TWI482695B - Method for manufacturing forged carbon fiber product, protecting casing, and casing of electronic device - Google Patents

Description

Method for manufacturing forged carbon fiber product, protective casing and electronic device housing

The present invention relates to a method of making, and more particularly to a method of making a forged carbon fiber article.

In order to increase the service life of the electronic device, the outer casing or the protective casing of the electronic device requires the rigidity of the material to meet at least a certain strength, and whether it is made of plastic material or metal material, it must reach a considerable thickness to meet the required thickness. strength.

In the process, the plastic shell or the plastic protective shell is mostly formed by injection molding, so that all the structures can be formed by one injection molding, and then the decorative treatment such as painting is performed on the surface of the finished product according to the need. Therefore, even if the manufacturing process of the plastic case and the plastic protective case is relatively simple, the strength of the finished product is insufficient, and it is easy to wear and break.

If the outer casing or the protective casing is made of a metal material, it is necessary to form the respective members separately, and then form the outer casing or the protective casing by assembling. In addition to its complicated manufacturing process and long production cycle, its production cost is high, and the outer casing or protective casing has a considerable weight, so it is difficult to meet the requirements of lightweight.

Therefore, according to the existing materials, neither plastic nor metal can satisfy the demand for lightweight of portable electronic devices. Therefore, how to provide a forged carbon fiber product having a light weight and sufficient strength is one of the important problems that a person of ordinary skill in the art urgently needs to solve.

In view of the above problems, it is an object of the present invention to provide a forged carbon fiber product which is light in weight and sufficiently rigid.

To achieve the above object, the present invention provides a maker of a forged carbon fiber product. The law includes the following steps.

First, the carbon fiber article is separated into a plurality of carbon fiber sheets, wherein the carbon fiber articles comprise thermoplastics, and the thermoplastics comprise between 30% and 60% by weight of the carbon fiber articles. Next, the carbon fiber sheets are placed in a molding die, and the carbon fiber sheets are formed into a workpiece by hot press forging at an operating temperature of 160 ° C to 300 ° C.

In an embodiment of the invention, the thermoplastic comprises between 35% and 45% by weight of the carbon fiber article.

In an embodiment of the invention, the operating temperature is between 180 ° C and 200 ° C.

In an embodiment of the invention, the operating pressure of the hot forging process is between 20 kg/cm 2 and 35 kg/cm 2 . .

In an embodiment of the invention, the thermoplastic is selected from the group consisting of polyamide fibers, polypropylene, polycarbonate, polymethyl methacrylate, polyphenylene sulfide, or combinations thereof.

In an embodiment of the invention, the workpiece is an electronic device housing or a protective housing.

In an embodiment of the invention, the step further comprises applying an ultraviolet curable coating to one surface of the workpiece.

In an embodiment of the invention, the step further comprises a polishing step and a polishing step.

The present invention further provides an electronic device housing that is at least partially fabricated in the manner described above.

The invention further provides a protective housing for accommodating an electronic device, the protective housing being at least partially made by the aforementioned manufacturing method.

According to the above, in this case, a forged carbon fiber product is formed by hot press forging of thermoplastics and carbon fibers, and the forged carbon fiber product formed by the forging process is stronger than the same volume and thickness of metal and plastic, and the weight thereof is the same. The volume and thickness of metal and plastic are lighter.

1‧‧‧Electronic device housing

2‧‧‧Protection housing

S01~S03‧‧‧ method steps

1 is a schematic view showing the steps of a method for manufacturing a forged carbon fiber product according to an embodiment of the present invention.

2 is an electronic device housing produced by the manufacturing method of FIG. 1.

Figure 3 is a protective housing produced by the method of Figure 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a method for fabricating a wrought carbon fiber article according to a preferred embodiment of the present invention will be described with reference to the accompanying drawings, wherein the same steps will be described with the same reference numerals.

Please refer to FIG. 1 , which is a schematic diagram showing the steps of a method for fabricating a forged carbon fiber product according to an embodiment of the invention. 2 is an electronic device housing produced by the manufacturing method of FIG. 1. Figure 3 is a protective housing produced by the method of Figure 1.

The invention provides a method for manufacturing a forged carbon fiber product, comprising at least the following steps.

First, the carbon fiber article is separated into a plurality of carbon fiber sheets, wherein the carbon fiber article contains a thermoplastic (step S01). Moreover, the thermoplastics comprise between 30% and 60% by weight of the carbon fiber article, and the carbon fibers comprise between 70% and 40% by weight of the carbon fiber article. In another embodiment, the thermoplastic may be more than 35% to 45% by weight of the carbon fiber article.

Carbon fiber articles may be in the form of strips, blocks, or plates, but are not limited by these shapes. In addition, the thermoplastic herein may be nylon, polypropylene (PP), polycarbonate (PC), polymethyl methacrylate (PMMA), polyphenylene sulfide (PPS), or a combination thereof. , but not limited by these materials.

And the separation method described in step S01 may be direct destruction, cutting, tearing, pulverizing, punching or cutting, etc., but in any separation manner, the purpose of this step is to separate the carbon fiber sheets into a plurality of Carbon fiber sheets of equal or unequal size for subsequent molding steps.

Next, the carbon fiber sheets are placed in a molding die (step S02). Here, "insertion" is to stack the carbon fiber sheets in a molding die, and the carbon fiber sheets are stacked in a second staggered manner in a partially staggered manner. The advantage of such a stacking method is that, in order to facilitate the subsequent press forming process, the carbon fibers are overlapped and staggered to increase the rigidity in the horizontal and vertical directions, and the problem that the formed workpiece has a specific unidirectional anisotropy can be avoided.

In addition, the additional effect of this step is that when the carbon fiber sheets are hot forged, the carbon fiber sheets will have different patterns (like marble patterns) according to different stacking modes, so that different workpiece products can be provided. Different patterns and variations.

Next, the carbon fiber sheets are formed into a workpiece by hot press forging at an operating temperature of 160 ° C to 300 ° C (step S03). In another embodiment, the operating temperature can be further limited to a range of 180 ° C to 200 ° C.

Moreover, in step S03, after the thermoplastic is melted again (which may be partially melted or fully melted), the molding die (that is, the appearance of the workpiece) is shaped, and by remelting, the carbon fiber sheets can be strengthened. The inter-fixing force increases the overall rigidity.

Moreover, the advantage of using thermoplastics in this embodiment is that, in addition to recycling the excess sapwood or waste material after the workpiece is completed, the waste generated by the process can be reduced and the environmental protection trend can be further met. If a thermosetting plastic is used, it is not possible to strengthen the fixing force between the carbon fiber sheets in this step (only the pressure can be made to deform the carbon fiber sheets into a workpiece).

Further, in the present embodiment, the operating pressure of the hot press forging process is between 20 kg/cm 2 and 35 kg/cm 2 . In another embodiment, the operating pressure can be further limited to 30 kg/cm 2 .

In addition, in other embodiments, after the workpiece is formed, the surface of the workpiece may be further processed, for example, the step of coating the surface of the workpiece with the ultraviolet curing coating, the polishing step, the grinding step, or forming a scratch-proof mold. and many more.

Moreover, in the embodiment, the workpiece formed in step S03 may be the electronic device housing 1 (FIG. 2) or the protective housing 2 (FIG. 3), but is not limited by the two products. Moreover, the formed workpiece does not need to be an integral part of the electronic device housing or the whole of the protective housing, or may be only a partial structure of the electronic device housing or a partial structure of the protective housing.

For example, taking FIG. 2 as an example, the electronic device housing 1 can be partially formed by the above-mentioned manufacturing method (the surface is shown in dark gray), and the rest can be made of a metal housing. Or, as shown in FIG. 3, the protective casing 2 of this embodiment is used for accommodating an electronic device, such as a smart phone, and the protective casing 2 can partially adopt the workpiece formed by the foregoing manufacturing method. Gray representation).

In summary, the present invention forms a forged carbon fiber product by separating a carbon fiber article containing a thermoplastic material into a plurality of carbon fiber sheets, and then forming the forged carbon fiber product by hot press forging, and the forged carbon fiber product formed by the hot press forging process has the same rigidity. Volume, thickness of metal, plastic Stronger, its weight is lighter than metal or plastic of the same volume and thickness, so it can achieve the purpose of providing a forged carbon fiber product with light weight and sufficient rigidity.

The above is intended to be illustrative only and not limiting. Any equivalent modifications or alterations to the spirit and scope of the invention are intended to be included in the scope of the appended claims.

S01~S03‧‧‧ method steps

Claims (10)

A method for manufacturing a forged carbon fiber article, comprising the steps of: separating a carbon fiber article into a plurality of carbon fiber sheets, wherein the carbon fiber article comprises a thermoplastic, the thermoplastic comprising 30% to 60% by weight of the carbon fiber article. The carbon fiber sheets are placed in a molding die; and the carbon fiber sheets are formed into a workpiece by hot press forging at an operating temperature of 160 ° C to 300 ° C. The manufacturing method of claim 1, wherein the thermoplastic comprises between 35% and 45% by weight of the carbon fiber article. The production method according to claim 1, wherein the operating temperature is from 180 ° C to 200 ° C. The manufacturing method according to claim 1, wherein an operating pressure of the hot press forging process is between 20 kg/cm 2 and 35 kg/cm 2 . The manufacturing method of claim 1, wherein the thermoplastic is selected from the group consisting of polyamide fibers, polypropylene, polycarbonate, polymethyl methacrylate, polyphenylene sulfide, or a combination thereof. The manufacturing method of claim 1, wherein the step further comprises: coating the ultraviolet curable coating on a surface of the workpiece. The manufacturing method of claim 1, wherein the step further comprises a polishing step and a polishing step. The manufacturing method of claim 1, wherein the workpiece is an electronic device housing or a protective housing. An electronic device housing, which is at least partially produced by the manufacturing method according to any one of claims 1 to 7. A protective housing for accommodating an electronic device, the protective housing being manufactured at least in part by the manufacturing method according to any one of claims 1 to 7.