TW202208157A - Multi-layer plate having composite material - Google Patents

Abstract

A multi-layer plate having a composite material is described. The multi-layer plate having the composite material includes an aluminum-based thin sheet and a composite material layer. The aluminum-based thin sheet includes a first passivation layer, an aluminum-based metal layer, and a second passivation layer sequentially. The aluminum-based thin sheet includes an first surface and a second surface, which is opposite to the first surface. The first surface and the second surface are set with a plurality of micro holes, and a diameter of the micro holes in the second surface is ranging from 0.5[mu]m to 10[mu]m. The composite material layer includes a thermoplastic polymer and a fiber material. The composite material layer has a third surface and a fourth surface, which is opposite the third surface. The second surface is adjacent to or connected to the third surface, and at least one portion of the thermoplastic polymer fills into the macro holes in the second surface.

Description

Multilayer board with composite material

The present disclosure relates to a hybrid material fabrication technology, and more particularly, to a multi-layer board with a composite material and a fabrication method thereof.

Consumers' demand for 3C products is not only light and thin, but also pays more and more attention to the metal texture of the casing. For example, the materials of currently commercially available laptop casings can generally be divided into three categories, namely plastic, metal, and fiber composite materials. The metal shell is sturdy, elegant in appearance, and delicate in touch. Therefore, the demand for high-end notebook products is mainly metal texture, especially the texture of aluminum alloy with anodized color.

At present, the casings of thin and light notebooks are mostly made of aluminum alloy anodized materials. With the pursuit of thinner and lighter notebooks, the demand for materials that are lighter than aluminum alloy anodized shells and at the same time have a metallic feel has also increased.

One solution is to use materials that are lighter than aluminum alloys. Generally speaking, the density of aluminum alloy material is about 2.70 g/cm ³ . Materials lighter than aluminum alloys include magnesium alloys and carbon fiber composite materials, wherein the density of magnesium alloys is about 1.83g/cm ³ and the density of carbon fiber composite materials is about 1.55g/cm ³ , both of which can reduce the weight of the shell. However, magnesium alloy and carbon fiber composite materials can only be painted by spray painting, which is prone to problems such as fat edges or orange peel. In addition, the texture of magnesium alloy and carbon fiber composite material after painting is not as good as that of anodized aluminum alloy.

Another solution is to attach an aluminum alloy skin to the surface of the plastic structural member by gluing, so as to obtain a metallic shell. However, the strength of the plastic itself is low. In order to obtain the bending strength that meets the product specifications, the thickness must be increased, so the requirement of light and thin volume cannot be achieved.

A solution is to coat metal particles on the outer layer of the glass fiber composite material by cold spraying, so as to obtain a lightweight shell with a metallic texture. However, the pressure of cold spray can cause the glass fiber composite to deform. If it is replaced with carbon fiber composite materials, although the deformation caused by cold spraying can be suppressed, the cost will increase and it will not be competitive in the market.

One technology is to metallize the surface of the plastic material by vacuum vapor deposition, and then anodize the surface of the metallized plastic material part to make the appearance of the part more textured. However, such a technology is expensive due to vacuum coating. In addition, for large-sized or high-molecular materials, it is not suitable to form a metal film by such a deposition method.

Another mobile phone case manufacturing technology is to form an oxide layer on the surface of the metal part, wherein the oxide layer has tiny holes. The metal part is then immersed and corroded to make holes again, so that the holes made again are connected with the tiny holes in the previous oxide layer to form a double-layer three-dimensional space structure. Next, the resin is injected and injected into these double-layered holes, so that the resin and the oxide layer on the metal parts can achieve a mechanical locking effect, thereby increasing the bonding strength between the resin and different materials such as the metal parts. However, since the hole diameter is too small, the gas in the hole often cannot be discharged during non-injection processes such as sheet thermocompression bonding, which results in poor bonding between resin and metal parts, and is prone to delamination between dissimilar materials.

Therefore, one object of the present invention is to provide a multi-layer board with composite material and a manufacturing method thereof. The aluminum-based sheet and the composite material layer are laminated and hot-pressed to form a multi-layer board with composite material. By adjusting the lamination ratio of the aluminum-based sheet and the composite material layer, different multi-layer boards of light-weight and metallic-like composite materials can be successfully obtained.

Another object of the present invention is to provide a multi-layer board with composite material and a manufacturing method thereof, which can firstly generate microstructure holes with obvious acute angle morphology on the surface of the aluminum-based sheet by chemical etching. In this way, the laminated structure of the aluminum-based sheet and the composite material layer can be directly hot-pressed, so that the hot-pressed aluminum alloy sheet and the composite material layer can be firmly combined, without using an adhesive for the bonding between the aluminum-based sheet and the composite material layer. Dissimilar bonding.

Another object of the present invention is to provide a multi-layer board with composite material and a manufacturing method thereof. There is no adhesive between the aluminum-based sheet and the composite material layer, so that the multi-layer board can pass through the acid and alkali solution in the anodic treatment process. There will be no delamination phenomenon, which can effectively produce multi-layer boards with various metallic textures and light weight.

According to the above object of the present invention, a multi-layer board with composite material is proposed. The multi-layer board with composite material includes an aluminum-based sheet and a composite material layer. The aluminum-based sheet sequentially includes a first passivation layer, an aluminum-based metal layer, and a second passivation layer. The aluminum-based sheet includes a first surface and a second surface opposite to the first surface. A plurality of micro-holes are evenly distributed on the first surface and the second surface, and the diameter of the micro-holes on the second surface is 0.5 μm to 10 μm. The composite material layer contains thermoplastic polymer and fiber material. The composite material layer has a third surface and a fourth surface opposite the third surface. The second surface is adjacent to or connected to the third surface, and at least a part of the thermoplastic polymer is embedded in the micro-holes of the second surface.

According to an embodiment of the present invention, the diameter of the micro-holes on the first surface is 0.01 μm to 0.1 μm.

According to an embodiment of the present invention, the average roughness of the second surface is 1.5 μm to 3.5 μm.

According to an embodiment of the present invention, each of the above-mentioned micro-holes has an acute-angled shape.

According to an embodiment of the present invention, the thickness of the first passivation layer is greater than the thickness of the second passivation layer.

According to an embodiment of the present invention, the above-mentioned multilayer board with composite material further comprises a second aluminum-based sheet, wherein the second aluminum-based sheet is adjacent to or connected to the fourth surface.

According to the above purpose of the present invention, another method for manufacturing a multi-layer board with composite material is proposed. In this method, at least one aluminum alloy sheet is provided. A plurality of micro-holes are evenly distributed on the third surface and the second surface of each aluminum-based sheet which are opposite to each other. At least one composite material layer and the at least one aluminum-based sheet are alternately laminated to form a multi-layer board, wherein the number of composite material layers is less than or equal to the aluminum-based sheet. The multi-layer board is subjected to a hot pressing operation so that a portion of the composite material layer is embedded in the micro-cavities of the adjoining aluminum-based sheets. A passivation process in anodizing is performed on the multilayer board to form a first passivation layer and a first surface on the third surface.

According to an embodiment of the present invention, the above-mentioned provision of the aluminum-based sheet includes chemically etching the aluminum-based metal layer of the aluminum-based sheet, so that micro-holes with acute-angle morphology are formed in the third surface and the second surface of the aluminum-based sheet .

According to an embodiment of the present invention, the above-mentioned provision of the aluminum-based sheet includes performing a hot rolling thinning process on the aluminum-based metal sheet to obtain an aluminum-based metal layer of the aluminum-based sheet.

According to an embodiment of the present invention, the above-mentioned hot rolling thinning process includes making the surface of the aluminum-based metal layer of the aluminum alloy sheet have a preferred orientation of (110) plane grains.

In view of the bottleneck in the development of materials with metallic texture in the prior art, the embodiments of the present invention provide a multi-layer board with a composite material and a manufacturing method thereof, which utilizes aluminum-based sheets to be laminated to thermoplastic fiber composite materials to form a composite material. Multilayer boards with composite materials. This multi-layer board is lighter than aluminum alloy and has a metallic texture, which is suitable for high-quality shell materials of 3C products. In addition, the multi-layer board can be adjusted to achieve different degrees of light weight by adjusting the lamination ratio, and the aluminum alloy sheet of the outer layer can be anodized to obtain the desired metallic texture after color development.

Please refer to FIG. 1 to FIG. 3 , wherein FIG. 1 is a three-dimensional schematic diagram showing a multilayer board with composite material according to the first embodiment of the present invention, and FIG. 2 is a partial enlarged cross-sectional schematic diagram showing the multilayer board of FIG. 1 , 3 is a scanning electron microscope image of an aluminum alloy sheet of a multi-layered plate with composite materials according to the first embodiment of the present invention. The multilayer board with composite material 100 a of this embodiment includes an aluminum-based sheet 110 and a composite material layer 120 . The aluminum-based sheet 110 includes a first passivation layer 112 , an aluminum-based metal layer 114 and a second passivation layer 116 in sequence. The composite material layer 120 includes a thermoplastic polymer 122 and a fiber material 124 dispersed in the thermoplastic polymer 122 . In this embodiment, the number of the aluminum-based sheet 110 and the number of the composite material layer 120 is the same, and both are one. As shown in FIG. 1 , the aluminum-based sheet 110 and the composite material layer 120 are stacked on each other. The aluminum-based sheet 110 has a first surface 110a and a second surface 110b opposite to each other. In one embodiment, the aluminum-based metal layer 114 has a third surface 114a and a fourth surface 114b. In addition, the third surface 114a, the fourth surface 114b, or both have a preferred orientation of (110) plane grains. In one embodiment, the third surface 114a, the fourth surface 114b, or both can be demonstrated by X-ray diffraction analysis to have a preferred orientation of the grains of the (110) plane. In one embodiment, the intensity of the X-ray diffraction analysis of the (110) plane on the surface of the aluminum-based metal layer 114 is greater than that of the (100) plane and the (111) plane.

In one embodiment, the first surface 110a and the second surface 110b of the aluminum-based sheet 110 are respectively provided with a plurality of first micro-holes 112a and second micro-holes 116a, as shown in FIG. 2 . In one embodiment, the average diameter of the first micro-holes 112a is smaller than the average diameter of the second micro-holes 116a. In one embodiment, the diameter of each of the first micro-holes 112a may be about 0.01 μm to about 0.1 μm. As shown in FIG. 3 , in one embodiment, the diameter of each second micro-hole 116a may be about 0.5 μm to about 10 μm. In another embodiment, the diameter of each second micro-hole 116a may be about 1 μm to about 4 μm. When the diameter of the second micro-holes 116a is greater than 0.5 μm, the thermoplastic polymer 122 in the composite material layer 120 can fully fill the second micro-holes 116a during the hot pressing process of the aluminum-based sheet 110 and the composite material layer 120 Therefore, the aluminum-based sheet 110 and the composite material layer 120 have good adhesion and air tightness. In addition, in one embodiment, the average roughness (Ra) of the first surface 110a of the aluminum-based sheet 110 may be about 0.1 μm to about 0.5 μm and the average roughness of the second surface 110b may be about 1.5 μm to about 3.5 μm μm. In some embodiments, the shapes of the second micro-holes 116a are mostly rectangular, rectangular, or polygonal acute-angled shapes, rather than arc-shaped shapes.

Referring to FIG. 2 , the thickness of the first passivation layer 112 is greater than the thickness of the second passivation film 116 .

Under the close bonding between the second passivation layer 116 and the thermoplastic polymer 122 , the bonding surface between the aluminum-based sheet 110 and the composite material layer 120 can resist the erosion of the acid and alkali solution of the anodization. In this way, anodizing can be performed on the multilayer board 100a with the composite material, so that the surface of the multilayer board 100a with the composite material has a metallic texture after the anodic treatment and color development. In some exemplary examples, after the multi-layer board 100a with the composite material is subjected to the salt spray test for 1000 hours, the surface layer can reach a 5B rating in the 100 grid test.

The composite material layer 120 has a first surface 120a and a second surface 120b opposite to each other. The first surface 120a of the composite material layer 120 is pressed against the second surface 110b of the aluminum-based sheet 110 , and a part of the thermoplastic polymer 122 of the composite material layer 120 is embedded in the second microstructure of the adjacent second surface 110b of the aluminum-based sheet 110 . in the hole 116a. Since the second micro-holes 116a of the aluminum-based sheet 110 have an acute-angled shape, the composite material layer 120 and the aluminum-based sheet 110 have good adhesion and air tightness.

The fiber material 124 in the composite material layer 120 may be, for example, carbon fiber or glass fiber. The thermoplastic polymer 122 can be, for example, polypropylene (PP), polyvinyl chloride (PVC), polycarbonate (PC), polyamide resin (PA), polyether ether ketone (PEEK), thermoplastic polyimide (TPI) ), or polyphenylene sulfide (PPS).

As shown in FIG. 1 , in some embodiments, the first passivation layer 112 and the second passivation layer 116 of the multilayer board 100 a with the composite material may be oxide layers of the material of the aluminum-based metal layer 114 , such as aluminum oxide (Al ₂ O ₃ ) layer. In one embodiment, the first passivation layer 112 is anodic passivated and thus has a different thickness and pore size than the second passivation layer 116 .

Please refer to FIG. 4 , which is a three-dimensional schematic view of a multilayer board with composite materials according to a second embodiment of the present invention. The structure of the multi-layer board 100b with composite material of this embodiment is substantially the same as that of the multi-layer board 100a with composite material in FIG. Therefore, the number of the aluminum-based sheets 110 and 140 of the multilayer board 100b with composite material is one more than the number of the composite material layer 120 .

The aluminum-based sheet 140 includes a third passivation layer 142 , an aluminum-based metal layer 144 , and a fourth passivation layer 146 in sequence. The aluminum-based sheet 140 has opposite first surfaces 140a and second surfaces 140b. The composition of the aluminum-based metal layer 144 may be the same as that of the aluminum-based metal layer 114 , or may be different from the composition of the aluminum-based metal layer 114 . In one embodiment, the aluminum-based metal layer 144 has a third surface 144a and a fourth surface 144b. In addition, the third surface 144a and/or the fourth surface 144b have a preferred orientation of (110) plane grains. In one embodiment, the intensity of the X-ray diffraction analysis of the (110) plane on the surface of the aluminum-based metal layer 144 is greater than that of the (100) plane and the (111) plane.

The first surface 140a and the second surface 140b of the aluminum-based sheet 140 are respectively provided with many micro-holes (not shown in the figure). The type and size of the micro-holes disposed on the first surface 140a of the aluminum-based sheet 140 and the micro-holes on the second surface 140b are the second micro-holes 116a and the first micro-holes 112a as shown in FIG. 2 , respectively. Since the types and sizes of the first micro-holes 112 a and the second micro-holes 116 a have been described in detail above, the micro-holes on the first surface 140 a and the second surface 140 b of the aluminum-based sheet 140 are not described here. Detailed description of type and size. In addition, in one embodiment, the average roughness of the first surface 140a of the aluminum-based sheet 140 may be about 1.5 μm to about 3.5 μm, and the average roughness of the second surface 140b may be about 0.1 μm to about 0.5 μm.

In addition, as shown in FIG. 4 , the thickness of the third passivation layer 142 is smaller than the thickness of the fourth passivation film 146 .

Under the close bonding between the thermoplastic polymer 122 and the second passivation layer 116 and the third passivation layer 142 , the joint surfaces between the aluminum-based sheets 110 and 140 and the composite material layer 120 can resist the erosion of the acid and alkali solution of anodization. In this way, the multi-layer board 100b with the composite material can be anodized, so that the surface of the multi-layer board 100b with the composite material has a metallic texture after the anodic treatment and color development.

In the multilayer board 100b with the composite material, the aluminum-based sheets 110 and 140 and the composite material layer 120 are alternately laminated, so that the composite material layer 120 is sandwiched between the aluminum-based sheets 110 and 140 . The first surface 120a and the second surface 120b of the composite material layer 120 are laminated with the second surface 110b of the aluminum-based sheet 110 and the first surface 140a of the aluminum-based sheet 140, respectively. In addition, the aluminum-based sheets 110 and 140 are respectively the two outer layers of the multilayer board 100b with the composite material.

A part of the thermoplastic polymer 122 of the composite material layer 120 is embedded in the second micro-holes 116a of the second surface 110b of the adjacent aluminum-based sheet 110, and another part of the thermoplastic polymer 122 of the composite material layer 120 is embedded in the adjacent aluminum-based sheet 140 in the micro-holes of the first surface 140a. Since the second micro-holes 116a of the aluminum-based sheet 110 and the micro-holes in the first surface 140a of the aluminum-based sheet 140 both have acute-angle morphology, the composite material layer 120 and the aluminum-based sheet 110 and the aluminum-based sheet All of the sheets 140 have good adhesion and air tightness.

As shown in FIG. 4 , in one embodiment, the third passivation layer 142 and the fourth passivation layer 146 of the aluminum-based sheet 140 may be oxide layers of the material of the aluminum-based metal layer 144 , such as aluminum oxide layers. In one embodiment, the fourth passivation layer 146 is anodic passivated and thus has a different thickness and pore size than the third passivation layer 142 .

Please refer to FIG. 5 , which is a three-dimensional schematic view of a multilayer board with composite materials according to a third embodiment of the present invention. The structure of the multi-layer board 100c with composite material of this embodiment is substantially the same as that of the composite material 100b with metallic texture in FIG. Therefore, the number of aluminum-based sheets 110 and 140 of the multilayer board 100c with composite material is the same as the number of composite material layers 120 and 150 .

The composite material layer 150 includes a thermoplastic polymer 152 and a fiber material 154 dispersed in the thermoplastic polymer 152 . The composition of the thermoplastic polymer 152 may be the same as that of the thermoplastic polymer 122 , or may be different from the composition of the thermoplastic polymer 122 . The composition of fibrous material 154 may be the same as or different from the composition of fibrous material 124 . The composite material layer 150 has an opposite first surface 150a and a second surface 150b.

Under the close bonding of the thermoplastic polymer 122 and the second passivation layer 116 and the third passivation layer 116, and the thermoplastic polymer 152 and the fourth passivation layer 146, the aluminum-based sheets 110 and 140 and the composite material layers 120 and 150 are formed between the The joint surface can resist the corrosion of acid and alkali solution of anodization. In this way, the multi-layer board 100c with the composite material can be anodized, so that the surface of the multi-layer board 100c with the composite material has a metallic texture after the anodic treatment and color development.

In the multilayer board 100c with the composite material, the aluminum-based sheets 110 and 140 and the composite material layers 120 and 150 are alternately laminated, so the aluminum alloy sheet 110 in the aluminum-based sheets 110 and 140 is an outer layer of the multilayer board with the composite material 100c . The first surface 150a of the composite material layer 150 and the second surface 140b of the aluminum-based sheet 140 are pressed together, and a part of the thermoplastic polymer 152 of the composite material layer 150 is embedded in the micro-holes of the second surface 140b of the adjacent aluminum-based sheet 140 . Since the micro-holes in the second surface 140b of the aluminum-based sheet 140 have an acute-angle morphology, the composite material layer 150 and the aluminum-based sheet 140 have good adhesion and air tightness.

Please refer to FIG. 6 , which is a three-dimensional schematic view of a multilayer board with composite materials according to a fourth embodiment of the present invention. The structure of the multi-layer board 100d with composite material of this embodiment is substantially the same as that of the multi-layer board 100c with composite material in FIG. 160. Therefore, the number of the aluminum-based sheets 110 , 140 , and 160 of the multilayer board 100 d with composite material is one more than the number of the composite material layers 120 and 150 .

The aluminum-based sheet 160 includes a fifth passivation layer 162 , an aluminum-based metal layer 164 , and a sixth passivation layer 166 in sequence. The aluminum-based sheet 160 has a first surface 160a and a second surface 160b opposite to each other. The composition of the aluminum-based metal layer 164 may be the same as the composition of the aluminum-based metal layers 114 and 144 , or may be different from the composition of the aluminum-based metal layers 114 and 144 , or may be the same as the composition of one of the aluminum-based metal layers 114 and 144 Unlike the other. In one embodiment, the aluminum-based metal layer 164 has a third surface 164a and a fourth surface 164b. In addition, the third surface 164a and/or the fourth surface 164b have a preferred orientation of (110) plane grains. In one embodiment, the intensity of the X-ray diffraction analysis of the (110) plane on the surface of the aluminum-based metal layer 164 is greater than that of the (100) plane and the (111) plane.

The first surface 160a and the second surface 160 of the aluminum-based sheet 160 are provided with many micro-holes (not shown in the figure). The type and size of the micro-holes disposed on the first surface 160 a of the aluminum-based sheet 160 and the micro-holes on the second surface 160 b are the second micro-holes 116 a and the first micro-holes 112 a as shown in FIG. 2 , respectively. Therefore, the types and sizes of the micro-holes on the first surface 160 a and the second surface 160 b of the aluminum-based sheet 160 are not described in detail here. In addition, in one embodiment, the average roughness of the first surface 160a of the aluminum foil 160 may be about 1.5 μm to about 3.5 μm, and the average roughness of the second surface 140b may be about 0.1 μm to about 0.5 μm.

In addition, as shown in FIG. 6 , the thickness of the fifth passivation layer 162 is smaller than the thickness of the sixth passivation film 166 .

Under the close bonding of the thermoplastic polymer 122 with the second passivation layer 116 and the third passivation layer 142, and the thermoplastic polymer 152 with the fourth passivation layer 146 and the fifth passivation layer 162, the aluminum-based sheets 110, 140, and 160 and The joint surface between the composite material layers 120 and 150 can resist the corrosion of the acid and alkali solution of the anodization. In this way, the anodic treatment can be performed on the multilayer board 100d with the composite material, so that the surface of the multilayer board 100d with the composite material has a metallic texture after the anodic treatment and color development.

In the multilayer board with composite material 100d, the aluminum-based sheets 110, 140, and 160 and the composite material layers 120 and 150 are alternately stacked, so that the composite material layers 120 and 150 are sandwiched between the aluminum-based sheets 110 and 140, respectively, and Between the aluminum-based sheets 140 and 160 . The second surface 150b of the composite material layer 150 and the first surface 160a of the aluminum-based sheet 160 are laminated. In addition, the aluminum-based sheets 110 and 160 are respectively the two outer layers of the multilayer board 100d with the composite material.

Another part of the thermoplastic polymer 152 of the composite material layer 150 is embedded in the micro-holes of the first surface 160 a of the adjacent aluminum-based sheet 160 . Since the micro-holes of the aluminum-based sheet 160 have an acute-angle morphology, the composite material layer 150 and the aluminum-based sheet 160 have good bonding and air tightness.

As shown in FIG. 6 , in one embodiment, the fifth passivation layer 162 and the sixth passivation layer 166 of the aluminum-based sheet 160 may be oxide layers of the material of the aluminum-based metal layer 164 , such as aluminum oxide layers. In one embodiment, the sixth passivation layer 166 is anodic passivated and thus has a different thickness and pore size than the fifth passivation layer 162 .

According to the above-mentioned embodiments, the present invention can achieve different weight reduction by adjusting the lamination ratio of the aluminum-based sheet and the composite material layer in the multilayer board with the composite material. For example, the multi-layer board with the composite material of the present invention can be at least 15% lighter than the aluminum alloy. Combining the above-mentioned embodiments, the multi-layer board with composite material of the present invention comprises at least one aluminum-based sheet and at least one composite material layer alternately stacked, and the number of composite material layers can be equal to or less than the number of aluminum-based sheets.

Please refer to FIG. 7 , which is a flowchart illustrating a method for manufacturing a multi-layer board with a composite material according to an embodiment of the present invention. When fabricating a multi-layer board with composite materials, step 200 may be performed first to provide at least one aluminum-based sheet, such as the aluminum-based sheet 110 in FIG. 1 , or the aluminum-based sheets 110 and 140 in FIG. 4 and FIG. Aluminum based sheets 110 , 140 , and 160 . In some examples, when the aluminum-based sheet is provided, the aluminum-based metal sheet may be subjected to a hot rolling thinning process to obtain an aluminum-based metal layer of a desired thickness. In one embodiment, when the aluminum-based metal sheet is subjected to hot rolling and thinning treatment, the surface of the formed aluminum-based metal layer can have the preferred orientation of the grains of the (110) plane. For example, the temperature during the hot rolling thinning process can be controlled at about 275°C.

In one embodiment, when the aluminum-based sheet is provided, after the aluminum-based metal layer is formed, a chemical etching operation may be performed on the aluminum-based metal layer to etch the aluminum-based metal layer, and an acute angle is formed in the surface of the aluminum-based metal layer. Morphology of micropores. The inventors found that an aluminum-based metal layer with a grain-preferred orientation of (110) planes on the surface can produce microstructured pores with obvious sharp-angle topography after chemical etching. The shapes of these micro-holes are mostly rectangular, rectangular, or polygonal acute-angled shapes, rather than arc-shaped shapes. In one embodiment, the pore size of each micro-hole may be about 0.5 μm to about 10 μm. In another embodiment, the pore size of each micro-hole may be about 1 μm to about 4 μm. In addition, the average roughness of the surface of the aluminum-based metal layer may be, for example, about 1.5 μm to about 3.5 μm.

The inventors also found that the grains with the (110) plane on the surface of the aluminum-based metal layer preferably have a lower elastic energy, so that the surface of the aluminum-based metal layer is likely to quickly generate a passivation film. Therefore, in one embodiment, when the aluminum-based sheet is provided, after the thinning of the aluminum-based metal layer is completed, a passivation layer can be formed to cover the surface of the aluminum-based metal layer, respectively. These passivation layers may be oxide layers of the material of the aluminum-based metal layer, such as aluminum oxide layers. The passivation layer can protect the aluminum-based metal layer to prevent the aluminum-based metal layer from being corroded by acid and alkali solutions.

After the aluminum-based sheet is provided, step 210 may be performed to provide at least one composite material layer, such as the composite material layer 120 in FIGS. 1 and 4 , or the composite material layers 120 and 150 in FIGS. 5 and 6 . The composite material layer and the aluminum-based sheet are alternately laminated to form a multi-layer board. In this embodiment, the steps of providing the aluminum-based sheet and the composite material layer can be adjusted, and the composite material layer can also be provided first, or provided simultaneously. The number of composite layers may be equal to or less than the number of aluminum-based flakes. In the multilayer board, when the number of aluminum-based sheets is multiple, one or two outer layers of the two opposite outer layers of the multilayer board correspond to one or two of these aluminum-based sheets. That is, the aluminum-based sheet is at least one outer layer of the multi-layer board, so as to provide the multi-layer board with a metallic surface. The compositions and changes of these composite material layers are as described in the above-mentioned embodiments, and will not be repeated here.

Next, step 220 can be performed to perform a hot pressing operation on the multi-layer board by using, for example, a hot-pressing machine, and thermo-compression bonding the cross-stacked multi-layer boards into a board to substantially complete a multi-layer board with a composite material, such as the above-mentioned one with a composite material. Fabrication of multilayer boards 100a to 100d. In the hot pressing operation, after the thermoplastic polymer in the composite material layer is heated and pressurized by a hot press, a part of the thermoplastic polymer can flow into the micro-holes on the surface of the aluminum-based sheet, so that a part of each thermoplastic polymer Embedded in the micro-holes of the adjacent aluminum-based sheets. Since the surface of the aluminum-based sheet is chemically treated with micro-holes with acute-angle morphology, the hot-pressing operation can cause the aluminum-based sheet and the thermoplastic polymer to have an anchoring effect, directly bond and lock, and make the multi-layer composite material. The board has excellent bonding force and air tightness, which can greatly improve the mechanical properties and reliability of the multi-layer board with composite materials. Therefore, in this embodiment, the dissimilar material bonding of the large-area aluminum-based sheet and the composite material layer can be performed without using an adhesive.

In some examples, by adjusting the stacking structure of the aluminum-based sheet and the composite material layer in the multilayer board with composite material, the flexural strength of the multilayer board with composite material can range from about 230 MPa to about 550 MPa, and the density is about 1.95 g /cm ³ to about 2.35 g/cm ³ , which is of great industrial value. The multi-layer boards with composite materials of each embodiment can be used as the shell of the lightweight 3C product, and the weight can be more than 15% lighter than that of the aluminum alloy.

After that, step 230 may be performed. Taking the structure shown in FIG. 2 as an example, an anode treatment passivation process is performed on the aluminum-based sheet 110 that has been overlapped with the composite material layer 120 to form the first passivation layer 112 . Since the aluminum-based sheet and the composite material layer have good adhesion and air tightness, and the surface of the aluminum-based sheet is covered with a passivation layer, the multilayer board with the composite material can be cured by the acid-base solution in the anodic treatment process. No delamination occurs. Thereby, the multi-layer board with the composite material can be further decorated by anodizing treatment and the subsequent color development process, so that the appearance color of the multi-layer board with the composite material is more diverse. Through the method of metal texture color development in the anodic treatment, the appearance painting method of the conventional carbon fiber composite material and magnesium alloy has advantages in texture, and there is no problem of volatile organic compound (VOC) pollution.

The following uses the experimental results of various embodiments and comparative examples to describe the technical content and effects of the embodiments of the present invention in more detail, but it is not intended to limit the present invention.

The material compositions and properties of the multilayer boards with composite materials of the examples and the comparative examples are listed in Table 1 below. Table 1 illustrate Example Comparative example 1 2 3 4 5 6 1 Material composition structure A B C D E F - Aluminum type M1/M3 M2/M3 M4/M5 M1 M2 M6 5052 fiber type G G G G G G - Aluminum sheet thickness 0.3 /0.15 0.3 /0.15 0.15 /0.1 0.3 0.3 0.2 0.8 Fiber thickness 0.2 0.2 0.2 0.4 0.4 0.4 - Structural thickness 1.1 1.1 0.8 1.0 1.0 0.8 0.8 characteristic density 2.331 2.287 2.090 2.253 2.309 2.130 2.75 Flexural strength 336 251 270 544 262 230 275 Flexural modulus 42 41 38 79 63 38 40

The unit of aluminum sheet thickness, fiber thickness and structural thickness in Table 1 above is mm, the unit of density is g/cm ³ , the unit of flexural strength is MPa, and the unit of flexural modulus is GPa. Next, the aluminum type M1 is an aluminum alloy sheet of type CA01 and a thickness of 0.3 mm, the aluminum type M2 is an aluminum alloy sheet of a type of 1050 and a thickness of 0.3 mm, the aluminum type M3 is an aluminum alloy sheet of a type of 1100 and a thickness of 0.15 mm, and the aluminum type M4 It is an aluminum alloy sheet of type 1050 and a thickness of 0.15 mm, the aluminum type M5 is an aluminum alloy sheet of a type of 5052 and a thickness of 0.1 mm, and the aluminum type M6 is an aluminum alloy sheet of a type of 1050 and a thickness of 0.2 mm. The fiber type G is glass fiber reinforced thermoplastic (GFRTP) with a thickness of 0.2 mm, wherein the thermoplastic polymer is polycarbonate. In addition, the structure A is the M1/G/M3/G/M1 stack structure, the structure B is the M2/G/M3/G/M2 stack structure, the structure C is the M4/G/M5/G/M4 stack structure, The structure D is the M1/2G/M1 stack structure, the structure E is the M2/2G/M2 stack structure, and the structure F is the M6/2G/M6 stack structure.

From Table 1 above, it can be seen that the multi-layer board with composite material of the embodiment of the present invention can effectively reduce the material density and achieve the effect of light weight while maintaining the structural strength equivalent to the aluminum alloy of the comparative example.

The reliability of the multilayer board with the composite material of Example 3 was verified. The salt spray test conditions of Example 3 are listed in Table 2 below. Table 2 Test room temperature (℃) Saturated cylinder temperature (℃) Laboratory relative humidity (%) Falling fog volume (mL/h) Compressed air pressure (kg/cm ² ) Specific gravity of brine (g/cm ³ ) pH (PH) 35 ±2 47 ±2 96 ~98 1.1 ~1.9 0.9 ~1.1 1.029 ~1.037 6.5 ~7.2

After the multi-layer board with composite material of Example 3 was subjected to the salt spray test under the conditions of the salt spray test in Table 2 above, no corrosion and anodic treatment peeling were found. In addition, after the salt spray test of the multi-layer board with the composite material of Example 3, the surface layer was rated as 5B after the 100-grid test, and the anodized treatment showed good reliability.

It can be seen from the above-mentioned embodiments that one of the advantages of the present invention is that in the embodiment of the present invention, the aluminum-based sheet and the composite material layer are laminated and hot-pressed to form a multi-layer board with a composite material. The lamination ratio of the thin sheet and the composite material layer can smoothly obtain the multi-layer boards of different lightweight and metal-like composite materials.

As can be seen from the above-mentioned embodiments, another advantage of the present invention is that the embodiments of the present invention can firstly generate microstructured pores with obvious acute-angle morphology on the surface of the aluminum-based sheet by chemical etching. In this way, the laminated structure of the aluminum-based sheet and the composite material layer can be directly hot-pressed, so that the hot-pressed aluminum-based sheet and the composite material layer can be firmly combined without using an adhesive for the bonding between the aluminum-based sheet and the composite material layer. Dissimilar bonding.

It can be seen from the above-mentioned embodiments that another advantage of the present invention is that there is no adhesive between the aluminum-based sheet and the composite material layer of the multi-layer board with composite material of the present invention, so the multi-layer board can pass the acid and alkali in the anodic treatment process. liquid, without the phenomenon of delamination, and can effectively produce multi-layer boards with a variety of metal textures and light weight.

Although the present invention has been disclosed as above with examples, it is not intended to limit the present invention. Anyone with ordinary knowledge in this technical field can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention should be determined by the scope of the appended patent application.

100a: Multilayer boards with composite materials 100b: Multilayer board with composite material 100c: Multilayer board with composite material 100d: Multilayer board with composite material 110: Aluminum base sheet 110a: First surface 110b: Second surface 112: the first passivation layer 112a: the first micro-hole 114: Aluminum base metal layer 114a: Third surface 114b: Fourth surface 116: the second passivation layer 116a: second micro-hole 120: Composite layer 120a: first surface 120b: Second surface 122: Thermoplastic polymer 124: Fiber Material 140: Aluminum base sheet 140a: first surface 140b: Second surface 142: the third passivation layer 144: Aluminum base metal layer 144a: Third surface 144b: Fourth surface 146: Fourth passivation layer 150: Composite Layer 150a: First surface 150b: Second surface 152: Thermoplastic polymer 154: Fiber Material 160: Aluminum base sheet 160a: First surface 160b: Second Surface 162: Fifth passivation layer 164: Aluminum base metal layer 164a: Third surface 164b: Fourth surface 166: sixth passivation layer 200: Steps 210: Steps 220: Steps 230: Steps

In order to make the above and other objects, features, advantages and embodiments of the present invention more clearly understood, the accompanying drawings are described as follows: [FIG. 1] is a three-dimensional schematic diagram showing a multilayer board with composite material according to the first embodiment of the present invention; [Fig. 2] is a partial enlarged cross-sectional schematic diagram showing the multilayer board of Fig. 1; [ Fig. 3 ] is a scanning electron microscope image of a multilayer board with composite material according to the first embodiment of the present invention; [ Fig. 4 ] is a perspective view showing a multi-layer board with a composite material according to a second embodiment of the present invention; [ Fig. 5 ] is a perspective view showing a multi-layer board with a composite material according to a third embodiment of the present invention; [ Fig. 6 ] is a perspective view showing a multi-layer board with a composite material according to a fourth embodiment of the present invention; and [ FIG. 7 ] is a flow chart illustrating a method for manufacturing a multi-layer board with a composite material according to an embodiment of the present invention.

Domestic storage information (please note in the order of storage institution, date and number) without Foreign deposit information (please note in the order of deposit country, institution, date and number) without

100a: Multilayer boards with composite materials

110: Aluminum base sheet

110a: First surface

110b: Second surface

112: the first passivation layer

112a: the first micro-hole

114: Aluminum base metal layer

114a: Third surface

114b: Fourth surface

116: the second passivation layer

116a: second micro-hole

120: Composite layer

120a: first surface

120b: Second surface

122: Thermoplastic polymers

124: Fiber Material

Claims (10)

A multi-layer board with composite material, comprising: An aluminum-based sheet including a first passivation layer, an aluminum-based metal layer and a second passivation layer in sequence, and the aluminum-based sheet includes a first surface and a second surface opposite to the first surface, wherein the A plurality of micro-holes are evenly distributed on the first surface and the second surface, the average pore size of the micro-holes on the first surface is smaller than the average pore size of the micro-holes on the second surface, and the micro-holes on the second surface The pore diameter is 0.5 μm to 10 μm, wherein the first surface is an outer surface of the multi-layer board with the composite material; and A composite material layer comprising a thermoplastic polymer and a fiber material, and the composite material layer has a third surface and a fourth surface opposite to the third surface, wherein the second surface is adjacent to the third surface or are connected, and at least a part of the thermoplastic polymer is embedded in the micro-holes of the second surface. The multi-layer board with composite material according to claim 1, wherein the diameter of the micro-holes on the first surface is 0.01 μm to 0.1 μm. The multilayer board with composite material according to claim 1, wherein the average roughness of the second surface is 1.5 μm to 3.5 μm. The multi-layer board with composite material as claimed in claim 1, wherein each of the micro-holes has an acute-angle shape. The multilayer board with composite material as claimed in claim 1, wherein the thickness of the first passivation layer is greater than the thickness of the second passivation layer. The multilayer board with composite material as claimed in claim 1, further comprising a second aluminum-based sheet, wherein the second aluminum-based sheet is adjacent to or connected to the fourth surface. The multilayer board with composite material as claimed in claim 1, wherein the surface of the aluminum-based metal layer has a (110) plane grain preferred orientation. A multi-layer board with composite material, comprising: An aluminum-based sheet including a first passivation layer, an aluminum-based metal layer and a second passivation layer in sequence, and the aluminum-based sheet includes a first surface and a second surface opposite to the first surface, wherein the A plurality of micro-holes are evenly distributed on the first surface and the second surface, the average pore size of the micro-holes on the first surface is smaller than the average pore size of the micro-holes on the second surface, and the surface of the aluminum-based metal layer has A (110) plane grain preferred orientation, wherein the first surface is an outer surface of the multilayer board with composite material; and A composite material layer comprising a thermoplastic polymer and a fiber material, and the composite material layer has a third surface and a fourth surface opposite to the third surface, wherein the second surface is adjacent to the third surface or are connected, and at least a part of the thermoplastic polymer is embedded in the micro-holes of the second surface. The multilayer board with composite material as claimed in claim 8, wherein the thickness of the first passivation layer is greater than the thickness of the second passivation layer. The multilayer board with composite material as claimed in claim 8, wherein the pore diameters of the micropores on the first surface are 0.01 μm to 0.1 μm and the pore diameters of the micropores on the second surface are 0.5 μm to 10 μm.

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