TWI499499B - Method of manufacturing composite shell - Google Patents
Method of manufacturing composite shell Download PDFInfo
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- TWI499499B TWI499499B TW102136189A TW102136189A TWI499499B TW I499499 B TWI499499 B TW I499499B TW 102136189 A TW102136189 A TW 102136189A TW 102136189 A TW102136189 A TW 102136189A TW I499499 B TWI499499 B TW I499499B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
- B29C51/085—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts with at least one of the shaping surfaces being made of resilien material, e.g. rubber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
- B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/462—Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C2043/3205—Particular pressure exerting means for making definite articles
- B29C2043/3261—Particular pressure exerting means for making definite articles thermal expansion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/543—Fixing the position or configuration of fibrous reinforcements before or during moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/545—Perforating, cutting or machining during or after moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- 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
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- 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
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0872—Prepregs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/08—Glass
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/34—Electrical apparatus, e.g. sparking plugs or parts thereof
- B29L2031/3481—Housings or casings incorporating or embedding electric or electronic elements
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Description
本發明是有關於一種外殼的製造方法,特別是指一種複合材料外殼的製造方法。
隨著各種電子通訊產品的普及,連帶使得電子通訊產品外殼的製作也格外受到重視。在各種常見用以製作外殼的材料中,藉由添加纖維而形成的複合材料由於有著質量輕、強度佳、可塑性強的特點,且還有很好的耐潮、抗腐蝕的能力,不但能大幅減輕整體重量,滿足使用者對電子產品薄型化的需求,也能幫助防止外殼內的構件受潮而損壞,因此在實際生產應用上,以碳纖維或是玻璃纖維材質所形成的複合材料來做為電子通訊產品外殼的材料,相當受到業界及使用者的青睞。
參閱圖1,為中華民國公告第I327959號「具編織纖維紋路殼體之製造方法」發明專利案所揭露之一習知的殼體1之製造方法。該方法是使用熱壓成型的方式,先提供多數個編織纖維布含浸熱固性樹脂材11,並將該等編織纖維布含浸熱固性樹脂材11堆疊成預定厚度後,裁切成預定形狀尺寸。接著,選用一上模具21,及一可與該上模具21形狀相配合之下模具22,並將堆疊且經裁切的該等編織纖維布含浸熱固性樹脂材11鋪設於該上模具21及該下
模具22之間。其中,該上模具21具有一母槽211,而該下模具22則具有一可與該母槽211形狀相配合的公塊221,因此,當該公塊221朝該母槽211擠壓而形成一鑄模狀態時,該等編織纖維布含浸熱固性樹脂材11也會隨著該公塊221而被擠壓入該母槽211中,並藉由該公塊221與該母槽211的形狀配合,而被熱壓成型成具有多個邊導角111的殼體1。
使用上述方式雖能透過該上模具21及該下模具22的設計成型出該殼體1,但是,在熱壓成型的過程中,由於該公塊221往該母槽211擠壓時會產生極大的阻力,使得該等編織纖維布含浸熱固性樹脂材11不易徹底被推入並伏貼於該母槽211中,造成原先預定應該要依照該公塊221及該母槽211的形狀而成型的邊導角111無法完全地被壓製,甚至如圖2所示般令該等編織纖維布含浸熱固性樹脂材11產生皺折或缺漏,而增加了產品的不良率。
復參閱圖1,若為了將該等邊導角111壓製好,則必需在該等邊導角111成型處增加該公塊221的外徑長度,以使該等編織纖維布含浸熱固性樹脂材11在該導角及該邊角成型處能更加伏貼於該上模具21。然而,如此一來,當熱壓成型完成之後,由於該公塊221與該上模具21在該邊導角成型處過於緊迫,會導致該上模具21及該下模具22不易脫模,使得製作過程更加不便。
為解決上述問題,參閱圖3,為中華民國公告第375568號「塑膠內襯或內夾超素性合金之防電磁波干擾電
器設備外殼及其製造方法」發明專利案所揭露之另一種成型方法,係利用一模具3對一塑膠板材4進行壓製成型作業。該模具3具有一成型空間31,及兩個與該成型空間31相連通的通氣管路32。首先,將該塑膠板材4夾設於該模具3中並位於該等通氣管路32之中間,再透過該等通氣管路32分別對該成型空間31施以不同的氣壓,藉此讓該塑膠板材4能依圖3中箭頭所示之方向,逐漸伏貼於該模具3內,而如圖4所示完成該等邊導角41的塑形。此種方法雖解決了習知殼體1為完美成型而脫模不易的問題,但由於氣體的施壓方向及力道強度難以控制,因此使用模具3並輔以灌氣成型的方式,仍會有邊導角41成型不完全的問題,甚至使該塑膠板材4在成型厚度上也會產生不均勻的現象。
因此,本發明之目的,即在提供一種製造程序簡便,並能提升邊導角成型良率的複合材料外殼的製造方法。
於是,本發明複合材料外殼的製造方法,包含一備料步驟、一備置步驟、一前置步驟、一成型步驟、一壓製步驟,及一脫模步驟。
該備料步驟,是準備一待成型的複合母材,該備置步驟則是用以備置一模具。該模具包含一第一模體、一套設於該第一模體外緣的套體,及一可與該第一模體形相配合的第二模體。該第一模體具有一頭部,及一延伸自
該頭部的壓設部,該套體具有受熱膨脹的特性,並包括一基部,該基部具有一與該壓設部相連的初接段,及一延伸自該初接段相連的抵壓段。該第二模體具有一可供該第一模體及該套體設置的塑形空間。
該前置步驟是將該複合母材置於該第二模體上,而該成型步驟則是加熱該第一模體及該第二模體,並同時以該第一模體及該套體共同將該複合母材壓入該塑形空間中,使該套體之抵壓段於該塑形空間中受熱膨脹而推頂該複合母材伏貼於該第二模體內。
該壓製步驟是加壓於該第一模體使該壓設部脫離與該套體之初接段的連結關係並直接抵壓於該複合母材,使該複合母材進一步被壓設成型。
最後,該脫模步驟是將該第一模體及該套體與該第二模體分離,並將壓設成型後的成品自該塑形空間中取出。
本發明之功效在於:利用該套體遇熱膨脹的特性,不但解決了脫模不易的問題,更使得該套體之抵壓段能夠於該塑形空間中推頂該複合母材,故能夠完美複製出預設的形狀。
51‧‧‧備料步驟
52‧‧‧備置步驟
53‧‧‧前置步驟
54‧‧‧成型步驟
55‧‧‧壓製步驟
56‧‧‧脫模步驟
6‧‧‧複合母材
61‧‧‧基材
62‧‧‧邊導角
63‧‧‧側翼
6’‧‧‧成品
7‧‧‧模具
71‧‧‧第一模體
711‧‧‧頭部
712‧‧‧壓設部
72‧‧‧套體
721‧‧‧基部
722‧‧‧凸垣部
73‧‧‧第二模體
731‧‧‧基座
732‧‧‧塑形空間
74‧‧‧固定件
799‧‧‧初接段
788‧‧‧抵壓段
777‧‧‧導面
766‧‧‧導弧
本發明之其他的特徵及功效,將於參照圖式的實施方式中清楚地呈現,其中:圖1是一示意圖,說明中華民國公告第I327959號「具編織纖維紋路殼體之製造方法」發明專利案所揭露之一殼
體的製造方法;圖2是一剖面圖,說明該習知殼體成形的缺點;圖3是一示意圖,說明中華民國公告第375568號「塑膠內襯或內夾超素性合金之防電磁波干擾電器設備外殼及其製造方法」發明專利案所揭露之成型方法;圖4是一示意圖,用以輔助說明圖3;圖5是一流程圖,說明本發明複合材料外殼的製造方法之一較佳實施例;圖6是一示意圖,用以輔助說明圖5;圖7是一剖面圖,說明該較佳實施例之一第一模體及一套體組合之態樣;及圖8是一示意圖,用以輔助說明圖5。
參閱圖5及圖6,本發明複合材料外殼的製造方法,包含一備料步驟51、一備置步驟52、一前置步驟53、一成型步驟54,一壓製步驟55,及一脫模步驟56。
首先,在該備料步驟51中,使用者先將多種基材61置於一熱固性樹脂(圖未示)中,使其堆疊固定並裁切成適當的尺寸及大小,而形成一待成型的複合母材6。在本較佳實施例中,該等基材61是選自玻璃纖維、碳纖維其中之一或其組合,而實際使用時,也可以是其它高分子聚合材或適合的材料,並不以纖維類為限。
而該備置步驟52是用以備置一模具7,該模具7包含一第一模體71、一套設於該第一模體71外緣的套體
72、一可與該第一模體71形狀相配合的第二模體73,及一可設置於該第二模體73上的固定件74。配合參閱圖7,該第一模體71具有一頭部711,及一延伸自該頭部711的壓設部712。該套體72包括一基部721,及一凸伸自該基部721的凸垣部722。該基部721具有一與該壓設部712相連的初接段799,及一延伸自該初接段799相連的抵壓段788,該初接段799遠離該抵壓段788之一側則具有一向下傾斜的導面777,該導面777與該第一模體71之頭部711間保持一距離,而該第一模體71之壓設部712是抵壓於該凸垣部722上並與該初接段799相鄰。在本較佳實施例中,該套體72是以具有受熱膨脹特性的材質製成,其材質可選自於塑膠、橡膠,或其它同性質之高分子聚合物所組成的群體。
參閱圖6,該第二模體73具有一基座731,及一由該基座731圍繞界定而成並可供該第一模體71及該套體72設置的塑形空間732。需特別說明的是,該基座731是特別成型有一導弧766的態樣,而該套體72之抵壓段788也是呈現有弧度的設計,使該抵壓段788與該基座731可供該複合母材6在壓製時成型出預設的邊導角62(見圖8)。
參閱圖5及圖8,接著進行該前置步驟53,是將該複合母材6夾置於該固定件74與該第二模體73之間,然後進行該成型步驟54。在該成型步驟54中,使用者先加熱該第一模體71及該第二模體73,並同時以該第一模體71及該套體72共同將該複合母材6壓入該塑形空間732
中,使該套體72之抵壓段788於該塑形空間732中受熱膨脹而推頂該複合母材6伏貼於該第二模體73內。
進一步說明,在該成型步驟54中,該第一模體71及該第二模體73是以高週波加熱的方式加熱至135℃,並藉由該套體72熱脹冷縮的特性,使該套體72的抵壓段788能因膨脹而更進一步地推抵該複合母材6,讓該複合母材6與該基座731的導弧766間不再有間隙,並與熱固性樹脂在高溫下反應定型成該塑形空間732與該壓設部712之間所界定的形狀。
接著再進行該壓製步驟55,加壓於該第一模體71使該壓設部712壓過該凸垣部722而直接向下抵壓該複合母材6,讓該複合母材6能進一步被壓設成型,此時,由於該抵壓段788及該導弧766的形狀設計,不但能使該複合母材6完美成型出預設的邊導角62,並透過該第一模體71之頭部711向下壓設,而使該複合母材6會擠入該套體72之導面777與該第一模體71之頭部711間的間隙,令該複合母材6依該導面777的形狀而成型出一側翼63。至此,該複合母材6透過該第一模體71及該套體72的壓設,已成型出一成品6’。
最後,進行該脫模步驟56,將該第一模體71及該套體72與該第二模體73分離,並將壓設成型後的成品6’自該塑形空間732中取出。需特別說明的是,由於該套體72的材質具有熱塑性的特徵,因此即便該套體72要抽出該塑形空間732時會與該側翼63有相抵觸的情形,但
藉由該成型步驟54時所留下的餘溫,該套體72仍會呈現略帶可塑性的彈性餘裕,只要稍微加壓,即可使該套體72稍稍形變而能與該成品6’相脫離。加上該套體72之導面777是向下傾斜的設計,因此更能提供一良好的角度使該套體72自該側翼63的角度中抽出。
藉由以上所述之結構設計,本發明複合材料外殼的製造方法之較佳實施例,於實際使用時具有以下所述優點:
(1)產製良好的邊導角62:
本發明透過該套體72遇熱會膨脹的特性,使得該套體72將該複合母材6壓入該塑形空間732後能持續膨脹,並壓抵該複合母材6使其能完整伏貼於該第二模體73之基座731預設的導弧766形狀,故能完美複製並產出良好的邊導角62。
(2)簡省工序:
藉由該第一模體71及該套體72的配合,使該複合母材6於該塑形空間732中可一次成型出良好的側翼63及邊導角62,而不需要於該壓製步驟55後另外加工,有效節省生產過程中的人力及時間成本。
(3)容易脫模:
由於該套體72是具有熱脹冷縮的性質,因此當完成該壓製步驟55後,該套體72
只要經稍微冷卻即可輕易地隨該第一模體71從該塑形空間732中移出,因此不會產生難以脫模的問題。加上該套體72之導面777是呈向下傾斜的設計,更提供了該套體72與該側翼63間一個良好的錯動方向,讓脫模更加順利。
(4)容易調整:
當使用者欲於該複合母材6上形成不同形態的邊導角62及側翼63時,使用者不需要再重新開模,而只要變換該套體72之抵壓段788的形狀,或是變更該初接段799之導面777的傾斜角度或態樣,即可讓該複合母材6最後定型之輪廓隨之調整改變。
另外,需特別說明的是,在本較佳實施例中,該套體72與該第一模體71之間是透過該凸垣部722的方式,使該第一模體71可先抵於該套體72之凸垣部722上,但實際使用時,該套體72與該第一模體71間的連結方式也可以有其它種選擇,例如:在該備置步驟52中,該套體72是以黏著的方式與該初接段799相連,而在該壓製步驟55中,該第一模體71之壓設部712會因受壓而脫離與該初接段799的黏著關係,使該壓設部712直接向下抵壓該複合母材6。諸如此類能夠讓該第一模體71及該套體72間呈分段壓設該複合母材6的設計,皆在本發明之考量範圍中。
綜上所述,本發明複合材料外殼的製造方法利用該套體72遇熱膨脹的特性,不但解決了脫模不易的問題,更使得該套體72之抵壓段788能夠於該塑形空間732中推頂該複合母材6,故能夠完美複製出預設的邊導角62形狀。另外,透過該套體72之導面777設計,讓該複合母材6能隨著該導面777的形狀及角度而一次成型出預設的側翼63之態樣,故確實能達成本發明之目的。
惟以上所述者,僅為本發明之較佳實施例而已,當不能以此限定本發明實施之範圍,即大凡依本發明申請專利範圍及發明說明內容所作之簡單的等效變化與修飾,皆仍屬本發明專利涵蓋之範圍內。
51‧‧‧備料步驟
52‧‧‧備置步驟
53‧‧‧前置步驟
54‧‧‧成型步驟
55‧‧‧壓製步驟
56‧‧‧脫模步驟
Claims (9)
- 一種複合材料外殼的製造方法,包含:一備料步驟,是準備一待成型的複合母材;一備置步驟,備置一模具,該模具包含一第一模體、一套設於該第一模體外緣的套體,及一可與該第一模體相配合的第二模體,該第一模體具有一頭部,及一延伸自該頭部的壓設部,該套體具有受熱膨脹的特性,並包括一基部,該基部具有一與該壓設部相連的初接段,及一延伸自該初接段相連的抵壓段,該第二模體具有一可供該第一模體及該套體設置的塑形空間;一前置步驟,將該複合母材置於該第二模體上;一成型步驟,加熱該第一模體及該第二模體,並同時以該第一模體及該套體共同將該複合母材壓入該塑形空間中,使該套體之抵壓段於該塑形空間中受熱膨脹而推頂該複合母材伏貼於該第二模體內;一壓製步驟,加壓於該第一模體使該壓設部脫離與該套體之初接段的連結關係並直接抵壓於該複合母材,使該複合母材進一步被壓設成型成一成品;及一脫模步驟,將該第一模體及該套體與該第二模體分離,並將壓設成型後的成品自該塑形空間中取出。
- 根據請求項1所述之複合材料外殼的製造方法,其中,在該備置步驟中,該套體之初接段具有一向下傾斜的導面,且該導面與該第一模體之頭部間保持一距離,使該壓製步驟中,該複合母材可依該導面的形狀而於該頭部 及該導面間成型出一側翼。
- 根據請求項1或2所述之複合材料外殼的製造方法,其中,在該備置步驟中,該套體還包括一凸垣部,使該成型步驟中該第一模體之壓設部是抵壓於該凸垣部上並與該初接段相鄰,而在該壓製步驟中,該第一模體之壓設部會壓過該凸垣部而向下抵壓該複合母材。
- 根據請求項3所述之複合材料外殼的製造方法,其中,在該備置步驟中,該模具還包含一固定件,該固定件是設置於該第二模體上,並於該前置步驟中將該複合母材夾置於該第二模體與該固定件之間。
- 根據請求項3所述之複合材料外殼的製造方法,其中,在該備置步驟中,該套體之材質是選自塑膠、橡膠,或其它同性質之高分子聚合物所組成的群體。
- 根據請求項3所述之複合材料外殼的製造方法,其中,該第一模體及該第二模體是以高週波加熱的方式加熱。
- 根據請求項3所述之複合材料外殼的製造方法,其中,在該備料步驟中,該複合母材是預浸有熱固性樹脂的基材,將其堆疊固定並裁切成適當的尺寸及大小。
- 根據請求項7所述之複合材料外殼的製造方法,其中,該等基材是選自玻璃纖維、碳纖維其中之一或其組合。
- 根據請求項8所述之複合材料外殼的製造方法,其中,在該成型步驟中,該第一模體及該第二模體是加熱至135℃,使該複合母材與該熱固性樹脂在高溫下反應而定型成該塑形空間與該壓設部之間所界定的形狀。
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US6174484B1 (en) * | 1998-11-16 | 2001-01-16 | General Electric Company | Apparatus and method for producing a compression molded product |
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US20080116334A1 (en) * | 2006-11-21 | 2008-05-22 | Ming Xie | Methods for fabricating composite structures having mounting flanges |
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TW201202014A (en) * | 2010-07-08 | 2012-01-16 | Advanced Int Multitech Co Ltd | Continuous shaping process for thin prepreg work piece |
FR2971195B1 (fr) * | 2011-02-04 | 2013-04-26 | Latecoere | Outillage de moulage pour la realisation d'une piece en materiau composite au moyen d'une preforme souple composee d'une peau et de preformes profilees solidarisees sur la dite peau. |
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TW200624143A (en) * | 2005-01-03 | 2006-07-16 | Advanced Int Multitech Co Ltd | Method for manufacturing a golf club head main body of composite material and its forming mold |
CN101890807B (zh) * | 2010-07-19 | 2012-10-10 | 哈尔滨飞机工业集团有限责任公司 | 一种利用硅橡胶热膨胀加压成型复合材料零件的方法 |
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