TW201805153A - Heterogeneous composites and products thereof - Google Patents

Abstract

Present invention is related to a heterogeneous composite having a first structure, a central plate and a second structure. The first structure comprises a woven fiber layer, a metal layer, a plastic layer or combination thereof. The central plate is a thermoplastic plate. The second structure comprises a woven fiber layer and a plastic layer or a woven fiber layer-with a non-woven fabric on bottom side. The first structure and the second structure are connected to the central plate by a glue layer. Mechanical strength difference between the first structure and the second structure is less than 20%. The central plate is a base plate providing mechanical supporting to the whole structure of the present invention. Material of the central plate is not limited and may be selected according to the requirement of the customer. Processing cost and thermal molding technique of the present invention are simpler than self- reinforced 100% polypropylene composite which leads to more market competitiveness of the present invention.

Description

Different material laminated composite materials and products thereof

A composite material, in particular a composite material in which different materials are laminated to each other.

At present, the trunk manufacturing industry is mainly based on hard-shell suitcases. The hard-shell suitcases can be mainly divided into plastic materials or metal materials. Plastic or metal can be processed into special shapes or shapes, and plastic or metal. The material is highly loved by consumers for its high strength, durability and water resistance compared to soft materials such as cloth.

The hard-shell suitcase of plastic material can be roughly divided into a traditional plastic plate or a composite plastic plate. The laminated plate is formed by laminating a single layer or a multi-layer plate. The plastic plate or the composite plastic plate is inexpensive. However, the structural strength is not good, and often it is unable to withstand strong impact and is quite easy to break.

In order to improve the shortcomings of the strength of the plastic sheet, a multi-layer woven plastic sheet or a composite woven plastic sheet woven from plastic strips or plastic fibers is developed, although the woven structure has better structural strength than the aforementioned plastic sheet, but multiple layers. The material, production, processing and labor cost of the woven plastic sheet are high, and the thermoplastic process is difficult. It is easy to cause fiber breakage or misalignment, and wrinkles are likely to occur at the bend after molding. The pattern cannot be continuous, and the multi-layer woven plastic sheet makes the thermoplastic Problems such as limited depth have led to the high unit price of luggage made of multi-layer woven plastic sheets, which cannot be popularized.

In addition to the shortcomings of high metal materials and heavy weight after lamination, the hard-shell suitcase made of metal cannot produce the trunk in the sewing process to avoid the cost of expensive hot-pressing molds, and is affected by external impact. The type cannot be rebounded by itself and needs to be returned to the factory for repair, etc., which are difficult to overcome with metal materials.

In order to solve the current problems in the production of plastic or metal hard-shell luggage, if the structural strength is increased, the cost is increased, or the cost is lowered, but the structural strength is sacrificed, and the material selection is limited, the present invention provides a different material. a laminated composite material comprising a first layer structure, a center substrate and a second layer structure, wherein the first layer is configured as a woven fiber layer, a metal layer, a plastic layer or a combination thereof; The substrate is a thermoplastic plastic sheet; the second layer structure comprises a woven fiber layer and a plastic layer or a woven fiber layer and a knitted nonwoven fabric; the first layer structure and the woven fiber layer in the second layer structure are respectively A glue layer is coupled to the center substrate; and a difference in mechanical strength between the first layer configuration and the second layer configuration is less than 20%.

Wherein, the thickness of the central substrate is 0.2 to 3.0 mm; the thickness of the woven fiber layer or the knitted non-woven layer is 0.2 mm to 0.5 mm; the thickness of the plastic layer is 0.05 to 0.15 mm; and the thickness of the metal layer is 0.1 ~0.5mm.

The material of the center substrate comprises polyethylene terephthalate, polypropylene, polyethylene, nylon, polycarbonate or polymethyl methacrylate; the material of the woven fiber layer comprises polyethylene fiber and polypropylene. Fiber, carbon fiber, glass fiber, Kevlar fiber, nylon fiber or natural fiber; the plastic layer is made of polypropylene, nylon, polyurethane, thermoplastic polyurethane, polyethylene terephthalate, Surlyn plastic, Pebox plastic, Polycarbonate or polymethyl methacrylate; the material of the metal layer comprises aluminum, magnesium aluminum alloy, stainless steel, copper, chrome-plated copper or titanium alloy; and the material of the rubber layer comprises copolyolefins, copolyamines, and Polyester, thermoplastic polyurethane, polyolefin, polyamide, epoxy or polyester colloid.

Wherein, the adhesive layer penetrates into the fibers of the woven fiber layer, and accounts for one-third to one-half of the volume of the woven fiber layer.

Wherein a portion of the fibers of the knitted nonwoven fabric are wound or wound around a portion of the fibers of the woven fabric layer.

Wherein, the surface of the plastic layer of the first layer structure has a sublimation or printed text or pattern.

The present invention further provides a luggage case, an ice skate upper and a brace, which are made of the above-described different material laminated composite material.

As can be seen from the above description, the present invention has the following advantages:

1. The present invention penetrates a central substrate of a thermoplastic plastic material as a main structural filling layer and a supporting layer of a composite material of a different material to solve the disadvantages of the prior art plastic sheet structure having poor strength and strong impact resistance; The material of the center substrate is changed a lot, and the material of different materials can be used to adjust the required structural strength, rigidity and impact resistance, and the center substrate is not a woven structure, and the thickness can be arbitrarily adjusted, and the braid is layered relative to the existing one. The multi-layer woven plastic sheet material has lower processing cost, simpler thermoplastic process and more market competitiveness.

2. Since the first layer structure of the present invention is similar to the mechanical strength of the second layer structure, it is not easy to cause fiber breakage, misalignment, wrinkles at the bend, or the pattern cannot be continuous during subsequent processing, and the present invention The woven fiber layer is less than the existing multilayer woven plastic sheet having the same thickness or strength, and the thermoplastic depth is less affected.

3. The present invention utilizes a metal material as the outermost layer and laminates a metal substrate laminated composite material obtained by laminating a center substrate and a woven fiber layer, and the center substrate can be used as a support layer and a filling layer of the integral composite material, and the woven fiber layer can also be used. Providing good rigidity and strength, the metal composite material of the invention not only has better overall rigidity and structural strength than the existing metal laminated plate, but also achieves weight reduction effect. For example, aluminum alloy has a specific gravity of 2.7 g/cm ³ , and an aluminum plate with a thickness of 1 mm produces a weight of 2,700 g per square meter. However, the metal-based composite composite material of the present invention can be utilized 0.2. The mm-thick aluminum plate is matched with the 0.8mm fiber woven layer and the center substrate. With the same thickness of 1mm, the weight per square meter of the invention is only 1400g, which can reduce nearly half of the weight and maintain structural strength, rigidity and impact resistance. Sex does not decrease.

Further, the woven fiber layer and the center substrate can improve the shortcomings of the metal-clad hard-shell luggage of the prior art, which cannot be rebounded by the external force and then need to be returned to the factory for repair, and the metal of the present invention is different. The material laminated composite material can be processed by the sewing process, and the manufacturing process is more flexible.

4. The woven fiber layer of the present invention can be selected according to the use of different fiber materials, colors, patterns and weaving methods, and at the same time achieve the effect of aesthetics and increase the structural strength and rigidity of the overall composite material composite material. The woven fiber layer has a high specific surface area, and can be easily bonded to and adhered to other different materials through the glue/film and the pressing process.

5. The invention is obtained by laminating and laminating various materials such as a woven fiber layer, a plastic center substrate or a metal, and is combined with different materials between the plastic and the metal and different structures between the woven material and the plate to achieve the appearance of the finished product. The effect of pattern, thickness, rigidity and structural strength, and the flexibility of material and structural strength is high.

6. The woven fiber layer can make the invention not need to be formed by hot pressing die processing, but can directly form a three-dimensional shape by using a sewing technique, such as a trunk case, a bag, etc., thereby eliminating the expensive production cost of the hot press die, and the invention When the external force is impacted to cause a concave defect, the center substrate and the woven fiber layer allow the invention to rebound and restore the original shape, and the existing metal luggage can not be returned to the original shape and needs to be returned to the original factory. Repair problem.

Referring to FIG. 1, a different material laminated composite material 10a according to a first preferred embodiment of the present invention comprises a first layer structure 13a, a center substrate 11a and a second layer structure 15a stacked in sequence. The first layer structure 13a A glue layer A is respectively disposed between the second layer structure 15a and the center substrate 11a for bonding to each other.

The first layer structure 13a of the present embodiment is formed by laminating a woven fiber layer 131a and a plastic layer 132a. The woven fiber layer 131a can provide the appearance of the woven texture of the different material laminated composite material 10a. The woven structure has better and superior structural strength than the general plastic sheet. The thickness of the woven fiber layer 131a in the embodiment is preferably 0.2 mm to 0.5 mm, and the material of the woven fiber layer 131a is not limited, and may be made of polyethylene (PE), polypropylene (PP), poly It is woven from materials such as polyethylene terephthalate (PET), carbon fiber, glass fiber, Kevlar fiber, nylon fiber (Nylon), and natural fiber.

The plastic layer 132a is coated on the surface of the woven fiber layer 131a, and can serve as a protective layer of the woven fiber layer 131a or provide a glossy texture. Further, the surface of the plastic layer 132a can be sublimated or printed. Add decorative text or patterns. The thickness of the plastic layer 132a in the embodiment is preferably between 0.05 and 0.15 mm. The adhesive layer A may be adhered to the plastic layer 132a. The plastic layer 132a may be made of polypropylene. , PP), Nylon, Polyurethane (PU), Thermoplastic Urethane (TPU), Polyethylene Terephthalate (PET), Surlyn® Plastic (Commodity) Name) or Pebox® plastic (trade name), polycarbonate (Polycarbonate, PC) or polymethylmethacrylate (PMMA) plastic film.

The second layer structure 15a is overlapped with the first layer structure 13a by a woven fiber layer 151a and a plastic layer 152a, and the glue layer A may be disposed between the woven fiber layer 151a and the plastic layer 152a. The woven fiber layer 151a and the plastic layer 152a are made of the same material as the woven fiber layer 131a and the plastic layer 132a.

The central substrate 11a is one of the main technical features of the present invention, and is sandwiched between the first layer structure 13a and the second layer structure 15a, and can provide the integral composite structure filling and support of the different material laminated composite material 10a. The function of increasing the overall structural strength; the central substrate 11a has a lower cost advantage than the existing multi-layer woven plastic sheet which is laminated with fiber woven fabric. The center substrate 11a of the present invention is preferably made of a thermoplastic plastic, and has good recyclability in addition to thermoplastic processing characteristics, and has a thickness of 0.2 to 5.0 mm, and the material comprises polyethylene terephthalate (Polyethylene Terephthalate). , PET, referred to as polyester), Polypropylene (PP), Polyethylene (PE), Nylon, Polycarbonate (PC) or Polymethylmethacrylate (PMMA).

In the first layer structure 13a and the second layer structure 15a of the embodiment, the woven fiber layers 131a and 151a and the center substrate 11a are adhered to each other, and the material of the glue layer A used for adhesion is different according to the material of the adhesive interface. Contains copolyolefins, copolyamines, copolyesters or thermoplastic polyurethane adhesives.

The colloid A is mainly applied between the layers in the form of a transparent glue or a film, and the material is selected based on a material that follows the same or similar characteristics, for example, when the woven fiber layer 131a is made of polyethylene fiber, When the material of the center substrate 11a is a polyethylene plastic plate, the colloid A can select a copolyolefin colloid which is compatible with the polyethylene fiber and the polyethylene plastic plate, and can achieve good adhesion and subsequent effects.

In order to make the overall composite structure of the different material laminated composite material 10a, the stress of the first layer structure 13a and the second layer structure 15a bonded to both sides are balanced or lowered around the center substrate 11a; preferably, the The Compressive Strength or strength difference between the first layer construction 13a and the second layer construction 15a may be referred to as equilibrium between 0 and 20%. The so-called mechanical strength includes at least mechanical strength parameters such as bending strength, tensile strength and impact strength; when the stress between the first layer structure 13a and the second layer structure 15a is the same or similar, the subsequent processing can be reduced. The forming may cause problems such as warping, delamination, and texture compression of the inner layer, and the method of achieving stress balance between the first layer structure 13a and the second layer structure 15a may be through various layers of material selection, thickness, or woven fiber layer. The number of Dan (Denier, or Dan or Danny) is adjusted.

The first layer structure 13a and the second layer structure 15a are centered on the center substrate 11a to achieve a balance of stress, except that the first layer structure 13a and the second layer structure 15a are selected from the same material and thickness. In addition, if materials of different materials and thicknesses are to be used, the woven fiber layer 131a having a thickness of 0.2 mm and the plastic layer 132a having a thickness of 0.1 mm may be selected, for example, in the first layer structure 13a. The two-layer structure 15a can correspond to the woven fiber layer 151a having a thickness of 0.2 to 1300 mm and the plastic layer 132a having a thickness of 0.05 to 0.15 mm, and the first side of the center substrate 11a. The mechanical strength of the one-layer structure 13a and the second layer structure 15a can be balanced, so that the different-material laminated composite material 10a after heat pressing is flat, free from warping or wrinkling.

The woven fiber layer 131a, 151a and the rubber layer A of the present embodiment may be further combined in a semi-impregnation state. The so-called semi-impregnation means that the rubber layer A is infiltrated or impregnated into the woven fiber layers 131a, 151a. In the local fibers, the volume of the woven fiber layers 131a, 151a is about one-third to one-half, but the surface of the woven fiber layers 131a, 151a on the other side is not exposed or only A small amount is revealed. The method for achieving the semi-impregnation may be that the fiber woven layer 131a, 151a and the rubber layer A are superposed on each other, and the thickness or volume of the rubber layer A is adjusted to be smaller than the fiber woven layer 131a, 151a; By adjusting the hot pressing parameter, a relatively small amount of the adhesive layer A is only infiltrated or impregnated into the portion of the fiber woven layer 131a, 151a, and does not exceed or only a small amount of the other side surface is exposed to maintain the surface of the composite material of the different material. Clean, no glue or glue exposed.

In the first preferred embodiment of the present invention, the first layer structure 11a and the second layer structure 13a, in addition to the foregoing, the woven fiber layers 131a, 151a and the plastic layers 132a, 152a, please refer to Figure 2a - 2d, under the premise that the first layer structure 131a and the second layer structure 151a are in stress balance, the first layer structure 131a may also be only the woven fiber layer 131a (as shown in FIG. 2a and FIG. 2c) or The plastic layer 132a (as shown in FIG. 2b and FIG. 2d) is adhered to the center substrate 11a, and the second layer structure can simply adhere to the center substrate 11a only for the woven fiber layer 152a (as shown in FIGS. 2c and 2d). Not limited.

Referring to FIG. 2e, the second preferred embodiment of the present invention is substantially the same as the first preferred embodiment, except that the plastic layer 132a in the second layer structure 13a is replaced by a fiber non-woven fabric 153a. The partial fibers of the fiber non-woven fabric 153a and the local fibers of the woven fiber layer 131a are mutually entangled and fixed by a needle-punching method, and at this time, the rubber layer can be selectively applied between the fiber non-woven fabric 153 and the woven fiber layer 131a. A.

Referring to FIG. 3, a different material laminated composite material 10b according to a third preferred embodiment of the present invention has the same laminated structure as the first and second embodiments, and has a first layer structure 13b, a center substrate 11b, and a The second layer structure 15b is formed in a layered manner, and a layer B is adhered to each other, and the difference between the first embodiment and the second embodiment is that the first layer structure 13b is a metal material sheet. / ply layer, and the thickness is between 0.1 ~ 0.5mm.

The material of the first layer structure 13b comprises aluminum, magnesium aluminum alloy, stainless steel, copper, chrome-plated copper or titanium alloy; the second layer structure 15b is a woven fiber layer 131b, and the material comprises carbon fiber (glass fiber) and glass fiber (Glass). Fiber), Kevlar Fiber, Polyester Fiber, Nylon Fiber, or Natural Fiber; and the center substrate 11b is a thermoplastic plastic sheet containing poly(p-phenylene) Polyethylene terephthalate (PET), polypropylene (PP), polyethylene (Polyethylene, PE), nylon (Nylon), polycarbonate (Polycarbonate, PC) or polymethacrylic acid Polymethylmethacrylate (PMMA).

Since the first layer structure 13b of the embodiment is made of a metal material, and the center substrate 11b of the plastic material is not a compatible material, the adhesive layer B used for bonding between the two is preferably a polyolefin. Classes, polyamines, polyester colloids, can achieve better adhesion. The adhesive layer B used between the second layer structure 15b and the center substrate 11b may be the same as the above-mentioned embodiment 1 except that the materials of the polyolefin, the polyamide, and the polyester described above may be used. The same copolyolefin, copolyamine, copolyester or thermoplastic polyurethane adhesive is used, which also has good adhesion.

In order to achieve the stress balance between the first layer structure 13b of the metal material of the embodiment and the second layer structure 15b of the plastic or natural fiber material, centering on the center substrate 11b, when the first layer structure 13b is 0.2 mm When the aluminum plate is thin, the second layer structure 15b can select a woven fiber layer of 1300 to 1800 dan and a thickness of 0.2 to 0.5 mm, and the mechanical strength stress balance on both sides of the center substrate 11b can be achieved, so that after the hot pressing The different material laminated composite material 10b is flat, free from warping or wrinkles.

In the manufacturing method of the foregoing embodiments of the present invention, after the layers are stacked on each other, the hot pressing parameters are set according to the materials of the selected layers and the thickness of each layer, and then the laminated material is sent to the hot pressing table at a set temperature of 50 ° C, immediately. Heat to the set temperature, the temperature range is 150~178 °C, the pressure range is 14~20kg/cm ² , and after holding the temperature for 3~6 minutes, the hot press table is cooled to 50 °C, and the finished product is taken out.

In terms of application, the different material composite plate of the invention can be widely applied to products in various fields, such as a luggage case, a protective gear, an ice skate, a skate shoe, a notebook computer case and the like.

The above are only the preferred embodiments of the present invention, and are not intended to limit the scope of the claims of the present invention, and all other equivalent changes or modifications which are not departing from the spirit of the present invention should be included in the claims of the present invention. Within the scope.

10a, 10b‧‧‧Different material laminated composites
11a, 11b‧‧‧ center substrate
13a, 13b‧‧‧ first layer structure
15a, 15b‧‧‧Second layer structure
131a, 151a, 131b ‧‧‧woven fiber layer
132a, 152a‧‧‧ plastic layer
153a‧‧‧Fiber non-woven
20‧‧‧Luggage compartment
A, B‧‧ ‧ adhesive layer

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic view showing the layered structure of a first preferred embodiment of the present invention. 2a-2d are schematic cross-sectional views showing a first preferred embodiment of the present invention. 2e is a schematic cross-sectional view showing a second preferred embodiment of the present invention. Figure 3 is a schematic view showing the layered structure of a third preferred embodiment of the present invention.

10 a‧‧‧Different material laminated composites

11a‧‧‧Center substrate

131a, 151a‧‧‧woven fiber layer

132a, 152a‧‧‧ plastic layer

A‧‧‧ glue layer

Claims (9)

A different material laminated composite material, comprising a first layer structure, a center substrate and a second layer structure, wherein: the first layer is configured as a woven fiber layer, a metal layer, a plastic layer or a combination thereof The central substrate is a thermoplastic plastic sheet; the second layer structure comprises a woven fiber layer and a plastic layer or a woven fiber layer and a knitted nonwoven fabric; the first layer structure and the woven fiber in the second layer structure The layers are respectively connected to the center substrate by a glue layer; and the difference in mechanical strength between the first layer structure and the second layer structure is less than 20%. The material laminated composite material of claim 1, wherein: the central substrate has a thickness of 0.2 to 3.0 mm; the woven fiber layer or the knitted non-woven layer has a thickness of 0.2 mm to 0.5 mm; and the thickness of the plastic layer It is 0.05 to 0.15 mm; and the thickness of the metal layer is 0.1 to 0.5 mm. For example, the material laminated composite material of claim 1 or 2, wherein: the material of the center substrate comprises polyethylene terephthalate, polypropylene, polyethylene, nylon, polycarbonate or polymethacrylic acid. Methyl ester; the material of the woven fiber layer comprises polyethylene fiber, polypropylene fiber, polyethylene terephthalate fiber, carbon fiber, glass fiber, kewei fiber, nylon fiber or natural fiber; Including polypropylene, nylon, polyurethane, thermoplastic polyurethane, polyethylene terephthalate, Surlyn plastic, Pebox plastic, polycarbonate or polymethyl methacrylate; the metal layer is made of aluminum, magnesium alloy, Stainless steel, copper, chrome-plated copper or titanium alloy; and the material of the adhesive layer comprises copolyolefins, copolyamides, copolyesters, thermoplastic polyurethanes, polyolefins, polyamines, epoxy resins or poly Ester colloid. For example, in the material laminated composite material of claim 1 or 2, the adhesive layer penetrates into the fibers of the woven fiber layer, and accounts for one-third to one-half of the volume of the woven fiber layer. A portion of the material of the knitted nonwoven fabric is wound or wound around a part of the fibers of the woven fiber layer, as in the material laminated composite material of claim 1 or 2. For example, in the material-laminated composite material of the first aspect of the patent application, the surface of the plastic layer of the first layer structure has a sublimation or printed text or pattern. A trunk case which is made of a laminated material of different materials according to claims 1 to 6. The utility model relates to a skate upper, which is made by using a material laminated composite material of the first to sixth aspects of the patent application. A brace, which is made of a laminated material of different materials according to the first to sixth patent applications.