TW201334962A - 具有編織紋路殼體的製造方法及製得的殼體 - Google Patents

具有編織紋路殼體的製造方法及製得的殼體 Download PDF

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TW201334962A
TW201334962A TW101106828A TW101106828A TW201334962A TW 201334962 A TW201334962 A TW 201334962A TW 101106828 A TW101106828 A TW 101106828A TW 101106828 A TW101106828 A TW 101106828A TW 201334962 A TW201334962 A TW 201334962A
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Kai-Rong Liao
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
    • B29K2101/10—Thermosetting resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
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    • B32—LAYERED PRODUCTS
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    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
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Abstract

本發明提供一種具有編織紋路殼體的製造方法，包括如下步驟：提供未固化的編織纖維預浸布；於一透明或半透明的熱塑性塑膠薄膜的一表面塗覆一熱固性膠黏劑塗層；將該編織纖維預浸布與熱塑性塑膠薄膜具有熱固性膠黏劑的表面貼合，得到一組合體；將該組合體放入模具中進行熱壓，使該組合體成型所需的三維形狀，由此獲得一預製件；對預製件進行裁切，以去除餘料而得到具有所需三維外形的殼體。本發明還提供一種藉由上述方法製得的具有編織紋路的殼體。

Description

具有編織紋路殼體的製造方法及製得的殼體
本發明是關於一種具有編織紋路殼體的製造方法及由該方法製得的殼體。
纖維材料（如碳纖維、玻璃纖維等）具有較輕的品質、高強度的優點，且纖維材料藉由不同的編織方法加工後可形成立體紋路，故，編織纖維材料可使用在各種裝置設備的外殼上，使該等裝置設備憑藉具有編織纖維紋路的殼體，呈現出特殊的表面質感與紋路。
習知之具有纖維編織紋路的殼體的製造方法，包括下列步驟：首先，提供複數個含浸熱固性樹脂的編織纖維預浸布；然後將該等編織纖維預浸布堆疊成預定厚度；之後將其裁切成預定形狀尺寸；將該等經裁切的編織纖維預浸佈置入模具中，經模具熱壓成型後，形成預定形狀的殼體；最後進行修補過程，即對殼體表面填補、研磨、噴漆，由此獲得殼體成品。
在一般情況下，由於編織纖維布是由纖維交錯編織而成，故在含浸樹脂後難免會在纖維相交錯處形成有未填滿的空隙或凹洞，在熱壓過程中，編織纖維布表面的樹脂會流動至所述未填滿的空隙或凹洞，使表面產生坑洞而凹凸不平，故必須進一步加工，針對該等不平坦用樹脂加以填補，而後再磨平、噴漆。故，習知之製造過程需花費相當多的人力與時間進行修補，成本較高，所製得殼體成品的表面品質亦難以提高。
有鑒於此，有必要提供一種具有纖維編織紋路、表面平整光滑的殼體的製造方法，該方法製程簡單，成本較低。
另外，還有必要提供一種由上述方法製得的殼體。
一種具有編織紋路殼體的製造方法，包括如下步驟：
提供未固化的編織纖維預浸布，該編織纖維預浸布是由編織纖維布含浸樹脂形成；
於一透明或半透明的熱塑性塑膠薄膜的一表面塗覆一熱固性膠黏劑塗層；
將該編織纖維預浸布與熱塑性塑膠薄膜具有熱固性膠黏劑的表面貼合，得到一組合體；
將該組合體放入模具中進行熱壓，使該組合體成型所需的三維形狀，由此獲得一預製件；
對預製件進行裁切，以去除餘料而得到具有所需三維外形的殼體。
一種具有編織紋路的殼體，其包括一纖維層，該纖維層由固化的含浸有樹脂的編織纖維布形成，該殼體還包括一熱塑性塑膠薄膜，該熱塑性塑膠薄膜藉由一熱固性膠黏劑層黏合於該纖維層的表面。
上述具有編織紋路殼體的製造方法藉由於編織纖維預浸布的表面黏合一熱塑性樹脂薄膜，再藉由熱壓成型及裁切餘料後獲得具有編織紋路外觀的殼體。由於熱塑性樹脂薄膜覆蓋於編織纖維預浸布的表面，使殼體具有平整光滑的表面，避免了編織纖維預浸布直接形成殼體外表面時會產生坑洞而使殼體表面凹凸不平的缺陷。
請參閱圖1及圖2，本發明較佳實施例具有編織紋路殼體的製造方法包括以下步驟：
步驟S10，提供未固化的編織纖維預浸布10。該編織纖維預浸布10是由編織纖維布含浸樹脂形成。編織纖維預浸布10中含浸的樹脂為透明或半透明的熱固性樹脂，如環氧樹脂。該編織纖維布為選自碳纖維、玻璃纖維、克維拉（Kevler）纖維材料及混編（Hybrid）纖維中的一種編織而成。本實施例優選為碳纖維或玻璃纖維。該編織纖維布表面形成有交錯的立體編織紋路。
步驟S20，於一透明或半透明的熱塑性塑膠薄膜30的一表面上塗覆一熱固性膠黏劑層20。該熱固性膠黏劑層20為帶有環氧基團的膠黏劑。本實施例中，該熱固性膠黏劑層20為液體狀的環氧樹脂膠水。該熱塑性塑膠薄膜30為聚碳酸酯(Polycarbonate，PC)薄膜。
步驟S30，將所述編織纖維預浸布10與熱塑性塑膠薄膜30具有熱固性膠黏劑層20的表面貼合，得到一組合體40。貼合後，確保該組合體40內無氣泡、凸起、褶皺等。
步驟S40，將該組合體40放入預先設計好形狀的模具60中進行熱壓，使組合體40成型所需的三維形狀，由此獲得一預製件50。該熱壓過程中，模具60加熱至100℃-250℃，同時藉由模具60對組合體40施加10kg/cm2-180kg/cm2的壓力。所述熱壓過程持續時間大約為20-60分鐘。冷卻後，編織纖維預浸布10中的樹脂以及熱固性膠黏劑層20硬化，使組合體40獲得固定的三維形狀。當所述編織纖維預浸布10中含浸的樹脂為環氧樹脂時，根據環氧樹脂的固化溫度，熱壓過程中設置模具60的溫度為170℃。
步驟S50，對預製件50進行裁切，以去除多餘邊料，由此得到具有所需三維外形以及具有立體編織紋路外觀的殼體100。
可以理解，所述步驟S10與步驟S20的先後順序可以交換。
請參閱圖3，由上述方法製得的殼體100包括一纖維層110及藉由一熱固性膠黏劑層20黏合於該纖維層110表面的熱塑性塑膠薄膜30。
該纖維層110由固化的含浸有樹脂的編織纖維布（即編織纖維預浸布）形成。所述樹脂為透明或半透明，其可為熱固性樹脂，如環氧樹脂。本實施例選用透明的環氧樹脂。該編織纖維布為選自碳纖維、玻璃纖維、克維拉（Kevler）纖維材料及混編（Hybrid）纖維中的一種編織而成。本實施例優選為碳纖維或玻璃纖維。該編織纖維布表面形成有交錯的立體編織紋路。
該熱固性膠黏劑層20帶有環氧基團的黏合劑。為了使所述纖維層110的立體編織紋路可視，該熱固性膠黏劑層20具有較高的透明度。
該熱塑性塑膠薄膜30為透明或半透明狀，其可為聚碳酸酯薄膜。熱塑性塑膠薄膜30的厚度大約為0.2mm。
所述編織纖維布的立體編織紋路透過熱塑性塑膠薄膜30，使殼體100表面具有立體編織紋路的裝飾效果。
上述具有編織紋路殼體的製造方法藉由於編織纖維預浸布10的表面黏合一熱塑性塑膠薄膜30，再藉由熱壓成型及裁切餘料後獲得具有編織紋路外觀的殼體100。由於熱塑性塑膠薄膜30覆蓋於編織纖維預浸布10的表面，使殼體100具有平整光滑的表面，避免了編織纖維預浸布10直接形成殼體外表面時會產生坑洞而使殼體表面凹凸不平的缺陷。
10．．．編織纖維預浸布
20．．．熱固性膠黏劑層
30．．．熱塑性塑膠薄膜
40．．．組合體
50．．．預製件
60．．．模具
100．．．殼體
110．．．纖維層
圖1為本發明較佳實施例殼體的剖視示意圖。
圖2為本發明較佳實施例具有編織紋路殼體的製造方法的方塊流程圖。
圖3為本發明較佳實施例具有編織紋路殼體的製造方法中不同步驟的示意圖。
10．．．編織纖維預浸布
20．．．熱固性膠黏劑層
30．．．熱塑性塑膠薄膜
40．．．組合體
50．．．預製件
60．．．模具
100．．．殼體

Claims (9)

  1. 一種具有編織紋路殼體的製造方法，包括如下步驟：
    提供未固化的編織纖維預浸布，該編織纖維預浸布是由編織纖維布含浸樹脂形成；
    於一透明或半透明的熱塑性塑膠薄膜的一表面塗覆一熱固性膠黏劑塗層；
    將該編織纖維預浸布與熱塑性塑膠薄膜具有熱固性膠黏劑層的表面貼合，得到一組合體；
    將該組合體放入模具中進行熱壓，使該組合體成型所需的三維形狀，由此獲得一預製件；
    對預製件進行裁切，以去除餘料而得到具有所需三維外形的殼體。
  2. 如申請專利範圍第1項所述之具有編織紋路殼體的製造方法，其中所述熱壓過程中，所述模具的溫度為100℃-250℃，模具對該組合體施加的壓力為10kg/cm2-180kg/cm2。
  3. 如申請專利範圍第1項所述之具有編織紋路殼體的製造方法，其中所述編織纖維預浸布的編織纖維布為選自碳纖維、玻璃纖維、克維拉纖維材料及混編纖維中的一種編織而成。
  4. 如申請專利範圍第1項所述之具有編織紋路殼體的製造方法，其中所述編織纖維預浸布中的樹脂為透明或半透明的熱固性樹脂。
  5. 如申請專利範圍第1項所述之具有編織紋路殼體的製造方法，其中所述熱塑性塑膠薄膜為聚碳酸酯薄膜。
  6. 一種具有編織紋路的殼體，其包括一纖維層，其改良在於：該纖維層由固化的含浸有樹脂的編織纖維布形成，該殼體還包括一熱塑性塑膠薄膜，該熱塑性塑膠薄膜藉由一熱固性膠黏劑層黏合於該纖維層的表面。
  7. 如申請專利範圍第6項所述之具有編織紋路的殼體，其中所述編織纖維預浸布的編織纖維布為選自碳纖維、玻璃纖維、克維拉纖維材料及混編纖維中的一種編織而成。
  8. 如申請專利範圍第6項所述之具有編織紋路的殼體，其中所述編織纖維預浸布中的樹脂為透明或半透明的熱固性樹脂。
  9. 如申請專利範圍第6項所述之具有編織紋路的殼體，其中所述熱塑性塑膠薄膜為聚碳酸酯薄膜。
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