform
3, air exhaust hole
4: heat transfer member
41 heating source
5, release film
S. air tight space
C, a positioning frame
C1: first positioning frame
C11, C21 grid groove
C2: second positioning frame
P is pumping.
Detailed Description
In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, preferred embodiments accompanied with figures are described in detail below:
referring to fig. 1, a preferred embodiment of the method for forming a thermoplastic composite material of the present invention includes laminating a plurality of thermoplastic materials 1, covering a flexible film 2 on the laminated thermoplastic materials 1 to make the laminated thermoplastic materials 1 located in an airtight space S, and heating the laminated thermoplastic materials 1 and reducing the air pressure in the airtight space S to make the flexible film 2 apply pressure to the laminated thermoplastic materials 1.
The thermoplastic material 1 may be a thermoplastic resin such as polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE), polyphenylene Sulfide (PPs), polyether ether ketone (PEEK), polysulfone (PSU), polycarbonate (PC), or Polyether Sulfone (PEs). The thermoplastic material 1 may also be a prepreg formed by, for example, impregnating glass fibers or carbon fibers in the thermoplastic resin in advance, so that the thermoplastic material 1 can have a better strength.
The shape of the thermoplastic material 1 is not limited, and the thermoplastic material 1 can be cut from a base material according to the needs of workers or be pre-formed into a predetermined shape. In addition, the laminated thermoplastic materials 1 may have the same or different sizes and profiles according to the product requirements, and the invention is not limited thereto. In the present embodiment, the thermoplastic material 1 is exemplified as a pad of a shoe, the thermoplastic material 1 can be a sheet, and the thickness of the thermoplastic material 1 can be 0.1-0.22 mm. In this way, the at least two thermoplastic materials 1 may be laminated to form a mat of composite material of a predetermined thickness, for example, a plurality of thermoplastic materials 1 may be laminated to a mat of thickness 3 mm. In an embodiment, the thermoplastic material 1 is about 0.1 mm, 0.13 mm, 0.15 mm, 0.17 mm, 0.19 mm, or 0.22 mm thick.
Referring to fig. 1 and 2, when a plurality of thermoplastic materials 1 are stacked, the thermoplastic materials 1 can be positioned by a plurality of positioning frames C, respectively. Each positioning frame C has at least one groove, the size and the outline of the groove correspond to the thermoplastic material 1, and when the positioning frames C are laminated, the grooves of the adjacent positioning frames C are opposite. In this way, the thermoplastic material 1 can be placed in the groove of the positioning frame, and two thermoplastic materials 1 can be laminated by laminating, for example, two positioning frames C, which has an effect of quickly and accurately performing alignment lamination of the respective thermoplastic materials 1 and contributing to mass molding.
In the present embodiment, the two sizes of thermoplastic materials 1 can be positioned by a first positioning frame C1 and a second positioning frame C2, respectively. The cells C11 of the first positioning frame C1 and the cells C21 of the second positioning frame C2 are different in size (as shown in fig. 2, the first positioning frame C1 has long rectangular cells C11, and the second positioning frame C2 has short rectangular cells C21), so as to correspond to the thermoplastic materials 1 with different sizes, respectively. In more detail, the thermoplastic material 1 placed in the first positioning frame C1 has a different length from the thermoplastic material placed in the second positioning frame C2. In the lamination, a first positioning frame C1 is provided and a first size of thermoplastic material 1 (hereinafter referred to as the first thermoplastic material 1) is placed in the cell C11. Then, the second positioning frame C2 is stacked on the first positioning frame C1 on which the thermoplastic material 1 is placed, so that the grooves C21 and the grooves C11 are aligned and a part of the upper surface of the first thermoplastic material 1 is exposed. Finally, a second size of thermoplastic material 1 (hereinafter referred to as second thermoplastic material 1) can be placed in the channel C21 such that the second thermoplastic material 1 conforms to the first thermoplastic material 1 on the upper surface of the exposed portion. Therefore, the at least two layer body can be formed by the first positioning frame C1, the first thermoplastic material 1, the second positioning frame C2 and the second thermoplastic material 1. The at least two layers have an upper surface exposed from the second thermoplastic material 1 and a lower surface opposite to the upper surface exposed from the first thermoplastic material 1. Therefore, the first positioning frame C1 and the second positioning frame C2 can be used for positioning the thermoplastic materials 1 with different sizes. In another embodiment, the positioning of the thermoplastic material 1 of the third size may be performed by a positioning frame of a third size.
The thickness of each positioning frame C may be the same or different, and the thickness of each positioning frame C may be 0.1 mm to 0.3 mm, so that each thermoplastic material 1 is equal to or higher than the cell, and the flexible film 2 may be attached to the thermoplastic material 1 to apply pressure to the thermoplastic material 1. In addition, when the alignment of the thermoplastic materials 1 is completed, the positioning frames C can be removed and then the subsequent processes can be performed.
The soft film 2 covers the stacked thermoplastic materials 1, the soft film 2 may be made of a material having ductility and high temperature resistance, such as nylon, polyethylene or rubber, the soft film 2 may cover the surfaces of the stacked thermoplastic materials 1, and the soft film 2 covers the stacked thermoplastic materials 1 to form the airtight space S. In this embodiment, a plurality of thermoplastic materials 1 stacked one on another may be carried on a platform 3. The flexible film 2 covers the surface of the platform 3 together, so that the flexible film 2 and the surface of the platform 3 can form the airtight space S together.
The laminated thermoplastic materials 1 are heated at a temperature of 100 to 450 ℃ to fuse the contact surfaces of the adjacent thermoplastic materials 1. The heating temperature may be suitably set depending on the material of the thermoplastic material 1. For example, when the thermoplastic material 1 is PPS, PSU or PES, the heating temperature may be 300 to 400 ℃, when the thermoplastic material 1 is PC, the heating temperature may be 200 to 250 ℃, and when the thermoplastic material 1 is PEEK, the heating temperature may be 350 to 450 ℃. Thus, the thermoplastic material 1 is not heated excessively to cause deterioration or damage, and the heating time can be 10-180 seconds to avoid the heating time being too long. In one embodiment, the heating time may be 10-80 seconds, 60-140 seconds, or 120-180 seconds, depending on different process requirements. In another embodiment, the heating time required for the process is short, and the heating time can be 10 seconds, 20 seconds, 30 seconds, 40 seconds, 50 seconds or 60 seconds, which can greatly shorten the total time of the process.
In this embodiment, the platform 3 may have a heat conducting member 4 thereon, the heat conducting member 4 may be made of metal material with good thermal conductivity, such as iron, copper or stainless steel, and the heat conducting member 4 may have a heat generating source 41, and the heat generating source 41 may generate heat by heating with kerosene, electric heat or resistance heating. In this manner, a plurality of thermoplastic materials 1 stacked one on another may be placed on the heat conductive member 4 to be heated by the heat generating source 41. Preferably, a release film 5 can be disposed between the heat conduction member 4 and the stacked thermoplastic materials 1, and the release film 5 can be made of a heat-resistant material such as Polytetrafluoroethylene (PTFE). In some embodiments, the release film 5 may be a prefabricated film material, or may be a film formed by spraying during operation. In this way, the thermoplastic material 1 can be easily separated from the heat conductor 4. In addition, the release film 5 can be disposed between the thermoplastic material 1 and the flexible film 2, so that the thermoplastic material 1 can be separated from the flexible film 2. In other words, as mentioned earlier, when the number of layers is two, the first thermoplastic material 1 and the second thermoplastic material 1 are exposed to opposite sides of the layers (below the first positioning frame C1 and above the second positioning frame C2 as shown in fig. 1), respectively. A sheet of release film 5 is interposed between the first positioning frame C1 in which the first thermoplastic material 1 is placed and the heat conductor 4 so that the release film 5 directly contacts the first positioning frame C1 and the first thermoplastic material 1. Another release film 5 is interposed between the second positioning frame C2 with the second thermoplastic material 1 and the flexible film 2, so that the release film 5 directly contacts the second positioning frame C2 and the second thermoplastic material 1. Therefore, after the forming is finished, the multi-lamination layer body is not only easy to separate from the heat conduction piece 4, but also beneficial to preventing the soft 2 from being adhered to the layer body when being lifted, and improving the efficiency of the process.
In addition, in the present embodiment, the flexible film 2 is covered on the plurality of thermoplastic materials 1 stacked and then the plurality of thermoplastic materials 1 stacked and stacked are heated, but in another embodiment, the flexible film 2 is covered on the plurality of thermoplastic materials 1 stacked and the airtight space S is evacuated when or after the plurality of thermoplastic materials 1 stacked and stacked are heated, so that a degree of freedom in the process flow can be improved.
The air in the airtight space S is pumped down to a pressure of about 700 mmHG to about 760 mmHG, so that the air pressure in the airtight space S is reduced to a vacuum or near vacuum. At this time, the flexible film 2 covering the laminated thermoplastic materials 1 can be closely attached to the laminated thermoplastic materials 1 as the air pressure decreases (i.e., as the airtight space S gradually approaches the vacuum), and the laminated thermoplastic materials 1 are pressurized to closely press the laminated thermoplastic materials 1 and extrude the excessive air bubbles. In this way, the plurality of thermoplastic materials 1 stacked one on another can be formed into an integrated composite material. In this embodiment, the platform 3 may have a plurality of pumping holes 31, the pumping holes 31 penetrate through the upper surface and the lower surface of the platform 3, and each pumping hole 31 is aligned with the airtight space S, i.e., when the flexible film 2 covers the upper surface of the platform 3, each pumping hole 31 may be covered together. A pump P may be connected to the pumping hole 31 of the lower surface of the stage 3 through a pipe, which may have a valve to control the pumping pressure and maintain the air pressure of the airtight space S.
In addition, as shown in FIG. 1, in one embodiment, there may be at least two air extraction holes 31, and the heat conduction member 4 is located at the center between the two air extraction holes 31. That is, the heat conduction member 4 has a periphery, and the air exhaust holes 31 are disposed at equal intervals from the periphery. In an automated molding process, the heat-transfer member 4 is disposed between one of the suction holes 31 and the other of the suction holes 31, and the first positioning frame C1, the second positioning frame C2 and the thermoplastic material 1 are stacked on the heat-transfer member 4 by a holding mechanism (e.g., a robot). Wherein the clamping mechanism can identify the positions of the grooves C11 and C21, and respectively insert the first thermal material 1 and the second thermal material 1. The air holes 31 can be used as calibration points and are equidistantly arranged on the heat conduction member 4, which is beneficial for the clamping mechanism to perform more accurate alignment calibration on each stacked object above the heat conduction member 4.
As described above, in the method for molding a thermoplastic composite material according to the present invention, the soft film is covered on the plurality of thermoplastic materials stacked in the airtight space so that the plurality of thermoplastic materials stacked in the airtight space are positioned, and the thermoplastic materials stacked in the airtight space are heated so that the contact surfaces of the adjacent thermoplastic materials can be melt-bonded. By exhausting air from the airtight space, the air pressure in the airtight space is reduced, and then the soft film can be closely attached to the plurality of thermoplastic materials which are stacked mutually so as to apply pressure to the plurality of thermoplastic materials which are stacked mutually, and the effect of hot pressing the plurality of thermoplastic materials which are stacked mutually can be achieved through the pressure. Therefore, compared with the existing composite material forming method, the thermoplastic composite material forming method of the invention saves the preheating of the male die and the female die, and can save energy consumption. The temperature rise speed of the thermoplastic materials is higher than that of the mould, and the soft film can quickly apply pressure to the laminated thermoplastic materials by exhausting the airtight space, so that the operation time can be saved, and the effect of reducing the production cost is achieved.
Although the present invention has been described with reference to the preferred embodiments, it should be understood that various changes and modifications can be made therein by those skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims.
Claims (11)
1. A method of forming a thermoplastic composite, comprising:
laminating a plurality of thermoplastic materials, covering a flexible film on the laminated plurality of thermoplastic materials so that the laminated plurality of thermoplastic materials are positioned in an airtight space; and
heating the laminated thermoplastic materials at the temperature of 100-450 ℃ for 10-180 seconds, and exhausting the airtight space to enable the flexible film to apply pressure to the laminated thermoplastic materials.
2. The method of claim 1, wherein a plurality of positioning frames are provided, each positioning frame has at least one groove, the grooves of adjacent positioning frames are opposite to each other when the positioning frames are stacked, and after the thermoplastic material is positioned in the groove, the positioning frames are stacked to stack the thermoplastic materials.
3. The method of claim 2, wherein the number of the positioning frames is three.
4. The method of claim 2, wherein the thickness of the positioning frame is 0.1 mm to 0.3 mm.
5. The method as claimed in claim 1, wherein the laminated thermoplastic materials are loaded on a platform, the flexible film covers the surface of the platform, and the flexible film and the surface of the platform form the airtight space.
6. A method of forming a thermoplastic composite as claimed in claim 5, wherein the platform has a heat transfer member thereon, the heat transfer member having a heat generating source, and a plurality of thermoplastic materials laminated thereon are placed on the heat transfer member to be heated by the heat generating source.
7. The method of claim 6, wherein a release film is disposed between the heat conducting element and the laminated thermoplastic materials.
8. The method of claim 5, wherein the platen has a plurality of pumping holes, the pumping holes penetrating the upper and lower surfaces of the platen, the pairs of pumping holes being located in the airtight space.
9. The method of claim 1, wherein a release film is disposed between the flexible film and the stacked thermoplastic materials.
10. The method of claim 1, wherein the airtight space is evacuated at a pressure of 700 mmHG to 760 mmHG, so that the flexible film applies pressure to the plurality of thermoplastic materials stacked in phase.
11. A method of forming a thermoplastic composite, comprising:
laminating a plurality of thermoplastic materials, heating the laminated thermoplastic materials at the temperature of 100-450 ℃ for 10-180 seconds, and covering a flexible film on the laminated thermoplastic materials so as to enable the laminated thermoplastic materials to be positioned in an airtight space; and
and exhausting the airtight space to enable the flexible film to apply pressure to the plurality of laminated thermoplastic materials.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| TW110132648 | 2021-09-02 | ||
| TW110132648A TWI847057B (en) | 2021-09-02 | A molding method of thermoplastic composite material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115742261A true CN115742261A (en) | 2023-03-07 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210809575.2A Pending CN115742261A (en) | 2021-09-02 | 2022-07-11 | Method for forming thermoplastic composite material |
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| Country | Link |
|---|---|
| CN (1) | CN115742261A (en) |
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- 2022-07-11 CN CN202210809575.2A patent/CN115742261A/en active Pending
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| Publication number | Publication date |
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| TW202311000A (en) | 2023-03-16 |
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